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^ The above, plus, you want cast bar, do not use sintered bronze, it's not strong enough.

And you will need reamers and pilots to align ream the bushings.

I make a few bushings for the old...

Since the spoke angles are so much different for that hub, a custom rim is needed. Buchanan's can supply a rim with the correct holes for the spokes.

Jim

Once you remove the cam cover, the cam will come right out. Before you remove the cam cover, take the pushrods out to unload the cam. It would be easier to also remove the rear tappet block but not...

Yes. The crossover shaft is in the same place as the rear brake pedal shaft on the '74 and earlier. Which means, using the older parts, you can convert a '75 or '76 to right side shifting and left...

It may take a few tries. Just be ready, when the clutch breaks loose the bike is free to roll so don't hit anything.

Jim

Yeah, clutch could be stuck due to oily plates. Some of those older XLs tend to leak oil into the primary/ transmission from the primary breather valve.

Sit astride the bike with the trans in high...

You can use a Road King size battery, or even smaller, a Softail size battery and get it under the seat. Either one will have plenty of capacity for your bike. And you are right about the balance....

If you have a later S&S pump with the low feed fitting option, you can use the old oil line nipples with 1/8 NPT threads. Then a little bending of the stock (or replacement) oil lines, and I think...

I don't have to believe it, I know it. I've got one sitting right in front of me. Go learn something, jr.

Jim

I checked out your video. Nice bike! Sounded OK to me, but I'm on a cheap phone and I'm half deaf.

Jim

There are pressure waves and sound waves going back and forth in the pipe. The two waves behave a little differently, and travel at different speeds. But both are "reflected " from the end of an open...

Oh Lord, I don't want to get involved in an oil thread. Just shoot me now.

But, since you asked....

H-D recommended 20W50 for shovels in the later years. I am not a fan of multigrade oils in...

Yes, those two-piece intake clamps are definitely aftermarket. Sorry if my wording was confusing. I have in the back of my mind the thought that those intake clamps were an early Arlen Ness product,...

Not necessarily. Depends on the year/model. Most hubs that came with 39mm front ends are the same width as the earlier narrow glide hubs.

Jim

This was a 39mm single disc front end with the normal 11 1/2" rotor. I just put the 19" wheel back on it. Experiment gone bad.

Jim

Even if they are chromed, if they are the brass ones they will not be magnetic.

Jim

That's reversion and it is mostly influenced by the exhaust system. The air cleaner helps retain some of it. You can see it on drag bikes with velocity stacks quite often. And yes, it is one reason...

The problem is a common one. One solution is to machine the inside of each caliper for clearance. On the '78 style single piston H-D caliper, it's pretty easy. Cut at an angle, similar to the way the...

Corollary:

Occam's Razor

The simplest solution is usually the correct one.

Jim

The instructions in the service manual are for the stock, manual advance timer. That is NOT what you have, and so almost everything in the manual will not apply. Thank goodness for your pics, as that...

On that factory frame, the fabricated neck is what gives the front of the frame its torsional rigidity. You cut the sheet metal away, and there is nothing left. If you are good with building an...

That motor should have orings for intake to head seals. A couple of bucks at any H-D familiar shop. Looks like you have the two-piece intake clamps. If they are the original cast brass pieces, they...

You want the double sealed bearing for an ooen drive. That is a common inch size bearing, R16-2RS. Most that you will find are Chinese, and they are OK. It's a low-load application.

Jim

1) It looks like you have a Standard Blue Streak condenser, judging by the blue wire. That is my go-to at this point, good condensers being rather hard to come by, and subject to early failure.

2)...

I have not read this thread because I do not have one of those Chinese lathes, nor have I ever used one.

But I have done some valve work on the lathe, and so here's the thing:
You have to be able...