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    Harley Davidson Sportster 1970 1978 Service Manual 99484 78 OPT

    Uploaded by

    José Alexandre Gama da Silva

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 235
    SERVICE MANUAL 1978 1970 to Sportster %L/XLH/XLCH/XLT-1000 FOREWORD “This service and repair manual has been prepared with twopurposes in mind. Fits, twillacquainttheread- ‘er with the construction of the Harley-Davidson product and assist him in performing basic maintenance ‘and repair. Secondly it will introduce tothe professional Harley-Davidson mechanie the latest field-tested ‘and factory-approved major repair methods. We sincerely believe that this manual will make your associa ton with Harley-Davidson produets more pleasant and profitable. HOW TO USE YOUR SERVICE MANUAL Your Service Manual is arranged for quick, easy reference. This manual is divided into numbered sections entitled “Chassis,” “Engine” and “Transmission.” Sections are then divided into eub-sections. The Engine Section, for ex ample, is comprised of “Cylinder” and “Crankeasa" sub- sections, Use this manual as follows: 1, Check the Table of Contents located in the front of each ‘section to find subject desired 2. Page number is listed across from subject. 3. Each section is printed with section number for quick ‘general location of subject. Page number consists of sec: ton number and page number. > Information is presented ina definite order as follows Minor adjustments Minor maintenance or repair Complete disassembly Cleaning Major maintenance or repair ‘Assembly In figure tegends the number following a name of @partin- cicates the quantity necessary for one complete assembly. Allinformation for servicing partshouldbe readbefore r- pir work ig started to avoid needless disassembly, Harley-Davidson products 2907024. 2008800. 211601 SERVICE BULLETINS In addition tothe information given in this Service Manual, Service Bulletins are issued to Harley-Davidson Dealers fromtime totime, which cover interimengineering changes and supplementary information, Service Bullatine shoulé bbe consulted for complete information on the models cov fered in this manval USE GENUINE REPLACEMENT PARTS ‘To ensure a satisfactory and lasting repair job follow the ‘manual instructions carefully and use only genuine Harley: Davidson replacement parts. This is your insurance that the parts you are using will fi right, operate properly and lat longer. When you use gen ine Harley-Davidson parts you use the best WARNING — Gasoline is extremely flammable and high ly explosive under certain conditions. always stop en- gine, and do not smoke or allow open flame oF sparks when refueling or servicing the fuel system. or when us- ing solvent where specified in thi manufactured under one.or more of the following patents: U.S. Patents — 2986162 "2144621. 2144260, 32260904.2220702. 24348827. 2669772, Des. 226 626. G CHASSIS Ee 1970-78 SPORTSTER ENGINE XL/XLH/ TRANSMISSION Ei XLCH/XLT-1000 ELECTRICAL >) SERVICE MANUAL MISCELLANEOUS n in this manual applies to the 1970-72 8 XLT and the 1973-78 XL/XLH/XLCH COPYRIGHT 1978 BY HARLEY-DAVIDSON MOTOR CO. INC. ALL RIGHTS RESERVED Ho-sw-2/0s TABLE OF CONTENTS < a = ee oy ee PRODUCT Assembling 27 Repair Procedure 37 Petree Dru Ne and cng no = a fe se : ce eee Serccane Siengeneusaconte 12 Demertrganiton 234 etnscUinde tine Ea lecommended Operations at Asgomt sting Tappets 345 First 500 and 1,000 Miles 1-3. ‘Rear Shock Absorber BSte feces mel eet Regular Suitbolieteeiie Fork ; Push Rods Only 345 ae 19> aoes ses a ely TORQUE REQUIREMENTS ‘Servicing 36 Removing 317 Fastener Tightening 113 ae Front Wheel 238 Cleaning and Inspecting 317 cece en Speemsemtreiantty Lubrication System 1.18 Replacing Front Wheel Connecting Rod Bushing 3-20 eee OSs eee ca Soman pa re ete age eae = se 138 ett ste faeases sek 17! — Anemia Brakes 237 GEARCASE be ASSIS Rear Brake Foot Pedal ‘Check Valve 3.23 = mae ot fae Saas aiken Pee rere to Eon Zeer Bier cues 2. ee ae ce dine eer fale fowcrenoie Eyre ge tn aa oe eee cone oes ee WHEELS Cylinder 2-45, Bearing Replacement 3.31 ‘Service Chart 26 Bleeding Hydraulic ‘Assembling 3.32 escalate, on, aes eee wag I loa eee Sap eucment Ho MONE Pan eee = =ahin ay CMe ds: a acccaleee res SLES one Sen 3 Bar aaaiel ee a ae Aa Coe Tamme tg Ey