As John mentioned bolts down with a cotter pin throught the nut and bolts.

Also made a brass shim (.002) for each front bolt between the engine case and the frame. When I torqued the rear bolts down to specs I had .004 gap on each side.

And managed to get a new Diamond 530 chain installed. The old one was a Duckworth. Couldn't find anyone with one so went with the Diamond.

 

According to Palmer the front bolts go up through the skid plate like the earlier Pan's as you have no choice on one of them.

 

That is defintiely true for the earlier Pan motors that have the cradle for the generator (as in my 49 pictured below).



My 65 motor does not have that cradle.



Can see it done bottom up with the use of a skid plate. I do not have one.

This way, even if the cotter pin breaks, the nut comes loose and falls off going down the road, my bolts will still be there.

 

The hard tail was the last of that cradle and strap for the Generator I believe.

I understand the concept of the bolt falling out depending on orientation but a cotter pin breaking on a non-moving part is very unlikely bordering on impossible. I was just curious which way you put them in because the Palmer book is considered gospel here and Im trying to figure out what is correct vs preference.

 

Paul, you are absolutely correct on the direction of the bolts (as per Palmer). Just one of those areas on the bike that are preference for me. Just like the front fender lower tip, my kickstand, the generator cover (all Shovel accessories & parts).

yesterday/last night I finished the painting and plating details specific to the 65. Now have a printed copy that is a bit easier to read, rather than a single paragraph for each. And now i can go thru each section and look at what is correct & not correct and determine what I may need to change. One of those areas that I will not change for awhile at least are the shock absorber studs. Mine are cad plated (should be parkerized). Means complete disassmbly of the *** end. Right now that is definitely not happenening. Still going thru things so at the end I will make a complete list/areas that would make it more correct.

Cadmium Plated Parts

Motor:

Top motor mount brackets, head bolts and washers, lower mount bolts, lower motor nyloc #7775, OHV rocker housing oil lines and nuts, rocker housing oil line nipples, cylinder base nuts, crankcase studs and nuts, crankcase bolts, tappet guide screws, oil pump spring caps, oil pump tall nuts, oil pump stud lock washers, oil pump nipples #63540-521, crankcase relief pipe #24912-65, oil pressure switch adapter #26540-52 and generator bolts.

Carburetor:

Manifold clamp screws, manifold bolts, choke lever, choke shaft, choke rod, choke disc, lever screws, low speed needle ****, high speed needle ****, idle hole cover screw, float bearing pin screws, bowl lock nut, throttle lever connector #27450-36.

Circuit Breaker Cover:

Cover screws #2626, points base, shaft housing, and base bolts.

Transmission:

Hand and footshift rods, rod ends and rod end bolts. Footshift rod nuts #7744, gear shift, gear shift levers #33660-52 and #3406-52, tankshift lever stud and nut, handshift gate bolts, top cover screws sockethead #1765W and #1766W, vent screw, upper side cover studs, side cover stud washers and nuts and filler plug.

Clutch:

Foot and hand clutch rods, clutch rod ends, clutch rod lock nut #7638 and washer #7231, clutch release arm, booster spring cover, booster cover screws #2751, booster spring eyelet bolt #38502-52 and adjuster #38674-52 and booster bell crank, shaft and nyloc #7775

Axle and Wheels:

Spokes, spoke nipples, front axle, sleeve, washer #6591 and axle nut #7923, and rear axle adjusting screws.

Rear Brake:

Brake pedal, pedal bracket, clevis pin, master cylinder cap, wheel cylinder bolt #41743-58 and backing plate anchor nyloc #7933.

Front Brake:

Brake cable housing early #45041-65, brake cable housing late, #45033-65, hand lever pivot pin #45031-65 and retaining ring #11036, hand lever bracket clamp screws, front brake cable tube, adjusting screw, clip and clip mounting screw.

Front Fork:

Tube plugs #45776-49, filler plugs #45754-60, slider cap studs and flexlocs, and slider cap (optional with polished slider, steering damper anchor plate, steering damper **** screw, steel washers, anchor pin and **** tension spring (sidecar).

Chassis:

Head bearing cups, head cone nut #48330-48, dust shield, grease fittings, jiffy stand leg, shock absorber cam parts and stud nuts, seat post, throttle control coil bracket #56609-52 and screw #3720, rear fender mounting bolts, #4043W, primary cover cap screw #60564-65 (optional) primary cover inspection plate #60572-65, inspection cover screws #1354 W, and exhaust port clamp bolt.

Fuel and Oil:

Gas line and nuts, gas tank crossover line, gas filter, gas shut-off valve, shut off rod, shut off **** screw, shut-off rod seal cap, gas hose wire clamp #9998. Oil lines and nuts, oil tank drain plug, oil hose band clamps #10014, vent hose band clamps #10013, front chain oiler return line fitting #63533-65, and front chain oiler fitting at crankcase #60549-65.

