Servi-Car Restoration

Text and Pictures by Mark Trotta

Not too long ago, Harley-Davidson Servi-cars were easy to find and cheap to buy. Today, if you can find one that hasn't been butchered and actually runs and drives, it'll set you back as much as a vintage Shovelhead.

Much of the reason for this is that too many Servi-cars have been cannibalized over the years. Parts such as gas tanks, oil tanks, and front ends have been scavenged for Harley Panhead restorations, and frames have been cut apart to make custom trikes or Harley 45 clone bikes.

The Purchase

In 2014, I was searching for a new motorcycle project. I saw an ad on ebay for a Harley 45 motor with a frame and extra parts.

The engine case number (61G-XXXX) revealed it was a 1961 Harley trike, and I got the idea that if I could buy it for the right price, I could build a Servi-car from the frame up. Shortly after winning the bid, I hopped into my truck and drove from my home in North Carolina to Kentucky to pick up the engine, frame, and extra parts.

Included with the purchase was several mismatched wheels, incorrect gas tanks, and boxes of assorted Harley parts.

After bringing everything home, I sorted through everything, and was able to sell enough of the unwanted parts to get back what I had initially laid out.

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Frame

Considering it's over a half-century old, the Servi-car frame was in great shape. Looks like it was never repaired and all the tabs and mounts were still there.

Read: Servi-Car Frame Identification and Inspection

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Front End

When purchased, this trike did not have a front end. Trouble was, to find and buy a good used one, you're competing with Panhead restorers, who generally have a much higher budget.

I initially installed a used Wide-Glide front end which I found locally. It's not correct for a Servi-car, and was installed temporary until I found a correct one.

Hydra Glide Forks

Beginning with the 1958 model year, Servi-Car neck stem length and inner diameter were increased to accept Panhead Hydra-Glide front forks, and would stay in use on all subsequent trikes until production's end in 1973.

Eventually, I found a good used front end off ebay. It was given a complete overhaul before installing.

Before reassembling, the aluminum sliders were polished to a high gloss.

Harley hydra glide sliders after polishing

Read: How To Polish Motorcycle Forks

Read: Harley Forks Identification

Read: Hydra Glide Fork Seal Replacement

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Front Brake

Along with the front end overhaul, I installed an aftermarket front drum brake kit.

I thought I was going to have trouble with the foreign-made parts, but everything fit as it should and the front brake works fine.

Read: Hydra Glide Brake Drum and Shoes Installation

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Rear Brakes

Read: Servi-Car Rear Brakes

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Flathead 45 Motor

All year Servi's were powered by Harley's venerable 45ci flathead engine.

After splitting the cases and checking the bottom end, I fabricated a simple engine stand. The rest of the motor was gone over as well.

Harley 45 Engine Assembly

Harley 45 Bottom End

Harley 45 Cylinder Assembly

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Rear Axle

Read: Servi-car Axle Overhaul

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Drivetrain

After the engine was rebuilt and back on the frame, it was time to assemble the drivetrain.

All 1941-1973 Harley 45 drivetrains are basically the same and follow the same overhaul procedures. Some Servi riders switch to a bigger-tooth gear, but I chose to keep the stock 22-tooth motor sprocket.

Harley 45 transmissions are different than big flathead and big-twin units--they have the output shaft and chains on opposite sides. They have also a reverse gear, and use a different kickstart extension and side-cover than 45 solo models.

Read: Servi-car Drivetrain

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Chain-drive vs Belt-drive

Although belt-drive conversions are available, I kept the stock primary chain for several reasons.

First, belt drives require very precise alignment. The flanges on belt-drive pulleys are not intended to guide the belt. If alignment is not precise, the belt will use the pulley flanges as guides, which will wear out the belt prematurely.

Second, primary chains are much more forgiving--they will still work well even with a fair amount of discrepancy in location. A chain will "curve" to allow for differences between sprockets.

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All year Servi's were foot-clutch/hand-shift. Most were left-side shift, but some (mainly Police models) were right-side-shift.

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Gas Tank/Oil Tank

For over a year, I looked for a set of original Servi-car gas/oil tanks on ebay. I watched and bid on several rusted and dented original Harley tanks, all of which eventually sold for $900 or higher. Finally, I bought an aftermarket set for half the price.

Read: Servi-Car Gas/Oil Tanks

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Cargo Box

This Servi-car box had been in storage for over 30 years. It still had the original wood floor intact.

Countless hours were spent sanding the inside and outside of the box down to bare metal before repainting.

Read: Cargo Box and Fenders

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Electrical System

The electrical system was the last major part of this project. Because it was missing most of the electrics, there was really no extra expense to upgrade from 6-volts to a 12-volts.

I saved myself a lot of hassle and installed a Cycle Electric generator/regulator.