ae a Tube on Rin 214 ros 253 Operation 348 lls cae as Aligning Wheels cs ENGINE Inspecting an ening 3-40 \ouesan THROTILE Giver Cheong tape ae en oe | oreergeleed Spiral Type Description 34 Assembling 3-63, satis eel Pee emia eSNG TABLE OF CONTENTS (cont'd) Carburetor (Bendix) Operation Adjusting Disassembling Cleaning and inspection Assembling Carburetor (Keinin) Operation Adjusting Disassombiing Cleaning and Inspecting Assembling Installing Troubleshooting Chart Air Cleaner Fuel Tank Fuel Supply Valve TOOLS TRANSMISSION GENERAL Specifications Description cuuTcH Diagnosis Chart 1870 Clutch Controls Adjusting Clutch Release + Mechanism Adjusting Clutch Spring Tension Replacing Clutch Control Release Mechanism Inspecting Clutch Release ‘Mechanism Assembling Clutch lease Mechanism 41971 and Later Cluteh Controls ‘Adjusting Clutch Release Mechanism Adjusting Cluteh Spring Tension Disassembling Clutch Rolaase Mechanism ‘and Cluteh Cable Inspecting and Repsiring CCluten Release Mechanism and Clutch Cable ‘Assembling Clutch Reloase Mechanism ‘and Cluteh Cable Page Number 3-54 354 2656 3.56 3-56 358 3.58 358 361 261 3-62 3-62 3-62 3.64 3-66 3.66 266 3-69 43 43 aa 44 45 45 46 46 46 46 46 a8 Page Number 1970 cluch 48 Disassembling 48 Inepecting anc Repairing 48 Replacing Clutch Sprocket ‘Needle Bearing and Starter Clutch Assembling Clutch 1971 and Later Clutch Disassembling Inspecting and Repairing ‘Assembling Clutch Compensating Sprocket KICK STARTER General Disassembling Inspecting and Repair Assembling ELECTRIC STARTER, Starter Drive an Disassembling Solenoid 4.21 Disassembling Starter rive Shatt and Housing 4-22 ‘Assembling Starter and Solenoid a2 ‘TRANSMISSION Genera 423 1075 and 1976 Shier Linkage 423 Removing Transmission 4.24 Inspecting and Replacing Ports 4.25 ‘Assembling Transmission 4-28, Lubrieation 4:30 TooLs 431 ELECTRICAL WIRING ‘Wiring Diagrams 1970-71 XLH 53 1970-71 XLCH 55 1972 XLH Std, Se 55 1972 XLCH Std. Seat 5-6 1972 XLH Low Seat &-7 1972 XLCH Low Seat 5-7 1979-74 XL 59 1973-74 XLcH 59 1975 & 1976 XL B11 1975 81976 XLCH 11 1977 XL 513 1977 xLcH 513 1978 XL 515 1978 XLCH 515 ‘SWITCHES Button Solenoid Switch ‘Stop Lamp Front Brake Switen| Starter Relay Switch Lames Heaciamp ‘Adjusting Beam Bulb Chart GENERATOR (Checking, Testing and Repair Brushes Field Coils Armature ‘Commutator Disaesembling ‘Assembling ‘CIRCUIT BREAKER Deseristion Operation ‘Troubleshooting Adjusting Points Ignition Timing Disassembling and ‘Assembling Installing Circuit Breaker Disassembling and As- sembling 1971 & Later Models IGNITION con. “Troubleshooting Replacing Cables SPARK PLUGS Removing Plugs Cleaning, Inspecting and Repair Sorting Spark Gap Testing Spark Plugs Installing Spark Plugs REGULATOR - 1977 & EARLIER Tests ‘Test Specifications Testing Method | (Model XLH) Testing Method | (Mode! XLCH) Page Number 5.17 5418 518 519 5.21 521 521 523 5-23 323 325 5.26 8.27 528 6.29 5-29 529 5.29 5-30 621 5.33 5.33 a7 537 5.39 5-39 5.40 5-40. 5-40 5-42 5-43 TABLE OF CONTENTS (cont'd) “esting Method i (Model XLH) “Testing Method i (Moet XLCH) Servicing REGULATOR - 1978, General (Checking Charging System BATTERY care Charaing HORN ‘STARTER MOTOR Troubleshooting ‘Starter Motor and Orive Prestolite Starter Motor Hitaen: Starter Motor Prestolite and Hitachi Page Number 583 554 555 557 357 658 558 Starter Motors Toots MISCELLANEOUS INSTRUMENTS. Speedometer Tachometer PRODUCT TABLE OF CONTENTS PAGE General ...... sel Service ....... : Sears 4 Locating Troubles ...........cccsseeseees 2115 GENERAL PECIFICATIONS DIMENSIONS XLXLHXLCH Whee! Base seseesenee SBA" 88/2" Overall Length ===. 187076 87-1/4" 87-1/4" i977 @iater 7-3/4" 87-974" vera Width 1970-78 ar 1977 @iater 35" vera Height 1970-76 ar 1977 & ater ae" Rosd Clearance ....... 1970-72 6 6-1/2" yere77 Tava" 74/4" ‘cAPACTES XL XLCH Gasoline Tank (US. Gallons)... 400r22 400r22 Reserve : 2s 25 Oi Tank (Querts) === 3 3 Transmission (Pints) me W2 y) / ENGINE Model Designation Letters. XL XH, XLcH Type of Engine Numbor of Cylinders Placement of Cylinders Horsepower: 1970-71 158 hp at 8800 rpm 4972.7 | 61 hp at 6200 rpm 1978 ‘Taxable Horsepower Riigiecsesnse 7 Bore: 1970-71 "3.00 in (78.2 mm) 1972 8 liar 123.188 in. (81 mm) stroke : 3.8125 in.