New Henderson Parts from O4 Motors

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	New Henderson Parts Please see the Parts in Progress page for parts that will be available soon. New Parts November 2003: Camshafts - Valve Seats - Rod Bearings - Rocker Pins - Tool Pouch
O4 Camshafts for KJ/KL and Deluxe	NEW! KJ/KL and Deluxe camshafts. Brand new cams for both KJ/KL and DeLuxe models, DeLuxe cams are profiled from original NOS late model high lift cams as well as the KJ version. These new cams have thicker .750 shaft to avoid whip and twist for accurate valve timing. Hardened bearing and lobe surfaces .032 deep and treated to RC60 to 62 insure long life. Each cam is polished and shafts are teated with heat dispersants. The cam is the brains of your engine. These are special order and due to the many different processes usually take about 6 weeks to manufacture. Back to top of page

O4 Motors Cylinders	Cast Iron Cylinders. These brand new cast iron cylinders feature a beefed up barrel, slightly higher compression and are meant to use the original style flat top piston or the new forged cam ground pistons (see further down this page). They can be bored and honed to fit your existing set of good pistons, or overbored any size. These cylinders can accomodate a .100"+ overbore above the standard 2-11/16", and are cast iron like the originals but made from far better materials. They come complete with hardened valve seats, guides, stainless steel valves and springs installed, and are ready to bolt on. Your choice of finish includes either powder or ceramic coating. Sold in a matched set of 4 only.
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	These A356 aluminum Henderson cylinders are heat treated to T-6 and are experimental versions of the old cast iron factory originals. A complete set weighs 25 pounds less than originals. More info - See O4 Racing page.
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O4 Pistons	KJ Pistons. Our forged, cam ground pistons are the finest pistons ever made for a Henderson motorcycle. Each set comes complete with fitted pins, rings and spiral locks. We make the pistons to fit the bore you require, and pins are made to a standard .750" to allow honing of your factory rods. Original factory pins usually came out and scored the cylinder walls. These new pistons have the spiral lock grooves cut in, ready to go, so you know these pins won't come out. Our pistons are custom made for each order.
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Coated Pistons	Piston Coating Option. Reduces heat and friction and gives longer skirt life. Less friction means more power. Coatings are baked on and are only available as an option with our forged cam ground pistons.
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O4 Valve Seats	NEW! KJ/KL intake valve seats. The Streamliner intake manifold seats have been previously ground in many cases to the point where the valve is now higher up in the manifold than stock. To allow a full and unrestricted charge to the cylinder head the valve needs to clear down in the cylinder. Worn intake "snouts" also effect poor rocker geometry and add to side loading of the valve stem and accelerated guide wear. These custom valve seats will return the valve to proper height spec allowing unrestrictive flow and proper geometry. Back to top of page

O4 Valve Seats	KJ hardened exhaust valve seats. The old Henderson cylinders frequently have the exhaust valve seats "pocketed" from years of regrinding. Now you can renew the KJ exhaust valve seats to better than new condition. Since the shelf below the spark plug hole is only 1/4 inch thick normal style valve seats would only weaken this area. I've designed this two step seat for this special application so cutting is shallow and will not weaken the metal around the pocket. These seats have the same expansion and contraction rates as the original cast iron This kit comes complete with 4 seats, complete instructions for cutting and press fitting and a pouch of seal lock fluid weld to aid in heat transfer. We can also completly renew Henderson cylinders to like new condition including fin repair, threads, seats, boring, honing, sleeving and finishing. Finishes offered are either powder or ceramic coatings.
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O4 Manifold to Cylinder Head Seals	Intake manifold to cylinder head seals. The old style copper rings do not seal properly, causing intake leaks. Intake leaks cause loss of compression and upset the balance of air/fuel mix. The factory machining was not all that uniform and overtightening the intake manifold bolts caused either stripping of the cylinder threads or breaking the ears off the intake manifold. There are 16 bolts to hold the intake manifold in place and they should not be over tightened. These polycarbonate, stainless steel re-inforced gaskets fit snugly on the intake manifold snouts and conform to any cylinder to manifold irregularities giving you a perfect leakproof, high temp seal. At 1/16" thick these seals will compress and mold to the mating surfaces and has an added benifit by lowering the intake valve deeper into the cylinder and into the airflow and marginally increasing compression. This increased compression will not make your KJ/KL into a hotrod, but hey, every little bit helps!
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O4 Pushrods	Pushrods. Check your old pushrods by rolling them on a glass plate. These new KJ pushrods are made with the same attention to quality and durability as all O4 parts, made from the same materials as more modern pushrods, I give these a 100,000 mile warranty! I'd have to say that these will be the last set of pushrods you will ever need.

