My buddy Tim came down. He rode his big bagger down. I forget the exact year, but it's about an '80 FLH, full dresser. He's done some work to engine, cam, high compression, electronic ignition.... For a big bagger, it's pretty damn fast. And loud!

 

So we took a ride. Had some BBQ and stopped in Hog Alley, a Harley parts shop and Iron Horse dealer in Georgetown, TX. On the way back, we caught some rain. It's been a LONG time since I rode in the wet. And this was the first time for me and the FL/FX. I was soaked to the bone, but the bike didn't have any trouble. In fact, I was wondering why everyone else on the highway was going so slow.

 

It was a good ride. I have a minor blister on the left palm from using the clutch so much. The bike did stall once. The clutch was slipping... I used the wrong oil in the primary case... oops. But I bought the correct stuff at Hog Alley, so I should not have that problem again.

 

I doubt I put more than 300 miles on the bike since that last post. My dad took the bike to a local Harley mechanic around Jan '08 and had a new clutch and transmission seals installed. The mechanic also installed some new rear swing arm bearings I provided along with grease fittings. The transmission seals slowed the oil leak, but did not completely eliminate it. The new clutch really helped. The engine has been running great... really no new problems since this time last year.

 

Even though the oil leak persists, the weather was just too beautiful and I had to take the bike out for a spin. Park Road 4 is my favorite local route. It's winding, hilly, surrounded by blue bonnets, and usually free of traffic. I like to stop at the road side park just beyond Longhorn Caverns. The park is on top of a hill that looks out over Hoover Valley. It was a fun ride, albeit brief. The bike died on me again twice. Seems that it has trouble idling after running at highway speeds. It starts right up after a few seconds.

 

Well, the old boy is finally back on the road. I spent the day finishing the wiring, installing the rear fender, and mounting the brake light. I don't forsee making any major changes to the bike from this point on... just maintenance. After sitting for nearly 6 months, the bike started pretty easily and runs good. I'll admit that I was surprised. I topped off the tanks with fresh gas and went for a drive. I went down the same road that I broke down on during my last ride in November 2006. Unfinished business... and now that it's spring, the road and scenery are beautiful. Blue bonnets are everywhere and they smell so nice. The sun was setting, and some storm clouds were brewing. Birds were flying north in formation. I put about 35 miles on the clock today. At one point, the bike died as I was turning off the highway onto the back road. Fortunately, there was no traffic, so I pushed the bike around the turn to a safe spot, although on an incline, on the side of the road. The bike started right up... I couldn't explain it. I drove a little further and pulled over again on level grounf the check the oil level. It was down a little bit, but nothing serious. Maybe when the engine is hot, and after cruising, the idle was a little low... I dunno, but it seems to be OK. The S&S carb is said to be a little big for my 1200. I purchased a flat slide Mikuni at the recommendation of an old Harley mechanic, but have not installed it yet. He claims the Mikuni is better all around.

 

I have a pretty good oil leak. It appears to be coming from the drive sprocket on the back side of the primary cover. I'll probably take this one to a shop to have it fixed. That's a bit more work than I want to deal with.

 

Still working on the FX fender. Paint is done, relay holders are riveted on. I'm also finishing the wiring with wire loom to prevent any future shorts.

 

I bought a blank FX rear fender. It has no holes for a tail light. I have a tomb stone tail light that i will mount to the fender. I was really quite surprised that the FX fender fits perfectly, even matches the new seat... and looks great too. I've got to paint it, wire the light, and clean up some of the wiring under the seat. It should be on the road again soon... just in time for an early spring run through the Hill Country.

 

Gobble Gobble. I took the spring post off, and zip-tied the seat to the frame... actually worked pretty well. I went for a ride and only lost a few parts. The nut on my battery tie down disappeared, and the rear tire managed to rub through the insulation on the brake light wiring. The bike died all of a sudden. The wires grounded to the back fender and shorted out.... which killed the ignition. After a couple quick snips from some pliers, I was back on the road. Those relay fuses are great!

 

I purchased a new seat but haven't installed it yet.

