DIY Network

'48 Indian Motorcycle: Rebuilding the Front End It's time to rebuild the front end of DIY's '48 Indian Chief classic ride. From "Classic Rides" episode DCLR-302

With the '48 Indian Chief fork and parts back from the powder coating, it's time for host Craig Reynolds and antique motorcycle expert Chris Matthews to put everything back together.

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Host Craig Reynolds (left) and Chris Matthews tackle the front end assembly on DIY's '48 Indian Chief motorcycle.

Material/Tools for all Projects:

1948 Indian Chief Motorcycle
complete set of shop tools
bike jack

Materials/Tools for Rebuilding the Front End:

complete set of wrenches: SAE or Metric
complete set of Allen wrenches: SAE or Metric
fork
new Shock
springs
bearings
brass hammer

	Figure A
	Figure B
	Figure C
	With the new headlights and wheel installed, the new front end of the '48 Indian Chief is looking good!

Note: The fork and parts were powder coated back to the original black (figure A) instead of chrome.

Rebuilding the Front End of the '48 Indian Chief

1. The first step is to install the new neck bearings.

2. Place the top bearing on top of the bearing cup and using the brass hammer, tap around the edge of the bearing until it is fully seated in the cup (figure B).

3. Repeat this process for the lower bearing.

4. From the bottom, insert the steer tube up and through the headset. Use the hammer to seat it in place.

5. Slide the stem onto the upper portion of the steer tube, insert the keyway, and tighten the clamp using an Allen wrench.

6. The steering tension control knob is then screwed down on top of the stem. Tightening the knob will increase the force required to turn the handle bars.

7. On to the fork assembly — the swing arms and shackle pivot shafts bolt to the stem assembly and the lower mounting points on the steer tube. Set the arms with the pivot shafts in place and tighten the lock nuts.

8. The entire fork assembly will then slide onto the shackle pivot shafts (figure C). Apply a light coat of grease to the shafts, then slide the entire fork assembly on and place a lock nut on each shaft.

9. The springs bolt on next. Each spring is held in place with a nut on top and on the bottom. Simply slide the spring in place between the upper and lower pivot shaft, set the upper and lower lock nuts in place and tighten.

RESOURCES :

Welders
Lincoln Electric
Website: www.lincolnelectric.com

Kiwi Indian
Website: www.kiwi-indian.com

V-Twin Mfg.
Rims, Spokes, Hubs, Tire Irons and Truing Stand
Website: www.vtwinmfg.com

Motorcycle Lift
Handy Lift
Website: www.handy-lift.com

Various Tools
Eastwood
Website: www.eastwoodco.com

Hepavac Asbestos Vacuum
Bullseye
Website: www.bullseyecorp.com

Parts Washer
Safety Kleen
Website: www.safety-kleen.com

Chrome Polish
G & H Metal Finishers
282 Dakota St.
Paterson, NJ 07503

Belt Grinder
Ellis Manufacturing
Website: www.ellissaw.com

Powder Coating Shop
Best Signs
Phone: 865-922-5247
E-mail: bestsigns@tds.net

Coker Classic White Wall Tires, Tubes and Spoke Covers
Coker Tires
Website: www.coker.com