(96.8 mm) Piston Displacement 1970-71 rsvvssssssssess_ 839 eu in. (889 c0) 1972 & lier ‘0039 eu. n. (997-5 ce) Torque 152 lb-ft at 3800 rpm Compression Rao. 20%01 Spark Plugs (or breakin pried) No.4 {Alter break-in period, No.5 plug is recommended for aver- ‘age and hard service “The Vehicle Identification Number (VIN) is stamped on She right side of the engine erankease and on the frame Jteering head. k consists of a model code, 9 serial num- wr a manufacturer's Kenticntion and model year 85 shown inthe table Medel teers | "Now | Serietno. | mig. | Year Xtorx | 34 | 10000 | # 8 xucH” | 4a | andup | Harley- | (1978) A 40 | (agit | Davidson xu 26 ‘Aiways give this number when ordering parts or making an inquiry. TRANSMISSION Type vesseeseesesesnvsseess Constant Mesh ~Foot Shift Speeds. so 4 Forward XL XL XLCH | 1970.7) numberof [78788 XLcH Sprocket Teeth: | Later_| 1970-73"| Only ‘Engine ua | 34 34 ccuten se | 58 59 Tranemission 2 20 19 Rear Whee! 5 51 51 ‘Gear Ratios: Fis (tow) Gear |t063 | 11.16 -| 11.74 770 | 308 | 850 saz | 6m | 643 422 | 442 | 466 e TIRE DATA SPORTSTER TIRE CHART Whee! Whee! eserption | The Size Tame] Laced 375.197 XUW/xLCH/xLT [Gast 7 Spake | _MU80-19 Front Cast, 9 Spoke ising 425067 XLH/XLCH/XLT MN90-18 Rear XLH/XLCH Mq90-16T Rear 500-187 (Accessory) 510-167 WARNING — These tires have been specific 10 pro- ‘ide maximum handling stability and must be used ‘lusively for replacement. Te Size + Front -MMGO-19T (2.75 x197) Fear - 425% 187 Pressure a Fron = 26 bs Rear ~ 30, WARNING ~ Maximum prossure of ether tre is 32. IMPORTANT Ether Goedyear or Yokohama tre are supplied es ‘riginal equipment and are ientited according 10 the chart on page 1-1 anartubes ae denifid with ‘manuiacturers corresponding se numbers Thess ‘ites were specially designed to provide maximum foadabilty. Thess special tres must be used exclu ‘ively for replacement. Ties wil ft only taper base Fim! On th XLT modo, use only Yakehome’s ¥-260 forthe from ana ¥-622 forthe rar tie ‘The tir inflation pressures given are based ona i 2 weighing approximately 180 bs. When thi oad ‘ressure of roar ire 2 Ib. and frnt tre 1 I A — SERVICE SERVICING A NEW MOTORCYCLE Fre vE.veRy Service operations to be performed before delivery to cus tomer are specified in the Setting Up Instructions and Im- portant Instructions ineluded with new vehicle. CHECK AT FIRST'500 MILES 1. Drain oil tank through drain plug. flush with kerosene and refill with fresh oll 2. itmotoreycleis equipped with oi fi 3. Drain transmission and front chain compartments, Clean transmission magnetic drain plug, and refill with fresh oll. Use same grade oll used in engine. Reinstall plug. Han oil leak is noted, reinstall plug along with Seal Wesh- cr, Part No. 6370. 4, Lubricate all points indicated for 2000 mile servicing as Bed | sag | Shean | | «| m| uo] st) 25] 10 |50 Ja | rary sac | s3ago0 w]e | o || a | | 20] x0 | ® | ma | see) ee z > | EKET | rea00 | MICH CARBON) e Sr eS vem | = [axl om SegeT | cxgaoo | Matesenes | ol wae |e | ne | on | | fe | a | séeiw | P| Seumeneo | ee ate ZA. eye ee uta ult tenth ‘j 4 SPECIFIC FASTENER TIGHTENING pec a: aa SPECIFICATIONS: Rocke atm cover screw 2ofbs Cylinder head bolt 65 felts cairo comemen es Corb, Tietson) inte seat assy. 0-45 into Aste nut... i SO {tbs Carb. Tillotson} acct -purmp Brake vise mounting screw (1973) -_------.... S5ftlbs channel plug «. 23-28 ines. Brake dae mounting serew (1974 and later). 1Otlbs Clutch (1971 & later hub nut. 150 fs Fork stem pinch bolt sissies 2040 25 lbs Cylinder base nut STE 20 fet Handtebar clamping bolt 20'f-ibs Gear cover screws, chain cover screws, Caliper front brake) bolt 36f-bs andi pump 100 ines Brake die front brake) bot 35 fulbs ELECTRICAL COMPONENTS * [ENGINE COMPONENTS ent. ieee Pinion goar nut (1877 & 1978) . cee. SOftlbs Starter motor (Prestolt) thru bolt vcs. ....._ 20-25 in-bs Gear shaft nut... CNN Yoo%120 bs Starter motor (itachi) tir bolt 20-25 in.be + { | LOCATING TROUBLES The following check list will be helpfulin locating most op- “ating toubles ENGINE STARTS HARD 1. Spark plugs in bad condition, partially fouled or have improper gop. 2, Spark plug cab 4. Cireut breaker points out of adjustment or in poor con- dition, 4, Battery nearly discharged, 5. Loose wire connection ceil or circuit breaker. 6. Carburetor fuel mixture 10 rich or too lean. bad condition and “leaking. ‘one of battery terminals, or at 7. Defective ignition coil 8, Defective condenser. 