	NEW! KJ/KL Oversize Rocker Pins. 8620 carburized, heat treated and ground, these oversize rocker pins are to original specs except for an oversize shaft to allow ID honing of the rocker for a perfect like new factory fit. Internally threaded to accept original grease fittings. You will need to hone your worn rockers back into round. Back to top of page
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	NEW! KJ/KL Undersize Rocker Pins. Undersize KJ/KL rocker pins allow you to press a bushing in your original rockers and fit to size. This will give less friction and a wear part for your rockers that can be replaced when worn. A perfect solution. Back to top of page

O4 Tappets	Oversize tappets. Here's the solution to those worn out tappets and guides. These oversize tappets allow your existing guides to be internally ground and refitted with a new set of tappets. Old tappets are frequently worn and pitted on the lifter faces, causing damage to cams and poor engine performance. These new oversize tappets utilize your existing tappet screws. Hardened, ground and polished for maximum life. See Parts in Progress page for additional info.
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O4 Rod Bearings	NEW! KJ and DeLuxe rod bearings. Brand new shells and new custom formula no-lead babbitt made to fit original or the new O4 rods. Babbitt is cast using the centrifugal process to insure maximum density and adheasion to the shell. Shells are a few thou oversize to allow original rods to be resized for perfect fit and maximum heat transfer, custom no-lead babbitt is much harder than original to give longer bearing life. These bearings can be made to stock configuration or custom centifugal cast to very thin specs just like a modern insert bearing. After fitting bearings, you will need to bore to your crank spec. Back to top of page

