Not too long ago, owning a Harley-Davidson Servi-Car was within easy reach for many, both in terms of availability and affordability. However, times have changed. Today, locating an unmolested, running, and driving Servi-Car is a significant find, often commanding prices comparable to vintage Shovelhead motorcycles. This surge in value is partly due to the unfortunate trend of Servi-Cars being dismantled over the years, their valuable components scavenged to revitalize other classic Harley models.
Read More: Servi-Car History
A significant factor driving up the value and scarcity of complete Servi-Cars is the cannibalization of their parts. Essential components like gas tanks, oil tanks, and front ends have frequently been removed to aid in Harley Panhead restorations. Even the frames themselves have been cut apart, repurposed for custom trike builds or to create Harley 45 clone motorcycles, further diminishing the pool of original Servi-Car parts available.
The Beginning: Acquiring the Project
My own journey into Servi-Car restoration began in 2014, while searching for a new motorcycle project. An eBay advertisement caught my eye – a Harley 45 trike motor accompanied by a frame and a collection of miscellaneous parts.
Upon examining the engine case number (61G-XXXX), it was identified as a 1961 Harley trike engine. This sparked the idea of a full Servi-Car build, starting from the frame up, provided I could secure the lot at the right price. Winning the bid set the stage for a road trip from North Carolina to Kentucky, where I collected the engine, frame, and the assortment of parts. The acquisition included a medley of mismatched wheels, incorrect gas tanks, and various boxes filled with Harley components – a true treasure trove and a starting point for sourcing specific Harley Servi-Car parts.
Back home, sorting through the acquired components proved fruitful. Selling off the unwanted and incorrect parts not only decluttered the workspace but also recouped the initial investment, making the core Servi-Car project even more viable.
****************
Foundation First: The Servi-car Frame
Considering its age exceeding half a century, the Servi-car frame was remarkably well-preserved. It appeared untouched, free from prior repairs, and crucially, all original tabs and mounts remained intact. This solid foundation was essential for a successful restoration, providing a reliable base to build upon with correct Harley Servi-Car parts.
Explore Further: Servi-Car Frame Identification and Inspection
****************
Rebuilding the Ride: The Rear Axle
The rear axle is a critical component of the Servi-Car’s unique three-wheeled design. Overhauling this assembly is essential for ensuring proper function and safety. A thorough rebuild addresses wear and tear accumulated over decades of service, ensuring reliable performance of this key Harley Servi-Car part.
Learn More: Servi-car Axle Overhaul
****************
Steering the Course: Servi-Car Front Forks
A significant change in Servi-Car design occurred in 1958. The neck stem length and inner diameter were enlarged to accommodate Panhead Hydra-Glide front forks. This upgrade, implemented from the 1958 models onward, remained standard until Servi-Car production ceased in 1973.
Initially, my project trike lacked a front end entirely. The challenge then became sourcing a good used front end, a task complicated by competition from Harley Panhead restorers, who generally have larger budgets allocated for acquiring these sought-after Harley Servi-Car parts.
As a temporary solution, I opted for a Wide-Glide front end sourced locally. While not period-correct for a Servi-Car, it served as a functional interim measure, bridging the gap until a correct Servi-Car front end could be located and acquired.
Identify Your Forks: Harley Forks Identification
Years of searching eventually paid off. A correct front end was found, albeit requiring a complete overhaul. This discovery marked a significant step forward, enabling the restoration to move closer to authentic specifications using genuine Harley Servi-Car parts.
****************
The Heart of the Machine: Harley Flathead 45 Motor
Every Harley Servi-Car was powered by the reliable 45ci flathead engine. This robust powerplant is synonymous with the Servi-Car’s enduring legacy.
To facilitate the engine work, a simple engine stand was fabricated. This allowed for a comprehensive top-to-bottom inspection and rebuild of the motor, including splitting the cases and meticulously examining the bottom end – crucial steps in restoring original Harley Servi-Car parts.
Step-by-Step Guide: Engine Teardown and Inspection
Engine Reassembly: Harley 45 Engine Assembly
Bottom End Focus: Harley 45 Bottom End
Cylinder Work: Harley 45 Cylinder Assembly
****************
Power Delivery: Harley 45 Drivetrain
Harley 45 transmissions differ significantly from those used in larger flathead and big-twin models. Notably, the output shaft and chains are positioned on opposite sides. Servi-Car transmissions also incorporate a reverse gear, and utilize a different kickstart extension and side cover compared to 45 solo motorcycles – key distinctions when sourcing Harley Servi-Car parts.
