Preparing the Shovelhead to go Cross Country

[renchinrider]

It's been a long time since I updated my progress preparing the Shovel for the trip.  It seems I either have a few moments to work on the bike, or a few minutes to write--never a few minutes for both :-[!

Anyway, since my last update, I've completed a few things:

First, I spent a bunch of money and ordered a bunch of parts from J&P Cycles.  Thankfully, J&P is punctual with their shipping, and they stand behind their parts.  I've had many years of good experiences with them.  Though founder John Parham passed away last year, it seems that his son and the rest of the J&P leadership are determined to maintain the company's high standards.

While waiting for the parts, I disassembled, cleaned and repainted the front brake caliper...



Then I disassembled the fork legs.  I polished the fork sliders before rebuilding and reassembling the fork legs.  Here's a "before and after" comparison...

[url=https://flic.kr/p/27GbBjf]

I rebuilt the fork legs using new seals, keepers, etc...

The old fork slider seals were really deteriorated, and it took a while to extract them from the sliders without cracking or breaking anything ???!

[url=https://flic.kr/p/27GbA3C]

[url=https://flic.kr/p/NjyGLh]

Then I put on new fork boots, and added chrome caps to protect the rubber boots from UV deterioration.  Tonight I filled each leg with AMSOIL "Shock Proof" fork oil, and reinstalled the fork legs.

[url=https://flic.kr/p/294TmYF]

I spent an evening last week polishing the front wheel.  Now I'll pack and install its new wheel bearings and seals, and then reinstall the front brake caliper (which I've also finished rebuilding), front wheel and my new speedometer controller and cable.

Then I can move back to the mid-section, finish my electrical wiring repairs, and finally get to the tail end of the bike to rebuild the rear hub and replace the rear brake rotor! :)

I gotta hurry if I'm going to have the bike back together and shaken down before the deadline to head for Sturgis and the Cannonball!

[DonJuan]

Great project and write up, Rench!


Sent from my iPhone using Tapatalk

[renchinrider]

In between work calls over the weekend, I have accomplished a good bit toward getting the bike back on the road.

For starters, I applied this H-D bare aluminum preservative to my fork sliders, in hopes they won't corrode as quickly once I'm out riding and exposing the bike to the weather again.  I have no idea if it'll actually help, but I'll let you know in a couple of months!



Then I reinstalled the front fender.  Well, sorta:  The bike originally had a "chopped" front fender on it.  It looked great so long there wasn't any rain.  But (referring to my earlier entries about this bike  :D), it seems I ride more in the rain than out of it!  In rain, the chopped fender let the tire spray fly straight up in the air, and then into my helmet and chest.  A few years ago, I stumbled across this fender for $10, and I couldn't pass it up.  It's been sitting in a box ever since.  Its color isn't a perfect match, but it's close enough for what my wallet can tolerate for right now, and maybe I won't get quite so much rain in the face on this ride.

With the fender bolted on, I went straight to work on the front hub.  I pulled out the old seals and bearings, then cleaned everything.  Upon closer examination, I realized the bearings and races were just like new.  Had I just bought new seals, I could have re-packed the bearings and run them for a good while longer.  But, since I had everything apart, I opted to keep the original races in the wheels, and I packed the new wheel bearings, put in the new seals, and bolted the brake rotor back on.

[url=https://flic.kr/p/29zvDzE]

I positioned the new speedo sensor, opened up the brake pads, and pushed the front wheel into place.  I coated the front axle with grease to keep it from freezing in the hub, pushed it through the fork legs, and then torqued everything to spec.

