Welcome to Scribd, the world's digital library. Read, publish, and share books and documents. See more
Download
Standard view
Full view
of .
Look up keyword
Like this
7Activity
0 of .
Results for:
No results containing your search query
P. 1
Harley Repair Manual

Harley Repair Manual

Ratings: (0)|Views: 3,570 |Likes:
Published by Gary Cline

More info:

Published by: Gary Cline on Nov 08, 2011
Copyright:Attribution Non-commercial

Availability:

Read on Scribd mobile: iPhone, iPad and Android.
download as PDF, TXT or read online from Scribd
See more
See less

02/24/2014

pdf

text

original

 
Harley-DavidsonSingles
ModelCoverage
50ccM-50M-50S65ccM-65M-65SMC-6590ccX·90Z-90100ccMSR(Baja)SR·IOO125ccB(Hummer)165cc.175ccML(M-125)MLS(Rapido)TX125SX125ST(Model165)STU(Model165)BTF(Ranger)BT(Super-l0)BTU(Pacer)BT(Pacer)BTH(Scat)250ccBTH(Bobcat)SS175SX175C(Sprint)H(Sprint)SS(Sprint)SS250(Two-Stroko)SX250(~wo-Stroke)SS(Sprint)SX(Sprint)MAINTENANCE.2Lubrication...................................,..2Engine..:2TransmissionOil..",2ForkOil...,,,,,,..2AirCleaner......,,..2ServiceChecksandAdjustments,.......................,3WheelBearings,.3BrakeAdjustments3ClutchAdjustment',..3Recommended
Lupricants...
,,5Periodic
Maintenance5
TireSpecifications5Maintenance
Data,....
5TUNE-UP..,,6ValveTappetAdjustment.....'
6
BreakerPointIgnition,....,.....................6
Capacitor
DischargeIgnition.'',.........,9CarburetorAdjustments.....,...,.......,
9
ENGINEANDTRANSMISSION,.............'.....11Two-CycleEngineService,,......11EngineRemovalandInstallation..............
11
CylinderandPiston',,12Clutch.14Kickstarter.,..,.,.................,19Crankcase,,,,...........21Transmission..,....25Four·CycleEngines..,........,..........'....,.31EngineRemovalandInstallation'.31TopEndService,...........32Crankcase.,,..,.,,.......37Clutch,",39Transmission..,'....................,41350cc
Index
Kickstarter,",..,.,....',47EngineandTransmissionSpecifications,48LUBRICATIONSYSTEM..,,."48OilInjectedModels...,,,.,48SprintModels...',49FUELSYSTEMS.,...............51Carburetors....................................51M-50andM-65,...........,'.51M-125andlIf-100....,,.....,511\1-165,,...52B-Models.,.,,..,,.,,....53X-90,Z-90,SR-100,TX/SX125,,..........54SS/SX175/250.,,.,.......,.54
Sprint
Models,.,,.,56ELECTRICALSYSTEM..58
Magneto-Generator.,..,.'"..,,..
58Generafor(Model165),,...,',.,58Magneto-Generator
(B
Models).,60Generator(1972andEarlier)SprintModels,.......60Alternator(1973andLater)SprintModels,,,.,61Alternator(SX/SS175/250),61ComponentTesting,..............61WiringDiagrams........,.',..64
,'..,,,81
Drive,..,..,,,81Wheels.......'.,,...,..,81Brakes,...,,"",85Suspension,,............,87FrontForks',87HearSuspension,,,,93CHASSIS
1
 