9, Engine and transmission oil 100 heavy. (Winter opera tion) 10. Engine ignition spark not timed propery 11, Circuit breaker eam sticking in advance postion. ‘STARTS BUT RUNS IRREGULARLY OR MISSES *. Spark plugs in bad condition, or partially fouled ‘Spark plug cables in bad condition and “leaking.” ‘Spark plug gap too close or too wide. . Circuit breaker points out of adjustment or in need of saning Condenser connections loose. Dofective ignition coil Defective condenser. Battery nearly discharged. Loose wire connection at one of battery terminals, or at ‘coll oF cireuit breaker. 410. Intermittent short circuit due to damaged wiring in ulation. 11, Water or et in fu system and carburetor 12. Gasoline tank cap vent plugged or carburetor vent line closed off restricting fuel flow. 13. Carburetor fuel minture too rich or too lean. 14, Weak or broken valve springs. RANKING MOTOR DOES NOT OPERATE OR DOES NOT TURN ENGINE OVER 1. Ignition switeh or handlebar stop switch isnot on 2, Discharged battery, or loose or corroded connections. 3. Se 4, Clutch slipping. 5, Electric starter shaft pinion gear not engaging ter control circuit or solenoid defective. ENGINE TURNS OVER BUT DOES NOT START 1. Gasoline tank empty. 2. Gasoline valve shut off 3, Gasoline line clogged 4, Discharged battery or loose or broken battery terminal ‘connection. Check by turning light switeh “ON.” 5. Fouled spark plugs. 6. Spark plug cables in bad condition and “leaking. 7. Badly oxidized ignition circuit breaker point. 8, Circuit breaker and/or ignition timing points badly out of adjustment. 9. Loose wire connection at one of battery terminals, or at cil or circuit bresker. 10. Clutch slipping and starter not turning engine over 111, Engine flooded with gasoline as a result of over: choking 12, Engine and transmission oil too heavy (winter opers: tion). ‘A SPARK PLUG FOULS REPEATEDLY 1. Too cold @ plug fr the kind of service 2. Piston rings badly worn or in bad condition. PRE-IGNITION 1. Excessive carbon deposit on piston head or in combus- tion chamber 2, Too het 2 spark plug fr the kind of service or for type of engi 3. Defective sperk plugs. 4 Ignition timing too advanced. (OVERHEATING 1. Insufficient oll supply, or oil not circulating, 2, Carburetor fuel mixture to lean. 3. Ignition timing too late. DETONATION 1. Unsuitable fuel (octane rating to low) 2. Heavy deposit of carbon on piston head and in combus- tion chamber 3, Defective spark plug oF wrong heat range. 4, Ignition timing too early ae EXCESSIVE VIBRATION 1. Oylindor head bracket loose or broken, 2. Engine mounting bots loose. 3. Broken frame, 4, Tires or wheels defective LUBRICATION SYSTEM IL DOES NOT RETURN To OIL TANK 1. Oil tank empty 2. Scavenger pump gear key sheared. 3. Oil feed pump not functioning HIGH O1L CONSUMPTION 1. Breather valve incorrectly timed 2. Piston rings badly worn or in bad coneh 3. Chain ciler adjusting screw adjusted for an excessive amount of oi. 4. Oil leak to outside. 3 otherwise. ELECTRICAL SYSTEM GENERATOR DOES NOT CHARGE 1. Brushes baaly worn, 2. Brushes sticking in holders 3. Voltage regulator not grounded 4, Voltage regulator incorrectly adjusted 6, Defective voltage regulator. 6. Commutator dirty of oi 7. Positive brush holder grounded. 8, Generator “A terminal grounded. 8. Loose or broken wire in generator-battery circuit 10. Broken field coil wire or loose terminal (both coils) 11. Commutator shorted 12, Defective armature. CHARGING RATE IS BELOW NORMAL 1. Voltage regulator incorrectly adjusted, 2. Broken fold col wie or loose terminal (one coil). 3. Commutator worn and not turning true with shaft - ‘throws brushes at high speed, 4. Commutater dirty or oil. 5. Brushes gummy and sluggish in holders. 6. Defective armature 16 CARBURETOR FLoops 1. Inlet valve sticking, 2. Inlet valve and/or valve seat worn or damaged, 3. Dirtor other foreign matter between valve and its seat 4, Carburetor intot lover not set correctly 5. Excessive pumping of hand throttle grip. TRANSMISSION SHIFTS HARD 1) Bent shitter rod 2. Clutch dragging slighty 3. Transmission ol too heavy (winter operation) 4. Shifter forks (inside transmission) sprung as 8 result o! Using too much force when shifting, JUMPS OUT OF GEAR 1. Shifter rod improperly adjusted. 