 

I got it fixed. Turned out the lifter/tappet adjusters loosened up and backed off, causing the valve to loose all lift. How does that happen? I'm guessing after sitting dry for 15 years, then getting lubricated and vibrated, they just got loose. It was an easy fix once we diagnosed the problem. I also adjusted the clutch pack so now the clutch isn't slipping anymore. The bike runs much better now.

 

I took a 150 mile trip yesterday. I was able to mix it up with country highway, city freeways, inner city streets, and country back roads. I even got a little mist just to make things interesting.

 

I installed the baffles into the exhaust pipes to see how it would sound. It's quieter and sounds OK, but I think I want that obnoxious Harley roar. I bought a set of new pipes from Tim. They don't have baffles and the chrome is much better.

 

The "pogo" solo seat has got to go. It's too bouncy on bumpy roads, sits too far forward, and too tall.

 

The old boy left me stranded... on a dark highway, with no shoulder, and a 30' drop off. I tried kick starting it on the road, but nearly lost it and barely saved myself from a fall. I had to push it about 1/8 of a mile uphill to a driveway. A buddy was with me, so he gave me ride home where he and I picked up my truck and returned to load the bike. I haven't determined the problem yet.

 

Well, the bike is finally legal! I purchased a new regulator/rectifier and it appears to have solved my recharging problems. The new unit actually puts out voltage while the two old ones I tested didn't do anything. I haven't been able to get the front end checked out yet. Overall, the bike is running a driving well. I think the clutch slips a little bit when I shift gears and hit the gas.

 

My battery isn't recharging, so it's either the regulator or generator. The bike want to veer to the left, so either it's misaligned or the frame and/or forks are bent from a wreck my father had long ago. If I remember correctly, this bike was originally a San Antonio Police Department motorcycle that was wrecked. My father had the frame straightend when he purchased the salvaged remains. A shop next to Mike's hot rod shop can take a look at it for me.

 

My buddy Tim helped me remove and replace the front wheel. I took the wheel to the shop for a new tube and tire. The rim has some bad rust spot where the old tube collected moisture. I will need to keep an eye out for a replacement rim. The wheel bearings where shot too. I went ahead and replaced the speedo drive and cable as well. Once Tim and I got back to my house, we installed the new parts and aligned the front forks. I had Tim take it for a ride since he's more experienced than I am with these old scoots. He fell in love with it and threatened to steal it. It is a lot of fun. It has all those classic Harley traits (the good and the bad). I get some pics up very soon.

 

I took the bike for it first REAL ride. About 7 miles. The brakes are well, circa 1977 trying to slow a 750lbs beast.... not like the brakes on my CBR600F3. The engine and trans work well, no problems. It's going in for a front tire and a safety check ASAP.

 

My new brake setup arrived. I've got about $500 in the front brakes alone. It's installed, but I have yet to actually ride it and see if it stops. The last thing to really do is complete the wiring for the brake light and head light.... then take him for a test drive.

 

A bit of a setback today. I went back to the Harley shop to get some more parts... brake lines, throttle cables, and a few less important items. I measured the length of the cable and brake line with string. When I got home I installed the throttle cables and the front brake. While trying to bleed the brake, I noticed a constant leak at the caliper. It turned out that the new brake line either crossthreaded or somehow damamged the threads of the caliper. It wouldn't seal. The brake line was fine though. I'm afraid I may need a new caliper now.... $300 ugh. If the brake line had worked, I'd be out riding right now.

 

I installed the 10" Ape Hangers... I hate them, but considering they were the ONLY bars I could find with internal wiring for under $125 (these cost $38), I'll live with them for now. Since these bars are longer than stock, I'm using the +6" Clutch cable I bought by mistake.

 

I took a scary ride to the end of the street and back. NO BRAKES! I previously bled the rear brake, the front is not installed, but when it came time to apply the rear brake..... nothing but a STIFF pedal. No accidents, so I turned it around (which is a pain in the ass with Ape Hangers), and struggled to back it into the garage. First time out in 15 years.... nothing unexpected really :)

 

It Lives!!! And it runs great too. After 15 years of sitting in silence, the old bike rumbled back to the land of the fire breathing beasts.

