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 two-wheel 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 Servi-Car non-running with extra parts. Shortly after winning the bid, I hopped into my truck and drove from my home in North Carolina to Kentucky to pick up the trike. It was mostly disassembled, engine off the frame in pieces, and boxes and boxes of extra 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 age, 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

Rear Axle

Read: Servi-car Axle Overhaul

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Front End

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.

Today, original Hydra-Glide front ends are hard to find because they also fit Harley Panheads.

The forks were given a complete overhaul. Before reassembling, the aluminum sliders were polished to a high gloss.

Harley hydra glide sliders after polishing

Read: Harley Forks Identification

Read: Hydra Glide Fork Seal Replacement

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Front Drum Brake Replacement

Because nearly all of the original parts were missing, an aftermarket front drum brake kit was purchased and installed.

I thought I was going to have trouble with the aftermarket 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 complete motor was gone over before reassembly.

Remove and Install Gear Cover

Engine Assembly

Bottom End Assembly

Cylinder Assembly and Installation

Replace Breather Valve In Gear Cover

Scavenger Oil Pump Repair

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Drivetrain

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

From 1941 through 1973, Harley 45 drivetrains were 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

Chain-Drive vs Belt-Drive

Although aftermarket 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 perfect, the belt will use the pulley flanges as guides, which will wear out the belt prematurely.

Second reason is, metal 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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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 dented and rusty original tanks, all of which eventually sold for $900 or higher. Finally, I bought an aftermarket set for half that price.

Read: Servi-Car Gas/Oil Tanks

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

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Handlebars and Risers

Over the course of past 10 years, I replaced the handlebars three times.

The first set was too high, the second set was too flat. Finally, I settled on these.

The risers are 4" chrome (non-stock).

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Cargo Box

This Servi-car box still had the original wood floor.

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 most of the electrics were in poor condition or missing, there was really no extra expense to upgrade from 6-volts to a 12-volts.