Harley-DavidsonSingles
Commonmaintenanceproceduresareex-plainedindetailin"GeneralInformation."
Lubrication
ENGINE
Two-StrokeModelsThecrankshaftassembly(piston,conrodbearing,andleft-sidecrankshaftbear-ing)islubricatedbythegas-oilmixture.1973andlatermodelshaveanoilpumpdrivenoff
the
crankshaftwhichinjectsoilintotheintakeport.Thissystemdoes110trequiremaintenanceexcept£01:aperiodiccheckontheoilpumpcableadjustmentprovidedthattheoiltankiskept
full
ofoil.1972andearliermodelsuseapre-mix.Whenmixingtheoil,onallmodelsotherthantheM-100,usearatioofonepartoilto25partsgas(5ouncesoiltooneU.S.gallon).Thiscomestoaboutthreemea-suringcupfuls(theoilcupattachedtothegastankcap)toonegallonofgas.WhenmixingoilfortheM-IOO,dosoin
a
ratioofonepartoilto20partsgas(6
1
A
oztooneU.S.gal)oraboutfourcupfulstoonegallon.SprintModelsThetransmissionandenginearebothlubricatedbyacommonoilsupply
which
ismadeaccessiblebyafillerholelocatedontheright-sidecrankcasecover.Whencheckingtheoillevel,unscrewthefillercap,wipeitclean,insertthedipstickbutdonotscrewinthecap,thenremoveitandobservewheretheoillineends.Thismustbedonewiththemachinestanding
verti-
call
v
ona
flat
surface.The
oil
levelshouldbe
'no
higherthan'the"max"mark,andmustneverbeanylowerthanthe"min"mark.Changetheengineoilevery1,000milesinthesummer,orevery500milesillthewinterfornormaluse.1.Runtheengineuntilitsnormaloper-atingtemperatureisreached,removethedrainplug,gasket,andtheinnerandouteroilfiltersorthe.oilcapassembly(1972'andlatermodels),andallowtheoiltodrainintoasuitablereceptacle.Thefilterstopspringmaydropoffsobeawareofitslo-cation.2.Slowlykicktheenginethrough
sev-
eraltimeswiththeignitionturnedofftoremovethelasttracesofoilwhichremaininthecrankcase.3.Cleanthefiltersinasuitablesolvent,thenblowthemdry.Ifthefilterscreensarecloggedordamaged,theyshouldbereplaced.4.Inspecttheconditionofthedrainpluggasket,filterstopspring,oilfiltercap,andcapO-ringforadamagedconditionandreplacethemasnecessary.5.On1963andearliermodels,removethescavengerpumpfiltermagnetiCplug,pluggasket,andthefilterscreen,andallowtheoiltodrainintoasuitablerecep-tacle.Leanthebikeovertothelefttomakesurethatalltheoildrainsout.
2
Maintenance
1.Oildrainplug
2.Drainpluggasket
3,
inner
screen
4.Oute!'
screen
S.
Filterstopspri"96.Magneticplug7.plugga.$ket
(1963&
rller)
a.
Filter
screen
11963
&••
,Ii.,)
6.
CleanthefilterscreenandmagnetiCcapinasuitablesolventandblowthemdry.7.Inspecttheconditionofthescreen,gasket,andcapforaworn,dogged,
01'
damagedconditionandreplacethemasnecessary.8.Replacethedrainassembliestakingcaretoseatthefilterstopspringagainsttheclosedendoftheouterfilter.Theinnerfilterclosedendseatsagainsttheclosedendoftheouterfilter,andtheO-ringgoesbetweentheouterfilterandthefiltercap.Makesurethereisnogritontheplugthreads,theninstallandtightenthemse-curely.9.Add2qtofHarley-Davidsonoil,checkthelevel,securethefillercap,andkicktheenginethrough