All Servi-Cars produced throughout their run featured a foot-clutch/hand-shift configuration. While most were left-side shift, some models, primarily those intended for Police use, were configured for right-side shift, another detail to consider when seeking correct Harley Servi-Car parts.
With the engine rebuilt and mounted back in the frame, attention turned to assembling the drivetrain. The fundamental design remained consistent across all 1941-1973 Harley 45 models, ensuring similar assembly procedures. While some Servi-Car riders opt for a larger-tooth gear for modified performance, the decision was made to retain the stock 22-tooth motor sprocket, preserving originality in the Harley Servi-Car parts used.
Drivetrain Details: Servi-car Drivetrain
Chain-drive vs Belt-drive: Staying Original
Despite the availability of belt-drive conversions, the original primary chain was retained for several compelling reasons. Firstly, belt drives demand extremely precise alignment. The pulleys in belt-drive systems are not designed to guide the belt laterally. Misalignment can lead to the belt rubbing against the pulley flanges, causing premature wear. Secondly, primary chains are considerably more tolerant of slight misalignments. A chain can accommodate minor discrepancies between sprocket positions by naturally curving, offering greater flexibility and reliability in real-world conditions compared to belt-drive systems when considering Harley Servi-Car parts and their integration.
****************
Bringing it to a Halt: Servi-Car Brakes
Experienced Harley trike riders often point out that the original Servi-Car drum brakes are, at best, adequate. Two primary factors contribute to this assessment. The front drum brake is shared with lighter two-wheeled models, making it arguably undersized for a vehicle weighing around 900 pounds. While the rear brakes are more effective, they bear a significant portion of the vehicle’s weight, leading to increased wear and tear on these Harley Servi-Car parts.
Braking System Deep Dive: Servi-Car Rear Brakes
****************
Fuel and Lubrication: Servi-car Gas/Oil Tanks
The search for an original set of Servi-Car gas and oil tanks proved to be a year-long endeavor on eBay. Numerous rusted and dented original Harley tanks were tracked and bid on, yet all ultimately sold for prices starting at $900 and climbing higher. Eventually, an aftermarket set was acquired for approximately half the cost, presenting a more economical solution for these essential Harley Servi-Car parts.
Tank Details: Servi-Car Gas/Oil Tanks
****************
Cargo Capacity: Servi-car Box
The Servi-Car box acquired for this project had been in storage for over three decades. Remarkably, it still retained its original wood floor, a testament to its longevity and a valuable original Harley Servi-Car part.
Countless hours were dedicated to meticulously sanding both the interior and exterior of the box down to bare metal in preparation for repainting. This painstaking process ensured a smooth and durable finish for this prominent Harley Servi-Car part.
“A Servi-car box is never empty.” – a sentiment that captures the utility and enduring appeal of this classic vehicle and its Harley Servi-Car parts.
****************
Wiring it Up: Electrical System
The electrical system represented the final major phase of this Servi-Car restoration project. Given that most of the original electrical components were missing, upgrading from the original 6-volt system to a more modern and efficient 12-volt system incurred no additional expense. This upgrade simplifies finding replacement Harley Servi-Car parts in the future.
To streamline the process and enhance reliability, a Cycle Electric generator/regulator was installed. This modern component simplifies the electrical system and improves charging efficiency, a practical upgrade when considering readily available Harley Servi-Car parts.
Electrical System Guide: Harley Generator – Repair or Replace?
Ignition System Details: Harley 45 Timer And Ignition
****************
Breathing Easy: Servi-Car Exhaust
Harley-Davidson’s Servi-Car production numbers were relatively limited, and consequently, the number of surviving examples is also not large. This scarcity translates to limited options for sourcing replacement exhaust systems. For those undertaking a Servi-Car restoration and requiring an exhaust system, choices are often restricted, making exhaust components some of the harder Harley Servi-Car parts to find.
Exhaust System Insights: Servi-Car Exhaust And Why Getting Parts Is So Frustrating
****************
Lubrication Heartbeat: Harley 45 Oil Pump Repair
Maintaining proper oil circulation is vital for the longevity of any engine, and the Harley 45 flathead is no exception. Repairing or rebuilding the oil pump is a crucial step in ensuring the reliable operation of these vintage machines and their Harley Servi-Car parts.
