Unscrewing The Haley Pan Head: Removing The Head Cover

The Harley-Davidson Panhead engine is an iconic motorcycle engine produced from 1948 to 1965. Its nickname comes from the rocker covers, which resemble cooking pans. This engine replaced the Knucklehead engine and was, in turn, replaced by the Shovelhead engine. The Panhead engine was a significant improvement over its predecessor, addressing issues of heat dissipation and oil leaks. In this article, we will discuss the process of removing the head cover on a Harley-Davidson Panhead engine, including the tools required and the steps to take.

Remove the battery negative cable, fuel tank, and exhaust

To remove the battery negative cable, fuel tank, and exhaust on a Harley Panhead, follow these steps:

Begin by removing the battery negative cable. This is an important first step to avoid any electrical issues or safety hazards when working with fuel. Ensure the bike is switched off and secure, and then locate the battery. The negative cable is usually black and can be disconnected by carefully loosening or unscrewing it from the battery terminal.

Next, you'll want to remove the fuel tank. This process can vary slightly depending on the year and model of your Harley Panhead, but the basic steps are as follows:

• Start with a nearly empty fuel tank if possible. If not, you will need to drain the fuel into an appropriate container.
• Remove the front and rear fasteners holding the console assembly to the tank.
• Open the fuel door, remove the filler cap, and place a soft towel on the rear fender to protect the finish.
• Depending on your model, there may be additional Hex (Allen) screws under the fuel door that need to be removed.
• Disconnect the pump wiring harness plug and the fuel level sensor plug on the left underside of the tank.
• Disconnect the hard vent line and the fuel supply line. You may need a funnel and a hose to catch any remaining fuel.
• For fuel-injected models with a five-gallon fuel tank, disconnect the crossover fuel line at the front of the tank.
• Remove the rubber tank mount caps to access the mounting fasteners.
• Using a suitable tool, such as a 1/2" socket or T40 Torx driver, remove the front and rear tank mounting fasteners.
• With all connections and fasteners removed, gently lift the fuel tank from the bike and set it aside in a safe place.

Now, you can move on to removing the exhaust. This process can vary significantly depending on your specific model, but here are some general steps:

• Refer to your Harley Panhead's service manual for specific instructions on removing the exhaust.
• Ensure you have a clean and safe area to work in, as this process can be labor-intensive and require multiple days.
• Remove the top motor mount, including the horn assembly, and any other components that may be in the way, such as the fuel line and engine temp sensor.
• Carefully detach any sensor plugs and throttle cables, labelling them for easy reassembly.
• Remove the hardware securing the throttle body to the heads and gently slide it away from the motor.
• If needed, remove the coil mount and coil to create more space for the next steps. Ensure you label the wires and coils for reassembly.
• Loosen and remove the upper rocker box, and then remove the spark plugs.
• Raise the rear wheel and shift the motorcycle into high gear. Spin the rear wheel until you reach top dead center, reducing pressure on the pushrods.
• Remove the pushrod clips and then loosen and remove the breather assembly and rocker arm towers. Label and set aside these components.
• With the above steps completed, you can now remove the exhaust system. Again, the exact process will depend on your specific model, so refer to your service manual for detailed instructions.

Remember to work methodically and safely, and always refer to your service manual for detailed instructions specific to your Harley Panhead model.

Remove the derby cover and primary chain inspection cover

To remove the derby cover and primary chain inspection cover on a Harley-Davidson motorcycle, you will need to prepare a clean and safe area for disassembly. The process will involve removing several parts and it is important to keep your hardware and parts organised for easy reassembly.

First, remove the battery negative cable, fuel tank, and exhaust. Then, remove the top motor mount, including the horn assembly, the fuel line, and the engine temp sensor. Next, remove the air cleaner assembly and throttle cables, and carefully unplug all the sensor plugs at the throttle body. Label the sensors and corresponding plugs to ensure proper reassembly. Now, you can remove the hardware that secures the throttle body to the heads and carefully slide it away from the motor.

If needed, remove the coil mount and coil to create more space for the removal of the front rocker box. Be sure to label the coil and wires, both front and rear, especially for a single-fire ignition. Label your rocker box uppers and lowers on the front and rear, and then loosen and remove your upper rocker box.

At this point, you can remove the spark plugs, raise the rear wheel, and shift the motorcycle into high gear. Spin the rear wheel until you reach top dead centre, where there is the least amount of pressure on the pushrods. Remove the pushrod clips, then loosen and remove the breather assembly, followed by the rocker arm towers. Label and set aside the towers and pushrods. Now, you can loosen and remove the lower rocker boxes, exposing the heads.

To access the derby cover and primary chain inspection cover, you will need to remove the heads. Use a 1⁄2” 12-point socket to loosen the head bolts, breaking them free with a sharp motion and continuing to loosen them evenly in a cross pattern. Lift off the heads and remove the old head gaskets. Carefully slide the cylinders off the pistons and cylinder studs, being mindful to prevent any debris from entering the open crankcase. Label and set aside the cylinders.

