DIY Network

'48 Indian Motorcycle: Ignition Switch, Shift Lever and Seat From "Classic Rides" episode DCLR-309

Ignition switch and speedometer, installed

The wiring for the '48 Indian Chief will be complete once we get everything hooked to our ignition switch and dash cover. Once that's done, Chris and Craig install the shift lever and linkage, and then the seat.

Materials and tools:

wire clipper
wire strippers
barrel connector
complete set of SAE or metric wrenches

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Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

Note: This is a summary of steps included in the automotive restoration procedures shown in this episode of Classic Rides. These are general guidelines for restoration procedures on this particular make and model of motorcycle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

	Installing the ignition switch

Ignition Switch

The next connection we will be doing is for the ignition switch, and for this we will be using a barrel connector. This is the same process we used when we hooked up the circuit breaker.

• Insert one end from the harness and one end from the headlight wire into the barrel connector and crimp the ends tight.

• Repeat these steps for all the wires that connect to the ignition switch.

• Once all the wires are connected, the switch can be secured to its mount.

• Set the switch onto its mounting points, and insert a screw in each hole.

• Tighten the screws with a screwdriver.

• Next up is the dash cover, this sits in place covering the ignition switch and speedometer.

• Place the cover and make sure that no wires are being caught between it and the gas tanks.

• One the cover is in place, install the screws and tighten with a screwdriver.

	The replacement "Indian Chief" shift knob
	The original shift knob

Shift Lever

Our next project is the shift lever and linkage. Unlike modern motorcycles, the Indian has a foot clutch and gear shifts are accomplished with a hand lever. There is a tubular bracket on the frame that the lever pivots in.

• To start, put a small amount of grease in the bracket.

• Slide the shaft of the shift lever through the bracket and once seated all the way in, place the key way in the small slot on the end of the lever. This will lock the lever arm to the lever and prevent it from moving.

• Slide the lever arm on to the end of the shift lever and tighten its locknut.

• The linkage that connects the shift lever to the transmission is next. The rear portion of the linkages threads into the slave arm on the transmission, so once it's snug tighten it with a wrench.

• The front portion of the linkage attaches to the shift lever arm with a bolt. Set the linkage in place, thread on the bolt and tighten.

• One everything is tight, adjust the linkage so there is no slack when shifting.

	Spring bracket
	Craig and Chris tighten down the bolts to secure the seat.

Installing the Seat

• For the seat, the first step is to bolt the T-bracket to the bottom of the seat. Insert one bolt ant the front and two at the rear, pass them through the bracket and the seat mount and secure with lock nuts.

• Generously grease the seat pole and drop that into the seat tube of the bike frame.

• The "chummy" seat suspension goes on next. The bottom bracket of the suspension will bolt to the frame of the bike.

• Pass two bolts through the seat suspension bracket and through the frame. Secure each bolt with a washer and locknut and tighten.

• The upper part of the suspension will bolt to the underside of the seat with two small clamp brackets. Place the brackets around the upper bar of the suspension piece and insert a bolt through each hole.

• With a wrench, tighten the bolt into the underside of the seat.

RESOURCES :

Welders
Lincoln Electric
Website: www.lincolnelectric.com

Kiwi Indian
Website: www.kiwi-indian.com

V-Twin Mfg.
Rims, Spokes, Hubs, Tire Irons and Truing Stand
Website: www.vtwinmfg.com

Motorcycle Lift
Handy Lift
Website: www.handy-lift.com

Various Tools
Eastwood
Website: www.eastwoodco.com

Hepavac Asbestos Vacuum
Bullseye
Website: www.bullseyecorp.com

Parts Washer
Safety Kleen
Website: www.safety-kleen.com

Chrome Polish
G & H Metal Finishers
282 Dakota St.
Paterson, NJ 07503

Belt Grinder
Ellis Manufacturing
Website: www.ellissaw.com

Powder Coating Shop
Best Signs
Phone: 865-922-5247
E-mail: bestsigns@tds.net

Coker Classic White Wall Tires, Tubes and Spoke Covers
Coker Tires
Website: www.coker.com

Gaskets/Headers
James Gaskets
Website: www.jamesgaskets.com