Electrical System:

Starter motor support brackets, ignition coil mounting stud, spark cable clip #9970, headlamp and horn switch cover screws, stop lamp switch #72002-51, stop lame switch screws, tail lamp door screws, dash cover left hole plug, dash cover center bolt washer, instrument panel base, instrument panel mounting bolt.

Speedometer:

Body, tripmeter reset, tripmeter hole cover, cable clamp #67-75-57 A and cable housing.



Parkerized Parts

Motor:

Upper and lower motor mount bolts, cylinder base studs, cylinder base lock washers, crankcase drain plug, oil pump studs, oil pump bolt, oil pump stud nuts.

Carburetor:

Carburetor support bracket.

Air Cleaner:

Backing plate, mounting plate bolts and mounting bolt lock plate.

Transmission:

Starter pedal axle, starter spring stud, starter arm shaft, #33096-54, handshift rod end locknut and bolt #7752, footshift bracket, footshift cover front screw #2756, cam plunger cap screw #34053-36, transmission shifter cam shift lever, transmission mounting studs and nuts, mounting plate, mounting plate bolts, side cover studs.

Clutch:

Foot clutch pedal, foot clutch pedal bracket, foot clutch spider washer #36906-36, foot clutch shaft washer #36913-41, shaft lock washer #36909-36, release arm shaft, and clutch booster U-bolt.

Axle:

Rear axle, sleeve, collar, spacer and nuts.

Wheel:

Star covers and star cover screws.

Rear Brake:

Brake drum socket screws, wheel cylinder bolts #41752-58 and backing plate anchor and bolt.

Front Brake:

Brake drum socket screws.

Front Fork:

Stem nut #45718-48 and lock washer #45717-63, bracket pinch bolts, slider drain plug, and steering damper spring #46715-48 (sidecar).

Chassis:

Crankcase guard #24490-36, swingarm pivot bolt and lock, shock absorber studs, jiffy stand leg bracket and spring bracket, floorboard studs, bolts and nuts, seat mounting studs, bolt and spacers, seat post plunger, seat post nut, rod, seat T pivot bolt and nut, seat clevis pin #51918-29, seat clevis spring #51920-29, handlebar end screw, throttle control clip #9983, front fender mounting hardware, rear chain guard bolts, and exhaust pipe clamps.

Fuel and Oil:

Gas and oil tank mounting bolts and nuts, rear chain oiler clamps, rear chain oiler line and chain oiler screws.


Accessories:

All unmentioned nuts, bolts washers, lock washers, spacers and screws.

Sidecar:

Body mounting hardware, frame mounts and hardware, axle and nuts, leaf spring U-bolts, shackles, step bolt, footrest and mounting hardware, fender mounting hardware, recoil strap brackets, and spare tire mounting hardware.


Chrome Plated Parts

Pushrod covers and cover clips, shift gate and lever, foot shift cover #33644-65, shock absorber covers, handlebars, grip plug, front fender side trim and tip, Electra-Glide name plates, primary chain cover screws #2345, rear fender supports and mounting screws, #2414W, exhaust flex covers, S& Y exhaust pipe, tank name plates with white paint shield, chrome lettering and black painted background, gas caps, gas shut-off ****, oil tank cap, oil tank cap screw #62620-52, generator end cover, tail lamp door, dash cover center bolt, ignition coil cover, headlamp, horn, and spot lamp switch covers, voltage regulator cover, speedometer bezel, luggage rack and mounting bolts and mirror #91873-47.


Nickel Plated Parts

Clutch release arm shaft cover bushing


Zinc Plated Parts

Oil pressure switch, manifold clamps, neutral switch #71507-64, steel brake line, batter terminal bolts and nuts and ground wire frame bolts.



Plastic Parts

Red tail lamp lens.



Standard Color Painted Parts

Fenders, gas tanks, instrument panel cover (chrome optional), tail lamp body, tail lamp license lens screws, sidecar body and fender, sidecar front and rear body supports.



Black Painted Parts

*Optionally available in chrome through a package or individually.

Carburetor:

Body (dull).

Transmission:

Kick starter arm, kick starter spring, foot clutch release spring, foot clutch release spring, foot clutch bearing cover, and clutch booster spring

Wheels:

Rims* and hubs.

Brake:

Drums, rear backing plate, brake shoe springs, brake return spring, and hydraulic hose clip.

Fork:

Fork brackets.

Chassis:

Frame, swing arm, footboards, jiffy stand spring, saddle pan, safety guards*, seat T, handlebar clamp #56104-52, rear chain guard, muffler (chrome optional), and muffler supports.

