Good morning everyone. Well it's time for a rebuild.
1977 FLH, all original, never opened up. 74"
I am lolooking for advice on parts. New crank? Complete rebuild kits? Will most likely go with 80" jugs. Also advice about a 5 speed in a 4 speed tranny?
Thank you in advance.

 

are you sure it's time for complete rebuild or just need to be freshed up?
4 and 5 speed have the same 1:1 ration 5th or 4th gear... so 5 speed does not give you better cruising speed, if that's what you are looking for... it just adds one more extra gear in the mix

 

You mention it is 'all original'. Just remember, if so, it can only be original once. Any thoughts on pulling the jugs, checking the crank, and if it's good, just doing a top end?

And has been stated a 5-into-4 is really not an improvement. You would probably be better off with changing out motor, tranny and rear sprocket to give you more "umph" in the direction you want to go rather than adding the extra gear. And it would be less costly and time consuming as well.

 

Figure out what's bad before you start throwing money at it...

 

Well it's 38 years old, I would like to just go through the whole thing. I am not a mechanic but have a friend to guide me. I am starting to blow gaskets, cam seal blew, heads ststarting to leak. Lots of carbon build up in the jugs. I am thinking just do it all that way I am not fixing this, then that and so on.

 

Heck she is just broke in! How many miles on the motor? Got almost 69K on my 84 FLH before doing the top end. Redid the top end, new cam, oversized the hydraulic units and bored the blocks to match. Used Cometic (others prefer James) gaskets.

Also took the time to go through the front end, rear end and tranny, mostly replacing seals and fluids. Runs like a top.

Only non stock was going from a 22 amp system to a 32 amp system from CycleElectric (American made and worth the extra IMO anyway).



And no matter what way you go, just take your time and concentrate on doing one section at a time. Lastly take pics, lots of them from various angles as well as close ups. Helps document your work and helps when you reassemble and have that "now where/how did this go back together" moment.

 

I totally disagree with the above statements about 5 speeds. It does a lot more than just add another gear...and you cannot get the same results by just changing gear ratios...all that does is move the powerband....what ever you gain at one end, you lose on the other...with a 5 or 6 speed you can have both...and just the fact that the 5 speed shifts so much better makes the bike more fun to ride. Now the bad news...nobody makes a quality 5 speed in a 4 speed case...baker makes a 6 speed in a 4 speed case...which is a sweet unit...I have one...but make sure your not on heart medication before looking at the price. Your other option is to buy a case and build your own...sputhe and s & s both make cases... and cast off Harley gearsets are plentiful on ebay from people who changed to a 6 speed...you need a 1988 or earlier gearset if you want to use your existing clutch, or get an newer gearset and update to a spined shaft, diaphragm clutch and ball and ramp clutch release while you are at it.



http://www.sputhe.com/5-speed%20case...sion%20kit.htm


http://www.sscycle.com/product/5-45-...ns-p25213.html

 

Do it all at once. tare down and Measure, measure and re-measure. Hone or bore cylinders if needed ( im sure it needs one or the other ). Check valves on your bench with paint remover to see if you leak at the valves.( do not flip and fill combustion chamber, put a small amount of thinner in through the exhaust and intake ports ) get rid of the cork gaskets, add new age gaskets and o'rings. replace ALL woodruff keys. If your primary has the chain oiler...block it off and add 6 oz fluid to primary for the chain. I'm no expert put i'll pass on what I have learned. Oh and by the way. I rebuilt my 4 speed. very easy to do and there are not a lot of them left.
hope this helps in some way....

 

Thank you for all the advice.