I just finished my electricstart 42 flathead I started in 1990 (marriage, divorce, changed jobs twice, moved out of state, etc.). It wouldn't crank. Now I am no newbie to Harleys. I have owned as many as four at one time, probably twenty in my lifetime. Most were built by me from parts. I am also building a cafe racer KHK on the backburner. So when I went through the carb about half a dozen times, tuned it several times, replaced the starter (0.8kW Accel Ultra Tork which is a joke - but it was cheap even though the seller told me it was a 1.4 kW), took everything apart at least twice, and it still wouldn't start even after verifying spark, fuel, and timing. I opened the plugs from 0.025 to 0.030 with no change. Three weeks into trying to start this puppy, and today, I happened to forget to replace the distributor cap and it started instantly. I put the cap back on and it wouldn't start. Wow! I knew it was going to be something very simple, but I never expected this.
Close inspection showed the point terminal was barely touching the cap when it was in place. One screwdriver and a repositioned terminal, and starting was a breeze. It runs beautifully, and there is nothing like the sound of a new flattie through drag pipes. The starting system operates flawlessly. I used a non-electric start 65 inner primary, 65 output shaft with re-tapered end, used rod bearings in a hogged out old race, and machined inner for one of the original BDL belt drives with idler. Much hogging of aluminum, and a lot of fitting for the solenoid. I used a tin outer just because I liked the looks of it. Had a lot of trouble getting it all to fit and work together, but right now I feel it was worth it.
It has a 4 speed tranny, 5 gal tanks, swingarm Paugho frame, lowered shocks, disc brakes front and rear, and a late model battery fit into an old saddle tank. I had to modify the clutch arm drastically, and fitting the drag pipes to clear everything including the kick starter was a trial, but it all works. It also has turn signals, horn, etc. for safety reasons.
Then I painted it Seafoam Green!
Now I get to go through the NC title trials. In case you don't live in NC, we have the worst title system for rejuvenating old titleless bikes in the USA. I will use the MCO from Paugho to start the process. It isn't going to be fun.