[url=https://flic.kr/p/LUWLeX]

Once everything was back together, I used my Mity Vac and pulled new brake fluid thru the front brake system.  Thankfully, I almost immediately got response at the brake lever, and after one more bleed, I had it! ;D  I've worked the brake and watched the caliper numerous times over the past day, and have great pressure at the lever and NO LEAKS!  HOORAY! :)

[url=https://flic.kr/p/2aAxyg3]

[renchinrider]

I got a little more done today.  I installed my remote oil filter kit.  This kit uses a standard Evolution-style (Harley Big Twin, '84-'99) oil filter.  I'm retaining the cartridge filter in the oil tank as well.  These old Shovelheads circulate the oil through the engine via one outlet, and trickle oil into the primary chain (and clutch) case via another, and then pull all of the oil back into the oil pump, where the pump pushes it back into the oil tank (thru the cartridge filter).  I don't like this system at all, because the oil pump picks up some amount of debris coming from the clutch and starter system.  When I'm able to write a little more about my history with this bike, I'll tell the story of collecting such debris in the oil pump, and the learning opportunities that followed.  But for now I have neither the time nor money to pull the primary assembly apart and have the inner primary cover adapted to retain its own separate oil supply.  (That'll be one of the tasks to complete when I overhaul the engine in the future.)  Anyway, here's a shot of the new oil filter mounting plate.



Like all custom part installations, this came with its share of challenges.  After some grinding and filing, and a trip to Home Depot to get longer bolts, I got the mounting plate installed.

Then I pulled the oil return line off the oil pump, routed a new line up to the oil filter plate, and then ran the oil filter return line back, where I spliced it together with the original return line.  Thankfully, no challenge here:  The whole process took about 15 minutes! ;D  Well, that's after about 20 minutes of online research to make sure I knew which way the oil is supposed to flow thru the filter! :D

[url=https://flic.kr/p/LWP1sR]

[renchinrider]

With the oil filter installed, I was able to return to electrical work.  First, I installed a late model horn assembly, which is both more durable, and louder.  Thankfully, this mod couldn't have been any simpler, and took less than 30 minutes.



Once I got the horn done, I pulled the back end of the bike apart.  Next chance I get, I'll post some pics and share what I'm doing to ensure everything in the rear suspension and driveline are ready for this trip!

[renchinrider]

I got to spend another hour working on the bike this eve.  Since I had reworked the wiring to the rear taillight last eve, I was ready to bolt the fender back between the struts.  But before doing so, I decided to pull the wires off each of the circuit breakers, and polish up all the contacts to be sure I have good connections.  I covered everything with dielectric grease as I put each circuit breaker back together.  It was much easier to do all the circuit breakers before putting the rear fender back on.  This picture shows the circuit breakers ready to go back into their retaining brackets on the rear fender.



Then, as I put the rear fender back on, I used new bolts long enough to mount the old sissy bar, as well as the new saddlebag brackets I bought for the bike.  I picked up some leather saddlebags at Barber last year, and finally, I'm going to put them on and use them on this trip! :)

[url=https://flic.kr/p/2aEmuwh]

[renchinrider]

UPDATE:  I finished reassembling the Super Glide late last night! ;D  I still have to do one more "pre-flight", put some gas in it, and see if it'll start and run.  Then comes a shake down ride, which (true to form for this bike!!! :D) will happen in the rain.

But I've been able to confirm that all the electrical gremlins have been eliminated, everything (electrical, brakes, etc) works.  If the engine still runs as good as it did when I parked it three months ago, I should be ready for this ride.  Pics, etc to follow tonight or tomorrow from the weekend's feverish activity putting the bike back together and doing all of the adjustments, verifications, etc to give me the best chance of completing this 4,000 mile adventure!

[renchinrider]

I'm back from the shakedown ride...I covered 70 miles, and the only problem was that I didn't adequately secure the saddlebags, and had to resort to zip ties (fat ones) to secure the saddlebags to the hangers.  I don't think they're going anywhere now! ;D

Anyway, here's a short summary of the past three days' activity:

I rebuilt the rear wheel and installed a new brake rotor, along with a new brake caliper retainer.  I also scrubbed the chain and got all the gunk and dirt off/out of it.



