68 FLH Basket Case
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Seasoned HDF Member
Joined: Jun 2006
Posts: 30,881
Likes: 32,991
From: King George, VA
68 FLH Basket Case
Just started a project to help a friend put a 68 FLH back together. Its been sitting in parts for years. Apparently the motor was rebuilt but never put back into the bike. All the openings of the motor have been sealed but I don't know the condition of it. The wheels and tires are on the frame. Lots of nuts and bolts are in the bins with the pipes, oil tank, primary parts etc.
I'll be coming here for help that I can't find in the shop manual.
I'll be coming here for help that I can't find in the shop manual.
Last edited by EasternSP; Sep 24, 2011 at 08:16 PM.
Thread Starter
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Seasoned HDF Member
Joined: Jun 2006
Posts: 30,881
Likes: 32,991
From: King George, VA
I need help in how to put the inner primary onto the engine and tranny. Is a gasket required or just a film of gasket sealer? Any other tips I should know at this point?
I have read about the vacuume test. What can be used for this because I don't have a vacuume tool.
I have read about the vacuume test. What can be used for this because I don't have a vacuume tool.
Seasoned HDF Member
Joined: Oct 2005
Posts: 7,499
Likes: 3,717
From: Santa Klaus County, Cali
See you have the engine in the frame. now is the time to make sure it is properly fitted....
1. Insert rear bolts and torque to specs.
2. Use a feeler gauge to to see front motor mounts fitment to frame gap. If needed use brass shim stock (in a jam you can use beer can aluminum).
3. Insert front bolts and torque to specs.
4. Instal primary and bolts that secure it to the motor.
5. Next install and torque bolts that hold inner primary to transmission.
6. Your tranny case to frame nuts are loose at this point; this is a good time to see if you need to shim any of the 5 points to the frame.
Twizted should have some good advise about the vacumn test.
Looks like a nice project.
A question...how old are the tires? Look like old Goodyears. If so you might think about something newer for safety reasons.
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Seasoned HDF Member
Joined: Jun 2006
Posts: 30,881
Likes: 32,991
From: King George, VA
Thanks panz. Your'e right about the tires. This bike has been sitting under a tarp for about 20 years, in pieces. The engine was rebuilt about 5 years ago and sealed up.
I didn' t know about the feeler guage work required on the front engine mount. Actually, the bolts are missing from the parts that were delivered with the bike. The rear bolts were in the mount with the nuts.
So there is no sealer used at all in the assembly? Must he some pretty tight tolerances on this thing.
I didn' t know about the feeler guage work required on the front engine mount. Actually, the bolts are missing from the parts that were delivered with the bike. The rear bolts were in the mount with the nuts.
So there is no sealer used at all in the assembly? Must he some pretty tight tolerances on this thing.
Former Sponsor
Joined: Apr 2007
Posts: 5,360
Likes: 453
From: Davie, FL
Here is my friends. I put a 2006? FL dual disk fork into the OEM triple trees. The OEM forks & drum brake were stored in the garage. The bike is not original/restored but very clean and chromed. Runs & drives like new except with the needed new braking system. Do not loose hope and keep on it.
Elite HDF Member
Joined: Oct 2009
Posts: 3,922
Likes: 826
From: Toronto Canada
Thanks panz. Your'e right about the tires. This bike has been sitting under a tarp for about 20 years, in pieces. The engine was rebuilt about 5 years ago and sealed up.
I didn' t know about the feeler guage work required on the front engine mount. Actually, the bolts are missing from the parts that were delivered with the bike. The rear bolts were in the mount with the nuts.
So there is no sealer used at all in the assembly? Must he some pretty tight tolerances on this thing.
I didn' t know about the feeler guage work required on the front engine mount. Actually, the bolts are missing from the parts that were delivered with the bike. The rear bolts were in the mount with the nuts.
So there is no sealer used at all in the assembly? Must he some pretty tight tolerances on this thing.
you're about to find out why old harleys had a reputation for marking their territory
Cruiser
Joined: Aug 2011
Posts: 116
Likes: 1
From: North
Truthfully the case clearance should be done without the crank or top end. Too much weight. Just bare case is optimal. But you'll get it. Now would be a great time to convert to primary belt, shut off primary and chain oilers, get an O ring chain, and kiss most of the leaks goodbye. Just saying.
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Seasoned HDF Member
Joined: Oct 2005
Posts: 7,499
Likes: 3,717
From: Santa Klaus County, Cali
Thanks panz. Your'e right about the tires. This bike has been sitting under a tarp for about 20 years, in pieces. The engine was rebuilt about 5 years ago and sealed up.
I didn' t know about the feeler guage work required on the front engine mount. Actually, the bolts are missing from the parts that were delivered with the bike. The rear bolts were in the mount with the nuts.
So there is no sealer used at all in the assembly? Must he some pretty tight tolerances on this thing.
I didn' t know about the feeler guage work required on the front engine mount. Actually, the bolts are missing from the parts that were delivered with the bike. The rear bolts were in the mount with the nuts.
So there is no sealer used at all in the assembly? Must he some pretty tight tolerances on this thing.
Prior to 65 HD had a constant loss system on the primary chain oiler. With the e=start and aluminum inner/outer they developed a system that returned (sucked) oil back from the primary to the oil tank. Wasn't a perfect fit but got to give them credit...at least they were trying.
The only reason I suggest checking front motor mount to frame clearance is that if ya don't and the clearances are beyond specs after torque, you will bust the front mounts (ask me how I know).
Lot of guys running the old shovels and pans clean up the messy oil thing and convert to belt. A bit more noise and you need to make sure you have air going through but it does work. Me I will take the mess that goes with a stock set up. But it is all good...
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Elite HDF Member
Joined: Dec 2009
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From: navarre ohio
sealer can always be used..yamabond(yamaha) is the best aluminum case sealer made.i have used it on about every brand bike made. the oiler system is just a mess anyway. eliminate the oiler and just add oil to the primary like newer bikes..with he stock system there are all kinds of leaks,and starter gear shavings and clutch wear pieces get pumped thru the motor.i had a blown motor once caused by the starter gear grinding.had steel shavings all thru the motor