2. ‘Shifter forks (inside transmission) improperly adjusted. 3. Corners worn off shifter lutch dogs (inside tr Sion) ~ makes engagement difficult CLUTCH suPs 1. Clutch controls improperly adjusted, 2. Insufficient clutch spring tension 3. Worn and/or oil soaked friction discs (1970). 4, Worn friction dises 1971 & later), DRAGS OR DOES NOT RELEASE Clutch controls improperly adjusted, Clutch spring tension too tight. Friction dises gummy. Clutch sprocket keys badly worn, Clutch dises warped. Transmission cil to heaw. BRAKE DOES NOT HOLD NORMALLY 1, Brake shoe improperly adjusted. Brake controls binding 3. Brake linings impregnated with gr ‘over-lubrication. 4, Brake linings badly worn. 130 as a result of 5. Brake drum bealy worn oF scored. 6. Brake shoes not centered (HYDRAULIC BRAKE ONLY) 1, Master eylinder low an fluid 2, Brake line contains air bubbles. 3. Master or wheel cylinder piston worn or parts dete, CHASSIS TABLE OF CONTENTS PAGE Drive ....eseeeees 24 Wheels ...... : +25 Handlebar Throttle Control 217 Frame . pecvieen 12-19 2-21 2-35 2-47 2-53 Fiberglass . Tools % DRIVE ERONT CHAIN ENERAL The front chain should be checked every 2000 miles for correct adjustment, Check chain adjustment through oil filer opening located near the top of the chain cover. A correctly adjusted front chain should have free up-and- ‘down movement in the upper stand midway between en- gine and clutch sprockets as follows: Front chain adjust ‘ment: 8/8 to 7/8 in. chain slack with cold engine: 3/8 10 55/8 in. chain slack with hot engine. Check adjustment at tightest point on sprockets, found by rotating sprockets. WARNING — To prevent accidental starter operation. disconnect positive or negative battery lead before doing any work on the engine, drive or olectrical systems. ADJUSTMENT (1976 AND EARLIER) Figure 2-1) To adjust chain, remove let footrest, and rear brake foot lever. Place an oil drain pan under clutch and remove front chain cover screws, chain cover and gasket. ‘The front chain ie adjusted by means of @ shoe under rneath the chain which can be raised to tighten or lowered to loosen the chain. The chain adjuster is secured to the inner surface of the chain compartment by 3 bots. Simply loosen bolts and raise o lower chain adjuster. When chsin i correctly adjusted tighten bolts securely and reassem- ble remaining parts. il transmission with correct emount and type of lubri- ant as dascribed in “GEAR BOX,” Section 4 ADJUSTMENT (1977 AND LATER) (Figure 2-2) 1. Drive chain 4. Support bracket 2 Chain adjuster bolts (2) shoe 5. Support bracket br 3. Support bracket 8. Brace bolt Figure 2-1..6fit Chain Tensioner Adjustment (1876 and Earlier) ‘Adjusting Chain Tension The front chain can be adjusted without removing the chain cover. Adjustment is made by loosening locknut (6), Figure 2-2, and turning the slotted adjusting sorow (6) IN for tightening or OUT for loosening. ‘Screw (6) raises or lowers an adjuster assembly which ‘contacts the lower strand of the front chain and applies ‘pressure to make the chain operate with the right mount of free play, [After adjusting ie complated,retighten locknut (6) REPLACING ADJUSTER ASSEMBLY (Figure 2-2) f screw (6) is screwed in all the way and chain is still loos, the adjuster assembly or chain probably is worn ex- cessively and shauld be replaced. ‘To replace chain adjuster (2) remove drain plug anddrain oil from chain case. Remove gear shifter pedal, footrest, chain case cover and gasket. Chain adjuster (2) must be replaced fas an assembly when slider material is excessively worn or ‘damaged, To replace, relax chain tension by unscrewing chain adjuster screw (5, Figure 2-2), and remove adjuster. Remove spring from old adjuster and assemble to new adjuster. Remove foreign material from magnetic drain plug. Re- place and securely tighten drain plug. Replace case cover ‘and gesket, Install shifter pedal and footrest on shafts. Fill goarbox with correct amount of lubricant as described in “TRANSMISSION,” Section 4. Readjust chain for cor- rect tension as described previously tu 6 Chain Slider, nylon Retainer Cap (not shown) ‘Screw, adjusting Locknut Wash Boss 10, Bolt and washer Shoe _11. Cover, left side peed Figure 2-2. Front Chain Adjuster (1977 and Later) LUBRICATION ‘There is an opening between the front chain and