{"id":2507,"date":"2025-01-03T15:06:02","date_gmt":"2025-01-03T14:06:02","guid":{"rendered":"https:\/\/www.amal.lu\/?p=2507"},"modified":"2026-02-25T17:14:14","modified_gmt":"2026-02-25T16:14:14","slug":"restauratioun-harley-davidson-wl","status":"publish","type":"post","link":"https:\/\/www.amal.lu\/en\/restauratioun-harley-davidson-wl\/","title":{"rendered":"H-D 45 Flathead engine overhaul"},"content":{"rendered":"

Some of you might have already come across my bright red 1946 Harley-Davidson WL during a tour or at an AMAL exhibition. Here\u2019s a little winter tale explaining why an open-heart surgery became necessary for this old lady.<\/p>\n

I bought the bike in the winter of 2021 after quite a long search: it had to be a real civilian model (WL) and not a modified, so-called \u201ccivilized\u201d military machine (WLA or WLC). Additionally, for me, the engine and frame numbers had to match, and if possible, the original fork and tanks (yes, tanks; the left one holds the fuel, and the right one the oil) had to still be present.<\/p>\n

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Once the bike was safely in my garage, it was disassembled to ensure it would meet my aesthetic expectations. It was repainted in the original and (almost) period-correct Harley-Davidson \u201cFlight Red\u201d (psst, don\u2019t tell anyone: \u201cRace Red\u201d from modern Ford Mustangs is exactly the same shade of red, which makes touch-ups and painting much easier). It received 16-inch wheels, a completely new wiring harness, and various other upgrades. The engine and gearbox were working properly and were left as they were, apart from a new carburetor and after a general inspection.<\/p>\n

For about a season and a half and approximately 5,500 km, my WL ran perfectly without the slightest problem. But then, around the middle of the 2023 season, the trouble started, costing me a few of my already scarce hairs.<\/p>\n

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The bike suddenly began having severe ignition misfires while riding. There was no clear pattern to it: sometimes it ran fine, sometimes the issues started after 5 km, and sometimes only after 120 km. Occasionally, replacing the spark plug would fix the issue, but other times it wouldn\u2019t help at all. Over the following months, I tried several new ignition coils, checked the generator, inspected the entire wiring harness, and repeatedly tested the ignition itself. But no \u2013 sometimes it worked, sometimes it didn\u2019t. When pieces of metal that didn\u2019t belong there showed up during an oil change earlier this year, it was clear: the engine had to come out!<\/p>\n

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When the engine was finally removed and disassembled, I wasn\u2019t sure whether to be happy or cry. Happy because the so-called \u201cbottom end\u201d of the engine \u2013 the two crankcase halves, crankshaft, camshafts, pushrods, etc. \u2013 was in quite good condition. Apart from replacing a few bushings, repairing two attachment points on the casing, and addressing a few minor details, it wouldn\u2019t require too much work or money.<\/p>\n