2003 FXD - Complete Rebuild
I know I am not the fastest, and probably overthink and over complicate issues. This is also a when I have time project, so the normal order and timing of things gets out of whack. I also have this serious OCD issue where I have to put every tool away after every task, even if I know I am about to get the same tool out again.
I started this post hopping to get some advice along the way also, so please, if you feel I am ****ing something up, dont be shy. I am a High School Umpire as well as run a metal fab shop, so my skin is pretty thick. I am also very receptive to criticism.
That being said, I am at a point where waiting on a few parts, still trying to find a few others, and general inexperience has me questioning what to tackle next.
- I have the whole transmission assembled, but until I decide on Bar set up, I dont have a clutch cable installed. Am I ok to leave it dry for few more months? Or should I temporarily plug the cable hole and get fluid in it?
- If I assemble the cam chest, can I leave that dry?
- I know once I install the lifters and push rods I have to add engine oil at that point correct? To keep the lifters from getting air back in them? Which mean I need to have top end going also, correct?
- same with primary. Once I get the swingarm, can I do the primary side and leave it dry?
- Is there any harm in having everything assembled and adding fluids and not running/starting it? For a few months while I figure out the rest?
I guess I am basically wondering, should I leave the motor alone, get the rest of the bike sorted and then finish the motor last? Or is the process of going from the ground up ok?
What would you do?
Yours are all valid questions, and I'll commend you for the work you have done thus far on your Dyna. It's looking good. It's good that you asked, you'll get some good advice from the more experienced "Harley mechanics" here soon.
If it were my project I'd leave the engine for last. Mainly because after installing the lifters and closing up the camchest, I'd want to start the engine and get the oil flowing. A test run would follow to check out the primary and transmission function. Then the bike could sit while finishing up details, cosmetics and such. But, that's just my thoughts, I'm not a Harley mechanic.
Yours are all valid questions, and I'll commend you for the work you have done thus far on your Dyna. It's looking good. It's good that you asked, you'll get some good advice from the more experienced "Harley mechanics" here soon.
If it were my project I'd leave the engine for last. Mainly because after installing the lifters and closing up the camchest, I'd want to start the engine and get the oil flowing. A test run would follow to check out the primary and transmission function. Then the bike could sit while finishing up details, cosmetics and such. But, that's just my thoughts, I'm not a Harley mechanic.
I agree...going to move on and save motor for last.
I used my mad photoshop skills to do a very high resolution and detailed render of what the overall will be. Little unconventional, but so is a buying a $2k bike, stripping it down to nothing and dropping $35k into it.
Im still looking for a better image to go from, but this gets the idea across....
Cerakoted to match the HD Blonde motor, and red anodize on all the trim parts.
Last edited by malfvnction; Jul 9, 2025 at 12:14 PM.
switching to a 49mm front end I had to order the from fender. That should have significant less prep than these did. The previous owner decided he didnt like the 100th anniversary blue, so he taped over the center line, then applied somewhere between 3 and 300 coats of black paint. Not sure what the paint was but had to go all the way up to 36 grit to get it off. Hammered out a few dents in the fender and got them primed. Waiting on the high bills to cure, then will sand one last time and start getting some color on them.
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