trane- mission compartments, and the same oll supply auto: ‘matically lubricates moving parts in both compartments. For complete lubrication service on the front chain see “TRANSMISSION.” Section 4 REPLACING ‘Since the front chain is. automatically lubricated by running in ol, litle serviee will be required ether than, ‘checking chain adjustment every 2000 miles. However, if through hard usage the front chain does become worn, itis breakage and possible damage to the crankeases. To remove front chain, soe “DISASSEM: BLING CLUTCH,” Section 4 REAR CHAIN ADJUSTMENT (Figure 2-3) ‘The rear chain should be checked every 1000 miles for correct adjustment. A correctly adjusted rear chain should have 1/2 in, free up-and-down movement midway between mainshaft and rear wheel sprocket with weight of ‘motoreyele and rider on wheels. As chains stretch and wear in service, they will run tighter at one point on the Sprockets than anather, therefore always rotate rear whee! land check adjustment at tightest point of chain. Toadjust rear chain, loosen axle nut(1) on right side of mo: toreycle, Loosen locknut (2) from adjusting nut (2), on both sides of motorcycle. On 1973 to 1978 models also loosen anchor bolt (5) Turn adjusting nut (3) clockwise to move rear wheel back, tightening chain; turn adjusting nut (3) ‘counterclockwise, and at the same time, tapeach endo the ‘axle to move the wheel forward, loosening the chain, Turn ‘adjusting nut (8) on either side exactly the same number of turns to maintain alignment of wheel With Iocknut (2) tight ‘against adjusting nut (3), the distance from locknut to outer tend of adjusting stud (4) should be the same on both sides, 1. Reat axle nut 2. Adjusting stud locknut 3. Adjusting stud nut 4, Adjusting stud 8, Anchor bolt (1973) Center brake shoes, Check correct alignmentaf whos! by ‘observing that tre runs about midway between rear frame tubes and rear wheel sprocket runs centrally n the chain When readjustment is completed, be sure to securely re: tighten rear axle nut (1), rear wheel adjusting stud locknut {2)and anchor bolt (5) where applicable. After adjusting rear chain, the rear brake may be too tight. Readjust brake link: age, if necessary, as described in “ADJUSTING REAR WHEEL BRAKE,” Section 2. REAR CHAIN OILER (1976 AND EARLIER) (Figure 2-4) ‘At regular service intervals (1000 miles) make a close Inspection of rear chain. If it does not appear tobe getting sufficient lubrication, or if there is evidence of an over- ‘supply of ol, adjust rear chain oiler. ‘To adjust rear chain oiler, proceed as follows. Loosen lock rut (2), if used, and turn sorew (1) outward for more il ‘and inward for less oll. Turn screw only a fraction of aturn ata time: lock adjusting Screw in place if locknut is used. The quantity of oil needed to lubricate the rear chain is very small. The size of the opening (orifice) through wich cil bleeds to the chain is regulated by the adjusting screw. Sediment and gummy matter, accumulating in the oil supply, deposit in and around this orifie and gradually de- crease the cil supply tothe chain. A chain that has been lu- bricated perfectly the first 2000 miles may run shert of oit the second 2000 miles. For this reason, even though in- spection indicates the chain is amply lubricated, it i ad- visable to blow sway accumulated sediment and restore the orifice to its original size at intervals of approximately 2000 mil To clean rear chain oiler, proceed as follows: 1. If lockrut is used, back it out as far as possible. 2. Turn adjusting screw in until it bottoms on its seat Count the number of turns needed to turn the screw in 3. Remove adjusting screw and blow out orifice with com: pressed ar. 4 Roinstall adjusting serew and turn it in until it bottoms on its seat, 5. Turn adjusting screw out the number of turns counted in Step 2 above and leck in place with locknut if used. This is the original setting, Therear chain oiler should be stop mit oto flow ata rate of 2103 drops per minute, This sat ting is approximately 3/4 of e turn 1. Adjusting screw 2, Adjusting screw locknur (early 1970) Figure 2.3. Right Side Rear Wheel Figure 2-4. Rear Chain Oiler (1976 and Earl EAR CHAIN LUBRICATION (1977 AND LATER) ‘The 1977 and later motoreycl is not equipped with a rear chain oiler. Therefore, the rear chain should