a
coupletimeswiththe.ignitionoffbeforestartingtheengine.Whenchangingtheoil,replaceitwithanoilthegradeofwhichiscompatiblewiththelowesttemperatureexpectedbeforethenextoilchange.UseHarley-Davidsongrade58oilforuseintempera-turesbelow40degreesFahrenheit(40"F),grade75oilfortemperaturesabove40°F,andgrade105oilfortouringorhigh-speedoperationinhotweather.
CHECKINGOILPRESSURE
(SPRlNT)
.Inorderfortheenginetooperatewithasufficientamountoflubrication,theoilpumpmustdeliverbetween3-6psiat25mphinhighgearTheoilpumphasnoprovisionforadjustment,andmustbere-movedandrepairedifthepressuredropsbelowthespecifiedlimitsCheckthepressurebyattachingOilPressureGauge(H-Dpartno.96921-52)andtheassociatedhardwaretothecrank-caserockerannoilfeedlineconnection.Runthemachineonthecenterstanduntilareadingcanbeobtained.Ifthepumpdoesnotcheckout,inspectit'forblockagesomewherealongtheoillineswhichcouldcutdowntheoilflow.
TRANSMISSION
OIL
Allofthetwo-strokemodelshavesepa-ratetransmissioncompartments,forwhichthestateoflubricationrequiresperiodicattention.TheSprintmodelshaveacom-monoilsupplyfortheengineandtrans-missionassemblies.Theoillevelinthetransmissionsofallofthetwo-strokemodelsshouldbecheckedmonthlyorevery750miles.Theoilshouldbechangedto
suit
theseason,annually,every5,000miles,orimmediatelyifthetransmissioniseverimmersedinwater.
CHANGINGFORKOIL
Alloftheforkmodelsexceptthe
Tele-
GlideforkusedontheModel165,Hum-mer,Super-lO,Scat,Pacer,Ranger,andtheBobcathaveafillercaplocatedatthetopofeachforkleg,andadrainpluglocatedatthebottomofeachleg.TheTele-Glidemodelhasonlyafillerpluglocatedinthecenterofthelargehex-headcapscrewintowhichtheoilispoured.Harley-DavidsonSprintForkOilisrecommendedforuseinallbuttheTele-GlideforkswhichuseHarley-DavidsonChain-Saverorengineoil.1.Removetheforkfillercaps,placeasuitablereceptaclebeneaththeforklegdrainplugs,removethedrainplugs,andallowtheoiltodrainout..H.oldthefrontbrakeonandpumptheforkstoremovethelastoftheoil.On1969andearlierMLandMLSModels,removetheupperforkplug,inverttheforks,andletthemdrain.2.
If
itisne(''essarytoflushtheforkstoremovetracesofanincompatibleoilorforeignparticles,
£11
theforkwithkerosine,pumpthemseveraltimes,anddrainthemoutagain.3.Replacethedrainplugsandpourin
the
correctquantityplus10cctocompen-sateforthe'oilwhichwillremaininthefillerdevice,or
1.<1
oziftheforkshavebeentakendown
and
areperfectly
dry,
Refertothe"MaintenanceData"chartforcapaci-ties.4.Replaceandsecurethefillercapsandchecktheforks
for
smoothoperation.TheTele-Clidetypeforksdon'trequireforkoilchanges.Instead,theforkoilisre-plenishedevelY750mileswithonetubecapoilplugfullofoil.Thetubecapoilplugislocatedinthecenterofthetubecaps.AIR
CLEANER
Themetal,meshfilterelementscanbecleanedincleangasoline
01'
asuitablesol-vent.Diptheelementinclean,light-viscos-
 
