front end help, '76 flh
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front end help, '76 flh
What's up y'all, it's JC from the Sportster section. So I'm taking a couple of motorcycle classes at our local City College. A friend of a friend asked if I'd be interested in using his 1976 flh as a project bike. I says sure, problem is this thing has been lying around his garage for about 12+ years. He had electrical problems in '99 when he got it but didn't bother with it. Eventually he had somebody rewire the whole thing. When he got it back he started to mess with the front end, putting thicker forks on it. The problem is he doesn't have the proper spacers so the tire doesn't fit right. My question is how do I know kind of hardware to get for this front end. It's not the original front end but I think it's the original front wheel. I'm gonna go by California Choppers in SF this weekend and maybe they'll be of some help, they're pretty knowledgeable there. Went by the dealer and they said to get the manual. I have a Haynes manual and dude is digging out a manual he has. So any help here would be appreciated. I'm gonna measure the axle, measure the length of the forks and the space between them as well as the hub of the front wheel. Does this sound reasonable? Any advice (except for "get the manual", because it's on its way) would be welcome.
Club Member
Joined: Mar 2009
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From: Niles Canyon Ca.
Pictures my friend only way to tell what you have , stock FL wheel & front axle is pretty straight forward with just one spacer . Need to see what fork legs you have to put you on the right path .
Shops gonna tell you the same thing they will need to see it and the manual is useless for this .
Shops gonna tell you the same thing they will need to see it and the manual is useless for this .
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Pics, gotcha. I figured the manual might not be that useful for this since the forks are different. So, this Saturday we took the axle out looked at the wheel and spacers. It looks like we need a 5/16 inch spacer, but then the brake seems to be rubbing against the fork a bit. Still not sure about washers. It looks like we need the seals as well as maybe some bearings. First thing, I think, are the proper spacers and washers. I might go to Ace hardware and just pick up a couple of different sizes. I've been looking kits but like I said, I don't really know sizes I would need. Anything you can tell me would help. First two pics are of the forks. Then some pics of the front wheel with and without the fronk brake loosely on the fork. Definitely gonna need to either take that brake apart and clean it up or just get a new one. It's super rusty. Anyhoo, thanks in advance. jc.
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Joined: Mar 2009
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From: Niles Canyon Ca.
Ok I'm seeing 3 things here , those are later shovel FL lower legs that used the big banana caliper , that wheel looks to be off a later model but the width is same on the hub but the spacing on the caliper may be different and in that last pic it looks like an aftermarket brake bracket of some kind . I take it you don't have the spacers that go against the bearing that the seal rides on ? Those are a common size on that wheel style so a shop may some and you will need the correct one to get the brake bracket to sit right or you'll have problems . Find those and I'd pick up some 3/4" SAE washers from the hardware and pick through them to get the thinnest ones you can or a few 3/4" shims along with and stack those till get it where you want it as close as you can , measure with a dial caliper to get the size in decimals ( like .359" as and example ) and a shop can match up the closest to it for you and they can also get you a wheel shim pack or 2 so you can fine tune it .
I cheat doing this stuff I have a box full of old & new wheel spacers to play with and cheap lathe to make it if I need to .
Pics of all the brake stuff please see what you got and are trying to do , may be able to help there too . I'm down in the east bay in old town Niles in Fremont I do a lot of the old bikes and what your doing .
I cheat doing this stuff I have a box full of old & new wheel spacers to play with and cheap lathe to make it if I need to .
Pics of all the brake stuff please see what you got and are trying to do , may be able to help there too . I'm down in the east bay in old town Niles in Fremont I do a lot of the old bikes and what your doing .
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Alright, here's a couple of pics of the front brake we are dealing with. It's a Performance Machine unit from the 80's (I'm assuming). We just kinda put it on the fork to see how it would go on there. It was rubbing on the fork a bit but as you know we don't have the proper spacers. That 3rd pic, you think I can just take it apart and clean it up with a kit, or should my homeboy just get a new front brake caliper?
And I think we do have the spacers that go up against the bearings but they have a lot of rust on them. This dude has bags of stuff, but most of it has rust. I'm pretty sure it's just on the surface and we can clean it off. I'm looking at getting a hub rebuild kit-bearings, seals, washers and spacers. I think once we figure out exactly which spacer(s) we need to get I guess I can narrow one of those kits down. I'm kinda thinking and typing so...any info you have for me is more than welcomed.
And I think we do have the spacers that go up against the bearings but they have a lot of rust on them. This dude has bags of stuff, but most of it has rust. I'm pretty sure it's just on the surface and we can clean it off. I'm looking at getting a hub rebuild kit-bearings, seals, washers and spacers. I think once we figure out exactly which spacer(s) we need to get I guess I can narrow one of those kits down. I'm kinda thinking and typing so...any info you have for me is more than welcomed.
Road Warrior
Joined: Dec 2007
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From: Styxville
Alright, here's a couple of pics of the front brake we are dealing with. It's a Performance Machine unit from the 80's (I'm assuming). We just kinda put it on the fork to see how it would go on there. It was rubbing on the fork a bit but as you know we don't have the proper spacers. That 3rd pic, you think I can just take it apart and clean it up with a kit, or should my homeboy just get a new front brake caliper?
And I think we do have the spacers that go up against the bearings but they have a lot of rust on them. This dude has bags of stuff, but most of it has rust. I'm pretty sure it's just on the surface and we can clean it off. I'm looking at getting a hub rebuild kit-bearings, seals, washers and spacers. I think once we figure out exactly which spacer(s) we need to get I guess I can narrow one of those kits down. I'm kinda thinking and typing so...any info you have for me is more than welcomed.
And I think we do have the spacers that go up against the bearings but they have a lot of rust on them. This dude has bags of stuff, but most of it has rust. I'm pretty sure it's just on the surface and we can clean it off. I'm looking at getting a hub rebuild kit-bearings, seals, washers and spacers. I think once we figure out exactly which spacer(s) we need to get I guess I can narrow one of those kits down. I'm kinda thinking and typing so...any info you have for me is more than welcomed.
If you dont have the right spacers or a lathe to make them, JP Cycles and others sell a range of different size axle spacers. Or use the time-honoured stack of hardware store washers etc.
What will help your more with piecing this jigsaw back together than a manual would be a parts book. It has all the exploded diagrams of just how everything fits together. Still available from HD dealers. Or find an online HD dealer who has the parts fiches posted on line for ordering purposes.
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Club Member
Joined: Mar 2009
Posts: 66,126
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From: Niles Canyon Ca.
That looks like the old Hurst Airheart setup not the PM and they haven't made those in 30 years or so , at this point measure the distance between centers on mounting bolts and do your online homework looking for something that match's up . Even with a new seal kit & piston I doubt you'll get that apart and the alum corrosion will have pitted & crudded up everything bad .
You may send a pic to tech support at PM & Jay Brake and see what they come with ?????
You may send a pic to tech support at PM & Jay Brake and see what they come with ?????
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Club Member
Joined: Mar 2009
Posts: 66,126
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From: Niles Canyon Ca.
I can't squint that well anymore 
and that style hasn't been made since the early 80's so good luck if the pistons & bores are corroded .........
and that style hasn't been made since the early 80's so good luck if the pistons & bores are corroded .........