Knucklehead Build Part 7: Oil Tank and Fenders Install

Kevin has the transmission set into position. The transmission plate is secured to the frame but the transmission itself is left loose on the plate. Final tightening of the transmission will be completed once the primary drive and secondary chain is installed for alignment purposes.

The original clutch assembly on this Knucklehead was a hand shift with a foot, or rocker clutch. The clutch assembly is going to be converted to a more modern hand clutch with a foot shift.

To do so, Kevin will install a clutch cable mount on the frame down tube. The bracket mounts directly below the front oil tank mounts.

The clutch cable bracket is much like a clutch cable mount on a Shovelhead. The only exception is that the bracket is a (welded on) part of a Shovelhead head frame and not a separate bracket.

Kevin takes a minute to give us a quick tip on how to keep the clutch cable end from popping out of the clutch release arm. If the cable pops out of the arm, it can be difficult to reposition after the oil tank is installed due to lack of space. Kevin simply wraps the end of the clutch release arm with a short wrap of electrical tape. The tape can be easily removed from the arm after final assembly.

The Knucklehead oil tank is mounted on a plate and is introduced into the frame from the right side of the motorcycle. It is mounted in the front with two bolts that thread directly into a frame tab on the frame down tube. The clutch cable bracket is secured below the frame tab and is secured with two locking nuts.

Next, Kevin installs the rear fender. The fender is mounted to the back of the Knucklehead oil tank on the bottom and a bracket is used to secure the fender to the frame above. Kevin manipulates the fender straight in the frame and over the wheel. When everything looks uniform, the fender can be final tightened to the Knucklehead oil tank and the frame.

Next, Kevin will be preparing to install the primary drive, secondary chain, forward controls, fuel tank, oil and gasoline hoses.

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