850 Bearings	850 Bearings. I start with a 850 bearing material and custom-make a set for each motor. This bearing material wears much better than the old style babbit and has a better ability to transfer heat away from critical parts. The best choice in connecting rods, these bearings will not pound out like babbit and and will maintain diametrical clearances much longer. When using this bearing material it is recommended to use an external oil filter on your engine as it does not have the same embedability as babbit. These bearings can be used in rods with babbitted mains. Both completed bearing sets or plain castings are available. These bearing castings can also be machined to fit Indian 4, Ace, Cleveland.
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O4 Connecting Rods	Brand new Henderson KJ and DeLuxe connecting rods. Feature forged race quality chromemoly construction. These rod sets are made to the same weight as originals with improved pin oiling holes and a 90500 bronze bushed pin insert. Width has been relieved to provide more rod to case clearance. Precision honed to .751" to accept a standard .750" pin that I use with our forged cam ground pistons. They will accept original factory bronze backed babbit lined shells or the new 850 bearings. Can be purchased with bearings and shims, precision honed to fit your crank. After final machining, each rod is shot peened for extra durability. Overkill? You bet!
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Rod Rebuilding	Rod Rebuilding. We can rebuild your stock rods back to spec including straightening, balancing, regrinding caps, resizing the big end and bushing the pin ends. Rods can be rebuilt complete with new bearings, either babbitt or aluminum as an option.
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O4 Rod Bolts	Replacement rod bolts and castle nuts. These bolts are a grade 8 class bolt and nut. Original factory bolts were grade 5 or less. Don't use your old bolts and nuts and risk expensive damage to your engine. Set of 8 complete to fit KJ or DeLuxe.
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KJ Baffles	KJ/KL baffle plates. Just like the originals and designed for proper fit, the factory baffles were made to help stop over oiling in the upper end. Interestingly, the KJ manual shows that part # K-1063, photo #58, baffle plate screw used a cotterpin, K-603, photo # 59, to hold the baffle plates, I'm interested to know what the cotterpin did in this application. Email me if you know. Baffles come in set of 4
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DeLuxe Baffles	DeLuxe baffle plates. Most engines are missing these. Not much you can say about them. The factory designed these to stop too much oil from slinging up into the cylinder walls from both the rod bearings and the oil mist inside the case. Set of 2.
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O4 motor shim kits	KJ motor shim kits. These 6061-T6 aluminum shim kits are designed to replace the original type laminated shim kits. They are designed with extra facing allowing for smaller dia ground cranks. Made for proper fit around the studs, they will not allow the shim to press up against the crank when mains and rods are torqued allowing for a perfect fit after align boring or rod honing. With no interruption on the bearing fit this will give the crank complete oil distribution in the diametrical clearance. The 6061 assures no damage and good heat distribution and can also be finely lapped.
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	DeLuxe motor shim kits. Having the same technical specifications as the KJ kits, both these kits are complete and include all mains, rods and trans shims.
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Oil Pump	Oil pump gears and rebuilding. Brand new oil pump gears with wider face. I can remachine your old pump and fit new wider gears to give increased pressure and extra volume. Rebulit pumps complete and ready to bolt on.
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Timing Cover Gasket	Timing cover gasket. For KJ and DeLuxe this timing cover gasket is designed to eliminate the oil leak from the timing cover. This is a dificult place to seal up as in this area both case halves meet along with the timing cover. Thicker than original this gasket will form to the irregularities in this area and is stiffer and will not bunch up like an original style factory gasket. Reusable and high temp rated.
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KING clutch kit for Hendersons -	KING clutch kits for Henderson. Another excellent product from KING clutch these kits are specially designed for your Henderson DeLuxe and KJ. Heat treated to RC60 and lined with Kevlar, these plates will not introduce metal particles in your engine like original factory plates did. They allow you to use less spring tension for a softer feel and eliminate slipping, grabbing and gear grinding. Since old Henderson factory machining was pretty bad you may need to pre fit plates by touching up with a small stone to fit your hub. Just about every hub I've ever measured was a different size, but I guess that was acceptable for the 1920's and 30's. Kit includes 5 plates to replace the original 9. KING clutch also makes plates for Indian 4's, Indian Chiefs, Scouts, HD which are available from any KING dealer worldwide. For the worlds finest clutch, "Ride with the KING". More info on the KING clutch website www.king-clutch.com
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Wiring harness kit	Wiring harness kit for Streamline models. Part # SKJ-4810 photo # 424 and SKJ-484 photo # 425 in factory parts manual.
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- Front end spring kit	Complete Streamline front end spring kit. Includes 2 main springs, 1 spring fork rebound spring and 1 rebound bumper spring (heavy duty) plus 2 main spring rubber bumpers. K-6651 photo # 562, K-6652 photo # 560, P-410232 photo # 561, K-6654 photo # 563.
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	DeLuxe front end spring kit for spring fork assembly. Includes: Front fork main spring, long. Part # K-6647 photo # 576. Front fork rebound spring, short. Part # K-6646 photo # 580.
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Saddlebags	Henderson saddlebags. Never originally offered by the factory, these are long overdue. Designed to fit on both DeLuxe and Streamliner luggage racks, these generously oversize saddlebags are made from the finest leather with reinforced stitching and rivets so you can stuff them to the brim. Bags measure 16-1/2" wide by 15-1/2" tall and 7" deep. The leather is a good 3/16" thick and decorated with chrome buttons and conchos. Embossed on the flap with the Henderson logo, these bags will be the perfect solution for travelling or to finish off the look of your pride and joy. Available in black, tan or reddish brown.
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Henderson Tool Pouch from O4 Motors	NEW! Henderson Tool Pouch. Reproduction tool pouch for both DeLuxe and Streamliners. Authentic right down to the weight of the canvas. Patterned right from a very rare original. Tools not included of course! Click to see photos of an original Henderson tool kit, and read a story of true friendship! Henderson Apparel - Check out the new Henderson Apparel page for cool Henderson shirts and hats.
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