Next, I test fit the saddlebags.  Note the position of the rear turn signal in this picture.  The turn signal forced the saddlebag up and over the rear shock, and nothing would fit right.

[url=https://flic.kr/p/2aJHkNi]

So I fabbed some brackets and moved the turn signals back about 5 inches.  This was one of those "1 step forward and 2 steps back" moments:  I had to take the back fender back off in order to put on the fabbed brackets, then wrestle everything back on there again.  I had hoped it would be easier the second time...It wasn't ::)...

[url=https://flic.kr/p/28cQg6Q]

But fabbing these brackets gave me a place to mount a set of LED flashing auxiliary brake lights to try and add a bit more safety to the bike.

With the new brake lights mounted, my electrical upgrades were about wrapped up.  Here's what the circuit breaker area looked like when I was done--a lot cleaner, and much better connectors and splices! ;D  The only thing not pictured is an all weather power socket I added so I can charge my GoPro and phone batteries while I'm riding.

[url=https://flic.kr/p/28cQeXN]

At that point, I put the rear end back together, adjusted and lubed the chain, verified rear wheel alignment and brake function, and torque specs.

[url=https://flic.kr/p/28cQhhY]

Then I completed the myriad reassembly bits and pieces.  With the bike back together, I tested all the electrics, and then went into the tuning of the engine and drivetrain.  In this photo, I was verifying clutch adjustment.  Afterward, I verified adjustment of the primary chain, confirmed point gap and function, tuned the ignition timing, and confirmed pushrod adjustment.  No pics of any of that because it was dark and LATE! ???

[url=https://flic.kr/p/NQ5st5]

This morning, I dropped the bike down off the jack, and did another "pre-flight" inspection from one end of the bike to the other.  I poured some gas in it, and went to kickin'.  On the 3rd kick, she fired up, and sounded great! ;D  Everything was just wonderful until I looked down and saw oil gushing off the side of the oil tank :o!!!  I shut it down, pulled the seat off, and discovered I hadn't properly secured the cap on the oil tank.  what a mess! ::)  I re-secured the cap, cleaned the tank and the side of the engine, dumped absorbent all of the place, and re-started the engine.  Problem solved! ;D

[url=https://flic.kr/p/2aXQhe2]

On the shakedown ride, I immediately noticed the difference in the behavior of the front end, now that the forks have the correct amount of fluid in them!

I still have a nagging oil leak from the primary chain inspection cover.  I'll have to break down and put some RTV on the gasket tomorrow.  But otherwise, the bike is READY TO GO! :) :)  Sturgis, here we come!

[renchinrider]

I can't help but put in a plug for Vintage Fest at Barber...Note the new seat and saddlebags on the bike:  Both came from last year's Barber Vintage Fest.  I got the seat for a fair price, but it wasn't a steal.  The bags, on the other hand, are top-of-the-line Willie and Max bags, and I got a REALLY good deal on them!

If you don't find anything else at Vintage Fest, you'll find one of the most eclectic collections of motorcycles ever, and you'll meet more super-cool people than you could ever imagine...See you there!

[renchinrider]

And, finally:  Here's my roadmap for this trip:  Starting on Wednesday, I'll travel from Huntsville to Missouri, and make a short stop at Lake of the Ozarks Bikefest.  Then I'll travel to Junction City, KS and see my good friend Dean.  From there, I'll travel up through Valentine, NE to Sturgis.  Once the Motorcycle Cannonball participants depart Sturgis and head west, I'll travel across MN and see some family in Wisconsin.  From there, I'll travel southeast to Cherokee, NC for a weekend of riding with some dear friends from my Army days.  This is going to be a trip to remember! :)

Feel free to follow along in (almost) real time as I post pics on Instagram.  All my pics are public, so no need to have an Instagram account.  Just open Instagram, and search for "renchinrider."  There you'll see all my pics as I go.  Hope you enjoy the pics I'll post!