be checked ‘and lubricated at regular intervals. Under normal operating conditions, brush off the drt and lubricate chain at least every 300 miles. Use Herley- Davidson grade 75 of 105 (SAE 40 or 60) or “Chal Spray,” "Chain Saver” or "Chain Grease.” Apply at room temperature to both chain side plates and rollers. Apply with a brush or squirt can to thoroughly cover chain. Wipe off surplus lubricant. ‘SERVICING REAR CHAIN ‘At regular service intervals of 1000 miles, examine the tear chain for adequate lubrication and worn chain links ‘edditional chain lubrication is needed for 1978 and. models, adjust chain oiler according to the procedure de- ‘scribed in “REAR CHAIN OILER (1976 AND EARLIER} for 1877 and later models, refer to paragraph tiled, “REAR CHAIN LUBRICATION (1977 AND LATER}.” I she motoreycleis operated under extremely dirty. wet. or high speed consitions, extra cleaning and lubrication of ‘the rear chain may be advisable from time to time. Free chain from motoreycle by removing spring-locked ‘connecting link. Connecting link pins which have press fitted sido plates can be pressed apart with Chain Repair ‘Tool, Part No, 95020-38 which 18 supplied in accessory ‘der tool kt. A shop tools available for this purpose under Part No. 95021-28. Lay clean chain out flat and contract, chain by taking up all slack in its links. Measure the chain length. Then stretch chain out to its full length and again ‘measure chain length. if the difference between the two ‘measurements exceeds 1 in. the chain should be re- placed, In addition, if the chain has any stif links and is Visibly worn or damaged. it should be replaced. if @ new chain is not available and it ie necessary to repair the old ‘chain, remove damages links by pressing out riveted link pins with Chain Repair Tool Soak and wash thoroughly in @ pan of solvent such 2s kerosene, After removing chain from kerosene, allow kerosene to dain off oF blow off with sir hose. After chain 's completely dry, apply Harley-Davidson grade 75 or 105 (SAE 40 or 60) oil or "Chain Spray,” “Chain Saver,” or “Chain Grease.” Apply at room temperature to both chain side plates and rollers, Wipe all surplus lubricant from sur- face of chain. Install chain on motorcycle. Inspect connecting link and ‘spring clip closely for bad concition, Replace if at all ques- tionable, To install new press fitted connecting link, use Rear Chain Assembling Tool, Part No, 95020-66. Be sure spring clip 1s securely locked on pit ends, open end of clip ‘on outside, trailing direction of chain travel, as positioned ‘on motoreycle 24 WHEELS GENERAL Maximum tire mileage end good handling qualities are di- ely related to care given wheels and tires. A front tre kept in continuous service will wear irregularly and peaked and may affect handling, especially i over-infiated, ‘Therefore, itis extremely important that correct tire pres: ure be maintained at al times. ‘At regular intervals of 5000 miles, or at any time handling irregularities are experienced, see the chart below for recommended service WHEEL SERVICE CHART CHECK FOR 1. Loose axle nuts. 2. Excessive side-play or radial (up and down) play in wheel hubs 3. Loose spokes, 4, Alignment of rear whee! in frame ‘and with front whe ‘eccentric with hub (should not bbe more than 3/32 in} ‘or peaked front Gon 10, Steering head bearings. be 11, Shock absorber 12, Rear fork bearings. Tighten axle nuts (50 ft-1bs maximum torque). Replace whee! hub bearings as described in “INSPECTING. AND REPAIRING WHEEL HUBS.” Tighten or replace spokes as described under “TRUING WHEELS” and "SPOKING WHEELS.” Check wheel alignment as described inthis section, fr inspect and straighten frame as described in "FRAME." o repair roar fork as described in ‘REAR FORK, 5. Rims and tires out-of true ‘True wheels, replace rims or replace spokes as sideways, (should not be more described under, “SPOKING WHEELS” than 3/64 in) ‘and “TRUING WHEELS.” 