DIY Network

'48 Indian Motorcycle: Clutch and Brake Linkage; Running Boards From "Classic Rides" episode DCLR-307

The new running board, installed

The '48 Indian is really coming along in our restoration. The next couple of items in this particular project may seem minor, but without them we wouldn't be going anywhere.

Our existing clutch and brake linkage were in good condition functionally, but we had them re-chromed for a sharp, new look. The original running boards, on the other hand, were just worn out. We replace them with vintage replicas. The basic steps in the installation of those parts are summarized below.

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	The replacment running board
	The newly re-chromed linkages and kick-stand

Materials and tools:

complete set of wrenches, SAE or metric
pliers
brake and clutch pedals
linkage
running boards

Note: This is a summary of steps included in the restoration procedures shown in this episode of Classic Rides. These are general guidelines for restoration procedures on this particular make and model of motorcycle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

Installing the linkage

Clutch and Brake Linkages

Having just finished up with the battery and generator in the last project, we're already working on the left side of the bike. Now we can go ahead and install the clutch pedal and the clutch linkage.

• Slide the clutch pedal into its pivot boss, and secure it with a castle nut. The castle nut will allow you to insert a cotter pin so there will be no chance of it coming loose.

• Set the linkage in place between the clutch pedal and the slave lever.

• Insert the retention pin in each joint and then insert a cotter pin to lock them in place.

• Use the adjuster to take up any slack.

• Then over to the other side of the bike and insert the brake pedal. Tighten its castle nut and insert a cotter pin.

• The brake linkage is made up of two parts. Set both pieces in place, insert the retention pins and cotter pins.

• The center connection will be held in place by the return spring. This will attach to the frame and then insert the other end of the spring into the pin. This pin will have a number of holes in it, you'll want to insert the spring in the closest hole to the linkage. This will act as a cotter pin.
  

  Craig installs the new replacement running boards.

  
  

We can now finish up by installing the running boards.

• The first step is to install the attachment cleats on the bottom of the running boards. Insert and tighten the two bolts on each cleat. There are two cleats per running board.

• Once those are tightened, the running boards are ready for the bike. Set the boards on the bike and insert the bolts and lock nuts. Tighten and you are ready to go.

• One final step, and that is to install the front brake cable. Insert the barreled end of the cable into the brake lever.

• The other end should be routed down to the front brakes, passed through the adjuster, and then tighten in the lever arm pinch bolt.

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

Gaskets/Headers
James Gaskets
Website: www.jamesgaskets.com