My first panhead

[BigLakeBob]

Rough start for 1st Panhead. Last picture looks like the circuit breaker gear is not in mesh with the pinion gear. The stud tightened in the case should make that happen. Where is the idler gear stud? All can be fixed, you just need to correct the stud locations. I would also pull the cam and look to see if the area around the cam bushing is cracked or has been welded.

Shovel left case, guess you don't need an idler gear.

[echambers]

Looking for help and advice, just a refresher this is the Johnny Cash bike of many many different parts main concern now panhead right case shovelhead left case. I'm in hope somebody can tell me what I have as far as this gear case cover besides problems I already mentioned I noticed that the pinion gear shaft seemed smaller than the bushing it rides in. Shaft measures . 555" and bushing is .583" thinking I may need to get a new cover but have no idea what year to get that will correct these bushing problems.IMG_20251124_134258342_HDR.jpg IMG_20251124_134311144.jpg IMG_20251124_134438668_HDR.jpg

[echambers]

I hadn't thought about that angle but I do understand what you're saying that would be a lot to hold everything in place while welding. I've just noticed that the cover bushing for the cam is belled, it looks intentional like when the cover was installed after the welder repair things didn't quite line up.

[dukekleman]

Ed,

I noticed that the crankcase has some extensive welding done to the gear case area.
Past experiences tend me to believe there is a connection to the gear cover issue you show in photos above and this welding repair...?

Duke Kleman

[echambers]

IMG_20251124_111134579.jpg IMG_20251124_111209180.jpg Found a belly number on the right hand case doesn't mean a thing at this point but it's there. Also found problems with the gear cover.the bushing for the breaker gear is pretty wallowed out. Problem is it's not an inserted brass bushing just machine into the aluminum cover. I expect it would be pretty hard to get that centered to bore for a brass bushing. Probably best bet just get a new cover? IMG_20251124_104612869.jpg

[echambers]

I'm in West Central Indiana. Sullivan county about 20 miles south of Terre Haute. I have a reprint of the service manual that I have just started looking at for specs. Thanks for the response Duke.

[dukekleman]

Echambers,

Valve stem protrusion height is very important for many reasons.

Where are you located?

Duke

[echambers]

Robbie. Thank you I was thinking along those lines but it's always best to get verification from somebody that knows. I would expect that if it were an intake valve that it could be a problem. Is there a rule of thumb on seat depth and when it should be addressed? I'm not one to look for trouble but in this case would probably be in the best interest to disassemble the heads and inspect the guides along with seats and faces. Fingers crossed that it will all be good otherwise a new problem finding someone in my area that does head work.

[Rubone]

So I have pulled the heads for inspection and have found that the rear head has a bigger exhaust valve than the front head. The front measures 1 3/4" and the rear is 1 7/8" since it's the exhaust only would this be a problem? Rear head and piston are very dirty and it looks like had a head gasket leaking also. Pistons are both .010 over and seem a little loose going to pull the cylinders and measure . Any opinions will be greatly appreciated.IMG_20251122_154422431_HDR.jpg

Chances are the seat was too deep so an oversize valve fitted. On a stock motor it is a non-issue.

[echambers]

So I have pulled the heads for inspection and have found that the rear head has a bigger exhaust valve than the front head. The front measures 1 3/4" and the rear is 1 7/8" since it's the exhaust only would this be a problem? Rear head and piston are very dirty and it looks like had a head gasket leaking also. Pistons are both .010 over and seem a little loose going to pull the cylinders and measure . Any opinions will be greatly appreciated.IMG_20251122_154422431_HDR.jpg

[echambers]

IMG_20251119_134415274.jpg IMG_20251122_103327730.jpg Hello to all that took an interest in this post and thanks for all of your input. Just to update the printed title arrived in the mail yesterday 1987 Harley Davidson, court order title . So the journey begins.

[HD48FL]

Excellent, glad you got to the bottom of it. Good luck and enjoy the bike.

[echambers]

87 Home Build. Was last titled in Kentucky as an 87. Will be going through the Indiana court ordered title process.

[HD48FL]

Then why mention that you "found a small trail of breadcrumbs"? Good luck, keep us posted, at the end of the day, getting a title/registration means you get on the road, it's a bitsa bike and meant to be a rider. Title however the BMV tells you based on the existing VIN and ride the hell out of it.

[echambers]

I wish you the best of luck, you seem swayed to title this as a '58 and you are clearly missing the important thing, it appears you bought a bike with no title, yet it has a VIN. Not sure of your plans, but you can't remove a VIN, so that's why I say go to the BMV and apply for a title based on your Bill of Sale. This way they can figure out the VIN on the bike, it's not like you can hide that.

I am not trying to hide anything I appreciate your advice and concerns but as I mentioned earlier chances of titling it as a 58 are slim to none I am aware of that. I also have no plans of removing or altering the VIN I currently have. I went into this deal eyes wide Open knew what I was getting into and I'm working to resolve this in a honest and legal way. Once again as mentioned in past post I will be working with the BMV to get this straightened out. Am I missing something? No! I am going through the BMV with whatever process they recommend as mentioned very early in this thread. Thanks.