DIY Network

Disassemble Fuel System From "Classic Rides" episode DCLR-102

In this second episode of nine, host Kevin Tetz and Bill "Dunk" Dunkelberger, resident Harley-Davidson expert mechanic, will dig into the restoration project by upgrading the camshaft and valve system.

After evaluating the project 1965 Harley-Davidson Electra Glide in the first episode, host Kevin Tetz and Bill "Dunk" Dunkelberger will tackle the camshaft and valve system in this second episode.

This American classic, the last of the panhead series and the first American motorcycle that had an electric start, was stripped down to get better access to the engine and other components in the first episode.

Kevin and Dunk noticed some problems with power output and the fuel system when the bike was tested on the chassis dyno, and these issues will be addressed during this episode by installing a new camshaft and new intake manifold and servicing the tappet blocks.

Note: If you would like more information on the restoration plan and evaluation of the bike, click here for our first episode.

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	Figure A
	Figure B
	Figure C
	Figure D
	Figure E

Getting Started

• First the spark plugs were removed and some paper towels were put down in the holes to keep any debris from falling down in there.

• Next the air filter is removed. Start by removing the cover, followed by the filter element (figure A) and then finally the base.

  Note: The fuel lines have an inline filter (figure B), which isn't needed. A new petcock will be installed and the braided lines will be replaced.

• Take off the old carburetor by removing the choke cable and throttle cables first.

  Tip: You don't want to back your screws all the way out. Leave them in there so they don't drop and get lost on the floor or inside the engine.

• Continue taking the carburetor off by reaching around the intake manifold and loosening the carburetor bolts. And then go to the top one (figure C) and reach over and hold the carburetor in place while taking the top mounting bolt off. If you don't do this the carburetor could end up on the floor.

  Also keep in mind that the bike may have a full-float bowl so you want to keep it upright (figure D) with the orientation that's on the bike.

• Get the intake manifold by loosening all the fasteners on the components before taking anything off. This is a great tip that will eliminate the possibility of putting anything in a bind by releasing all the pressure on one side and having it build up on the other side. The intake manifold should then come off easily once you release the clamps.

  Alert: Right away be sure to use a rag and cover the ports before anything can fall down into the combustion chambers.

• There's one more thing to do before you can get into the camshaft upgrade and that's to drain the oil to keep it from getting into the crank case.

  Tip: Take a regular "bent" piece of cardboard to use as a guide. Put a little hook on it and let the oil flow down into the pan. Take the drain plug out and let the oil flow (figure E).

In the next segment Dunk will join our host to dig into the camshaft upgrade.

RESOURCES :

The Eastwood Company

The Eastwood Company is a supplier of automotive-restoration parts, tools and supplies.

The Easthill Group, Inc.
The Eastwood Company
Website: www.eastwoodco.com

RaceDeck Modular Flooring (SnapLock Industries)
SnapLock Industries
Website: www.racedeck.com

Ultimate Harley-Davidson
0789499746
Hugo Wilson
(October, 2003)
To order this title from Amazon, click here.
Dorling Kindersley / DK Publishing

Hugo Wilson's Hot Bikes
0751336947
Hugo Wilson
To order this title from Amazon, click here.
Penguin Books

The Harley-Davidson Century
0760311552
Darwin Holmstrom
(September, 2002)
To order this title from Amazon, click here.
Motorbooks International

Restoration Parts (Custom Chrome)
Custom Chrome
Website: www.customchrome.com

Performance Carburetor, Camshaft and Other Restoration Parts (S & S Cycle Inc.)
S & S Cycle Inc.
Website: www.sycycle.com

Ironclad Gloves

Manufacturers of work gloves for all types of work including automotive. Griptec™ Gloves with 3M gReptile™ gripping material.

Website: www.iclad.com

Motorcycle Restoration Parts (In the Wind Motorcycle Parts)
In Wind Motorcycle Parts
508 Lovell Rd.
Knoxville, TN 37932
Phone: 865-560-5650 or 865-777-0884
Fax: 865-777-0886

GUESTS :

William "Dunk" Dunkelberger
Restoration Coordinator / Mechanic
Harrly Hoggs & Piggletts
1409 Piney Rd.
Maryville, TN 37803
Phone: 865-681-7699
E-mail: hoggsandpiggletts@yahoo.com