Fuel and Oil:

Oil tank and oil tank bracket #66371-65,

Electrical:

Generator steel body, ends, and brush cover, starter motor body and ends, battery top cover #66371-65*, battery tray, license plate bracket, horn ignition coil bracket, terminal box, and regulator cover.

Accessories:

Leg shields, leg shield brackets.

Sidecar:

Frame, leaf springs, windshield frame and arms, brake backing plate and drum, spare tire carrier and recoil springs.



Silver Painted Parts

Cylinders, oil pump bodies, master and wheel cylinders, and exhaust header pipes, and sidecar spare tire carrier spinner hubcap.



Stainless Steel Parts

Air cleaner cover, foot-shift dust shield #34555-52, slider covers (optional), shock absorber cover clamps, muffler clamps, battery strap. Sidecar body top and side trim pieces and sidecar fender trim.


Natural Finished Parts

Aluminum rocker covers (polished), and heads, rocker cover D-ring, crankcases, gear cover manifold, carburetor bowl, starter cover, transmission case, transmission top cover, transmission filler plug, clutch hand lever and bracket, clutch booster bracket, front brake hand lever and bracket, hand lever bracket clamp #45030-65A, polished front brake backing plate (optional), and polished sliders (optional), steering damper **** (sidecar), polished handlebar clamp cover (optional), polished left and right headlamp housing (optional),outer and inner primary chain covers, speedometer drive housing, sidecar step and sidecar spare tire carrier spinner handle (optional).



Natural Brass Finish

Front chain oiler #24910-37, rocker housing oil line nipple #63542-63, throttle shaft, throttle disc. Body plugs (inside bowl), float valve and small terminal nut #7634.



Black Materials

Starter pedal rubber, shifter ****, footshift lever rubber #34609-52, hydraulic flexible lines, hydraulic steel line neoprene cover, footboard mats, saddle #52004-25, plastic control coil covers, plastic grips, oil hoses, vent hose, ignition coil, instrument panel rubber gasket, 16” tube rubber tire stems, windshield apron add on #57990-60, windshield winter apron add-on #57990-60, sidecar leatherette windshield, tonneau cover and seat, ribbed sidecar floormat,



Natural Material

Foot clutch friction washer #36889-41 and sidecar check strap.

 

Got passenger pegs assembled . Used Gorilla glue to make sure the rubber doesn't come off.






And after almost 50 years of faithful service I finially had to put my service manual in a binder. Bought it new. It had become a collection of loose pages. Majority of the glue holding the pages together had dried up. Seems like eveytime I opened it pages were falling to the ground or blowing away with the breeze. Had to happen sometime. Cover is in an insert in the binder. Photo of the pages make it look much better because pages are really yellowed. But it is still all there.

 

You are doing solid work...keep it up!

Be careful with the Gorilla Glue....it has a tendency to degrade rubber over time...

 

Thanks for the heads up!

And I have a couple of things to correct already. My lower motor mounts bolts should be cad plated with nylocks so I won't go putting the primary together until I correct that.

And another thing I finally figured out last night while reading through the detail section. Hellowneman initially mentioned it many posts back when he asked about the finish on my seat post (it is cad plated). I looked in the detail section and it states the seatpost is cad plated. However under the parkerized section it states the "plunger" is parkerized. The seat post sits below the plunger and has the spacers and springs attached to it. The vivisble part, the "plunger" is the section that appears above the seat post. I never considered the two seperately, just as a single unit, the "seat post". So that has to get fixed as well.

 

Oh you are in deep!!!!!!!!!!!!!!!!!!!!!!!

 

Kinda a like having a case of chicken pox, an itch you just gotta scratch but won't go away.

When I was trying to figure out what was the correct finish I did not have palmer's 3rd ed. And I had already had some plating done (including seat plunger and bolts). I went off his 2nd ed for for 1964 models for ideas on plating and paint. His 2nd ed only refers to the "seat post" under cad finish; there is no mention in either the 2nd or 3rd ed of the "plunger" so when Paul brought it up I could not make the connection.

And I misread the lower motor mount bolts. They are parkerized top and bottom on 45 models. 3rd ed clearly states top bolts, nuts and upper motor mount washers are parkerized on BT models; lower ones are cad finish.

As mentioned in a prior post I screwed up on the shock mounting studs (should be parkerized) but I wobn't mess with that until I find a good set of original shock (just the shocks, not the entire unit). Missed out on an OEM pair around February. Have all the parts finished properly but one of mine leaks and there is no repair possible that I am aware of. Spent 35 +shipping to send them back east to a company that thought they might be able to fix them but to no avail. I do have a pair of Sporty shocks that I may have a buddy help try and dissamble and see if there is a way to modify them so oil can be added. Same type of shock sealed but BT models were bigger.