Harley-DavidsonSingles
ityengineoilandallowittodrainthor·oughlybeforeinstallingitTakecaretoplacethefiltergasketbeneaththeelementwhenassemblingthefilterassembly.Thedry,corrugatedpaperelementis'cleanedbytappingtheelementtoshakethedirtfreeandblowingonitwith
com-
pressedair.Iftheelementisexceptionallydirty,itmaybecleanedincleangasolinetoremoveoilorsootdeposits.The
ele-
mentmustbereplacedatleastevelY10,-
000
miles,
or
moreoftenifusedindustyconditions.Replacetheelementifitiseverimmersedinwater.Thisalsoappliestothecartridgeelements
(H·D
partno.
29037·61)
excepttheyshouldbereplacedevery2,500miles.
ServiceChecksandAdjustments
AdjustingConeTypeWheelHubBearingsBearingssuchasthese(foundonsomeofthe
M
andMSmodels)mustbead-justedevery1,000milestokeepthewheelspinningfreelyontheaxlewithonlythesmallestamountofdrag.7
1.Axle6.Beorin.gcup2,Locknut7>Outerlocknut,brakeside3.Bearingccne8_Outerspccer,brckeside4.Dustcover9_Brokesideplcte5,Ballbearings10Innerwasher,brokeside
Conetypewheelhubbearings.
1.
Fniplug
1A.Rubberplug2,Drainplug
Adjustthebearingsinthefollowingmanner:
1.
Removethefrontwheel.2.Loosenthewheelbearingconelock-nutwitha
HAG
in.wrenchwhileholdingtheBatsidesoftheconewitha-IS
mm.
open·endwrenchorasuitableadjustablewrench.
3.
Rotatetheconetowardthewheeluntilitseatssnuglyagainstthebearing,thenbackitoff
%
turnsothereisslightplaywhentheaxleismovedsideways.
4.
Securetheconelocknutwhenthe
ad-
justment
is
correct,whileholdingtheconetopreventitfrommoving.
5.
Mountthewheelandrecheckthe
ad-
justmentasitmaybelostwhentheaxlenutsaresecured.BrakeAdjustments
FHONTBRAKE
Whenproperlyadjusted,thefrontbrakeleverwillmoveabout
1fs
{1/4
ontheSandBModels)ofitstotaldistancebeforethebrakebeginstoengage.Raisethewheel,spinittocheckfordrag,andreadjustitasnecessaIy.Loosentheadjustingscrewlocknutandrotatetheadjustingscrewclockwisetoin-creasethefreemovementofthehandlever,counterclockwisetodecreaseitsmotion.
If
itbecomesnecessarytoadjustthecablelength,dosobylooseningthecableset-screworclampstudandnut,andthenpullingonthecable.Alwaystakecaretosecuretheadjustingapparatusaftertheadjustmentiscompleted.Whenevernewshoesareinstalledon1970andlaterSprintmodels,theymustbeequalizedtomakesurethatbothshoescontactthedrumatthesametime.Per-formthisoperationbyadjustingthembothattheirrespectiveendsofthebrakerodcleviswhileholdingthebrakeon.Theclevisadjustershouldbeloosenedbeforethebrakeisoperated,andretightenedbe-foreitisreleased.
~,
~~
1.
AdjU-'itingsleevelower
lode
nut
2.Adjus.tingscrew
3.Adju5tingsleeveupperlocknut
4.Operatingleverslettedclevtspin5.Control
coil
spring
6.Broke
ape
rating
lever
Frontwheelbrokeadjustment(SandBModels)
1.
Adiuslings.crew2.Locknut
3.lowercleviscdjustment
4.Upperclevis
adjustment
5.
Brakecamshaft
qrecse
fitti
nqs
6.CableblockFrontwheelbrakeadjustment(1970andlaterSprintModels).
REARBMKE
Adjusttherearbrakebyturningtheknurlednut,ortheadjustingnut,until'thebrakebeginstoengageafterthebrakeleverisdepressed
lh
in.
(%-1
in.fortheSandBModels).Theadjustingnuthasanotchwhichsitsagainsttheclevispin
ill
thebrakeactuatinglevertokeepthead-justmentconstant.Turnthenutintotightenthebrake,andouttoloosenit.Aftertheadjustmentiscomplete,raisethewheelandspinittocheckfordrag,andreadjustitasnecessaly.ClutchAdjustment
M·MoDELS
Alladjustmentsfortheseclutchesareperformedatthecable.Iftheclutchfailstoholdandreleaseproperlyafter'beingadjusted,itwillhavetobetakenaparttodeterminethereason.Adjustthecablesothehandlevermoves
lJs_l!t
ofitstotalmovementbeforetheclutchbeginstodisengage.Loosenthecablescrewlocknut,turntheadjustingscrewouttoincreasetheplay,orintode-creaseit,andthensecurethelocknut.Ifyourunoutofroomatthecablead-juster,ifthecableclamphasbeenre-
3

Activity (7)

You've already reviewed this. Edit your review.
Joshua Brown liked this
1 thousand reads
1 hundred reads
Hawk Miles liked this
Hawk Miles liked this
Tom Bona liked this

You're Reading a Free Preview

Download
/*********** DO NOT ALTER ANYTHING BELOW THIS LINE ! ************/ var s_code=s.t();if(s_code)document.write(s_code)//-->