 

My garage is a total wreck. I'm going to load the bike up on a trailer and take it to the Harley shop for a new front tire, chain, and rear sprocket. While it's away, I can gut the garage. I don't have the front brake connected, and my wiring is not complete; only the ignition is wired. I finally found some handle bars that will work with my new controls.

 

I pulled off the old oil lines and replaced them. Cleaned the oil tank. I painted the oil tank, battery tray and mount, mounted them. Installed a new oil filter (ditched the old felt type with a new pleated paper type). I got the lower stem bearing installed and reaplced the handle bar riser bushings.

 

Just waiting on parts to arrive. I broke down and purchased a new S&S Super E carb kit ($350). The old Bendix carb needed a rebuild, and upgrading only cost a little bit more.

 

My parts arrived. I mistakenly ordered a clutch cable 6" too long... I'll need to purchase another. The tanks and fenders are all done. I purchased some items from a nearby Harley shop (about 40 miles away). Most of the parts worked. I got a great deal on a complete stem bearing kit. They did not stock the air filter I need, but had some updated oil filters. I picked up oil and fuel hoses today. The new battery is charged and ready to install. I need to pick up a little extra wire and complete the wiring.

 

I think I did really good.... I only ordered parts that need to be replaced. New throttle and clutch cables, new grips, and a battery tray pad. I really wanted that electronic ignition.... but I can always buy that later.

 

I'm on my way out the door to return the battery, pick up the correct battery, and get some additional paint supplies (sand paper). I might actually get the tanks and front fender painted today.

 

Well, I ran out of paint, so I had to pick up some more, and that caused problems. Spending a little money makes it easy to spend a little more. So, my sub $30 paint job is now at about $50. But it's done. The parts look fantastic from 10ft away and like a $50 paint job close. I purchased a paint product called "Nite Lites" by Duplicolor. It's a clear reflective paint like that on street signs. I am thinking about doing some ghost flames or something, but I did paint the tank emblems.

 

The wiring is crap. Dad used twine to "mount" the fuses to the frame. There is no consistency with wire color. The same wire might have 3 different splices and 3 different colors. The Oil Pressure indicator is wired as the High Beam indicator. Fortunately, I've found a simple wiring diagram on "the 'net" and have plenty of colored wire to fabricate a new wiring harness. All the rubber hoses need to be replaced. They are as hard as rock. The gas tanks appear to be in good condition. The front fork stem bearings are shot; I purchased new ones. The handle bar grips are toast. The engine turns over easily and still builds pressure. I removed the spark plugs, sprayed some lubricant into the cylinders and turned it over by hand many times.

 

I managed to get the front forks off so I can replace the stem bearings. I've tracked down most of the wiring... this shouldn't be too hard. I bought a new battery but it was too large.

 

74 cubic inch V-Twin mounted directly to the frame.... no rubber vibration insulators here! That's why they call them the "Milwaukee Vibrator."

 

Did a little paint work. I sanded down an old SuperGlide rear fender that my father found on the side of the road about 10 years ago. I'm trying to keep it cheap, so this is my sub $30 paint job. Since the only parts to paint are the fenders and the tanks, I figured I could splurge a little bit. I went with a red/blue "Mirage" paint made by Duplicolor. I'll get the tanks and front fender done soon.

 

So here is where I begin. This is a 1977-ish Harley Davidson FLH. It once belonged to the San Antonio Police Department. It was wrecked and my father purchased the remains. He rebuilt it when I was a kid from spare parts. It's really a '76, '77, '78 mish-mash of parts. It's been sitting in this condition for about 15 years. It's a kick start, has baffle-less drag pipes, Fat Bob tanks, Shovel Head, and a SuperGlide front end. The "police" seat was added after the bike went into storage. I'm going to try and resurrect this piece of old Milwaukee iron. My Dad's old goggles are still hanging from the handle bars.