The Flex-Hone for Motorcycle Transmissions

The Harley-Davidson Shovelhead is an air-cooled, V-twin motorcycle engine with rocker box “covers” that resemble inverted heads on coal shovels. Built from 1966 to 1984, the Shovel delivered 10% more horsepower than the Panhead engine, making Shovelhead bikes the motorcycle of choice for many police departments. Although the Evolution engine ultimately arrested Shovelhead sales, many third-party manufacturers still produce Shovel-like designs.

The Flex-Hone® and the Art of Motorcycle Maintenance

Today, bikers and motorcycle mechanics such as Hawg Rider rebuild original Shovelhead engines and tune newer motorcycle crate engines. At Hawg Riders All HD Tech Forum, “a place where everyone with a love of Harley is welcome”, the long-time chopper mechanic described how he “spent an entire day teaching a young guy” how to refurbish a leaking transmission for his Shovelhead bike. Along the way, Hawg documented this motorcycle maintenance project in pictures – including a shot of a Flex-Hone.®   

Shovelhead Transmission Rebuild

Although the tranny’s gears were in a “good shape”, the Shovelhead Harley needed a new crankshaft, bearings, bushings, seals, and kicker parts. After repairing and reinstalling the countershaft gear cluster, Hawg installed the transmission main seal and tackled the sprocket. The biker then turned his sights to the kicker parts, starting with the spring and moving onto the sliding ratchet gear. Next came the kicker gear, keyed to shaft and secured with a nut and lock-washer.

Using the Flex-Hone® with Kicker Cover Bushings

“I replaced his kicker cover bushings” Hawg explained, “since these are not some super ‘critical’ engine or internal part.” Using a hand drill and a Flex-Hone® fromBrush Research Manufacturing (BRM), the Harley mechanic fit the bushings to the shaft “nice and simple”, and reported that everything “works fine”.  He then installed the kicker shaft and cover to complete the transmission rebuild, which cost less than $150 in parts.

From rebuilding motorcycle engines to  honing motorcycle brake rotors, bikers and bike-builders are using the Flex-Hone® with classic motorcycles. What’s your Flex-Hone® story?