With the cylinders removed, you can now access and remove the derby cover and primary chain inspection cover. Remember to keep your workspace clean and organised to facilitate reassembly.

Loosen the clutch cable

To loosen the clutch cable on a Harley Panhead, you'll need to locate the clutch cable adjustment near the centre of the clutch cable. Hold the locking nut and twist the bottom of it to loosen the cable. Once the clutch cable is loosened, you can proceed to remove the derby cover and the primary chain inspection cover. This will expose the clutch adjustment screw, which can be loosened with a flat-blade screwdriver. As you loosen this screw, the nut will come off the clutch release assembly. From there, you can remove the clutch release assembly and detach the clutch cable.

It's important to note that loosening the clutch cable is just one step in the process of removing the outer primary cover on a Harley. Before beginning this process, it is recommended to consult a user's manual for a Harley-Davidson motorcycle. Additionally, remember to drain the primary fluid and remove the shift arm linkage before loosening the clutch cable. After loosening the clutch cable, you can continue with the remaining steps to remove the outer primary cover.

When working on your Harley Panhead, always prioritise cleanliness to ensure that no dirt or grime gets mixed in with the primary oil. This is crucial because contamination can cause damage to the primary drive or transmission. Keep your workspace clean and organised, and make sure to keep all parts that are removed away from any dirt or grime.

By following these steps and paying attention to cleanliness, you'll be able to safely and effectively loosen the clutch cable on your Harley Panhead.

Remove the clutch release assembly and detach the clutch cable

To remove the clutch release assembly and detach the clutch cable on a Harley Panhead, follow these steps:

First, loosen the clutch cable adjustment, which is located near the centre of the clutch cable. Hold the locking nut and twist the bottom of it to loosen. Next, remove the derby cover and the primary chain inspection cover using an Allen wrench to unscrew the bolts. Gently pry the cover off if necessary, being careful not to lose the spring behind it. Under the spring, you will find a clutch adjustment screw; loosen this with a flat-blade screwdriver. As you do so, the nut will come off the clutch release assembly.

Now, remove the clutch release assembly and detach the clutch cable. To do this, simply unscrew the clutch cable from the primary cover. Depending on the model, you may or may not need to remove the clutch lever to do this.

It is important to keep your workspace clean and free from dirt or grime. Ensure that any parts you remove are kept in a clean area, as you will need to apply a gasket for a proper seal when reinstalling the primary cover and derby cover.

Additionally, it is recommended to have a new side cover gasket, some oil/fluid to replace what is lost, and a small rubber O-ring on hand for the clutch cable entry point on the side cover.

Remove the cam/gear cover

To remove the cam/gear cover on a Harley Panhead, you will need to follow a few important steps to ensure the process is safe and successful. Here is a detailed guide:

Prepare Your Workspace:

• Ensure you have a clean and safe area to work. The motor may be apart for a couple of days, especially if you send the heads and cylinders to a machinist.
• Clean and lay out all the necessary tools and parts in a logical manner to easily identify and remember the order of reassembly.

Initial Steps:

• Remove the battery negative cable, fuel tank, and exhaust.
• Remove the top motor mount, including the horn assembly.
• In the same area, remove the fuel line and the engine temperature sensor.
• Remove the air cleaner assembly and throttle cables, and carefully unplug all the sensor plugs at the throttle body. You can take photos or label these sensors and corresponding plugs.
• Remove the hardware securing your throttle body to the heads and carefully slide the throttle body away from the motor.
• You may also want to remove the coil mount and coil for more room. Be sure to label the coil and wires, both front and rear, especially for the single-fire ignition.

Removing the Cam/Gear Cover:

• Now, remove the spark plugs, raise the rear wheel, and shift the motorcycle into high gear. Spin the rear wheel until you reach top dead centre, where there is the least amount of pressure on the pushrods, allowing for easier disassembly.
• Remove the pushrod clips and then loosen and remove the two bolts retaining the breather assembly.
• Evenly loosen and remove the rocker arm towers. Label them as front and rear and set them aside.
• Label and set aside the pushrods, being mindful of their positions (front exhaust, front intake, rear intake, rear exhaust).
• Loosen and remove the lower rocker boxes. At this point, you are stripped down to the heads.
• Use a 1/2" 12-point socket to loosen the head bolts. Break them free with a sharp motion and then continue to loosen them evenly in a cross pattern.
• Carefully lift off the heads and remove the old head gaskets.
• Now, you can slowly and carefully slide the cylinders off the pistons and cylinder studs, being cautious not to let any debris enter the open crankcase. Label and set aside the cylinders.
• Protect the cylinder studs by sliding short lengths of rubber hose over them.
• Finally, you can access the cam/gear cover. Remove the cover, being cautious not to pull out a cam in the process. Use the correct torque and sequence when tightening the screws.

Remember to always refer to your Harley Panhead service manual for specific instructions and torque specifications. Additionally, cleanliness is crucial, so ensure all parts remain free from dirt and grime during the process.

Frequently asked questions