6. Rims and tires out-of-round or See item 8, above, Replace as described in “REMOVING AND INSTALLING FRONT AND REAR WHEEL,” and “REMOVING AND INSTALLING TIRE AND TUBE. Inflate tres as described in "SPECIFICATIONS, Static balance may be satisfactory if dynamic balancing facilities are not available, however, {dynamic balancing is also recommended Correct adjustment and replace pitted or worn 198. Seo "FORKS. CCheck damping ection and mounting stud rubbers. See "FORKS. (Check for looseness. See “FORKS.” REMEDY REMOVING AND INSTALLING FRONT WHEEL (1972 AND EARLIER) (Figure 2-8) Raise front end of motoreyele high enough to permit re moving wheel; support motorcycle by suiteble blocking lunderneath frame. Disconnect brake control by removing brake clevis pin (1). Remove axe nut (2), and axle nut lock ‘washer (3). Remove brake anchor and shoe centering bolt {4}, and lockwasher (8). Loosen axle pinch bolt (6). With @ soft hammer loosen axle (7) and remove from hub and fork assembly. Remove front wheel and bra plete. sembly com- To reinstall front wheel and brake assembly, reverse the isassembly procedure. Center brake shoes as described in "ADJUSTING FRONT WHEEL BRAKE." Injactone ounce of “Grease-All” grease into the wheel hub. Tighten axle rut to 60 ft-lbs torque. Tighten pinch bolts (6) to 11 f-bs torque. Spin whee), to make sure it turns freely 28 ak clovis pin Axio nut ‘Axlo nut lockwasher ncher and centering bolt Z Se Ew AN] 1. Caliper mounting bolt 7. Slider cap nuts 2. Washer (2) & Axle 3. Locknut 9. Speedometer drive 4. Axle nut 10. Caliper 5. Axle lockwasher 11, Brake dise 6. Figure 2-5. Front Wheel Removal (1872 and Earlier) Figure 2-7. Front Wheel Removal (1974 to 1877) 1, Axle nut 2. Axle nut lockwasher 3. Slider cap nuts 4, Front wheel axle 8. Bleed iting 1. Left side caliper 5. Axle 2. Right side caliper 6. Axle nut 3. Caliper mounting 7. Axle lockwasher hardware (2 sets) 8. Axle washer 4, Slider cap hardware 9. Speedometer drive 2 sets) 10. Brake discs Figure 2 - Front Wheel Removal (1973) 26 Figure 2.8. Front Wheel Removal (1978) REMOVING AND INSTALLING FRONT WHEEL (1973) Fig- ure 2-6) ‘Support motorcycle underneath frame with front wheel raised. Remove axle nut (1), and axle nut lockwasher (2). Loosen slider cap nuts (3), With a soft hammer tap left end fof axle (4) to loosen it and start it out. Pull axle out of fork ‘assembly. Remove front wheel assembly and speedo- meter deve To reinstal, reverse above procedure. Align the brake pads while installing the wheel so that the brake disc goes be- tween caliper (7) pads. Be sure speedometer drive (6) ear engages hole in wheel hub when installed, Securely tighten axle nut (1) to 50 ft-lbs maximum torque and then tighten the two slider cap nuts (3) 1011 ft-lbs torque. This ensures proper alignment of the fork sides. REMOVING AND INSTALLING FRONT WHEEL (1974 TO 1977) (Figure 2-7) ‘Support motoreycle underneath frame with front wheel ‘aised, Remove brake caliper mounting bolt (1). washers (2) and locknut (3). Remove axle nut 4), lockwesher (5) and ‘washer (6). Loosen slider cap nuts (7) With a soft hammer tap left end of axle (8) to loosen it and start it out. Pull axle (8) out of fork assembly. Remove front wheel assembly and ‘speedometer drive (9). To reinstall, reverse above proce- dure. Align the brake pads while installing the wheel so that the brake disc goes between caliper (10) pads. Be sure speedometer drive (9) ear engages hole in wheel hub when installed. Securely tighten axle nut (4) 10 50 ft-lbs, ‘exercising care not to overtighten, and then tighten the ‘wo slider cap nuts (7) o 11 f-lbs torque. This will ensure correct alignment ofthe fork sides. REMOVING AND INSTALLING FRONT WHEEL (1978) Fig- ure 2-8) ‘Support motorcycle underneath frame with front wheel raised. Detach both the right and lett caliper assert from the fork sliders by removing mounting hardwa Let caliper assemblies hang down loose out of the wa shown in figure. Remove axle nut (6), lockwasher (7) and ‘washer (8). Loosen slider cap hardware (4). With 2 soft hammer tap left end of axle () to loosen it and start it out Pull axle (6) out of fork assembly. Remove front whee! as- ‘sembly and speedometer drive (8) 3) CAUTION — Do not operate front brake lever when the ‘front wheel is removed because the brake caliper piston may be forced out of the bore, requiring disassembly of ‘the brake system to gat it properly reseated. To reinstall wheel, reverse above procedure. Be sure ‘speedometer drive (9) ear engages hole in whee! hub ‘when installed. Securely tighten axle nut (6) to 60 ft-lbs and then tighten slider cap hardware (4) to 11 ft-lbs torque. This will ensure correct alignment of the fork sides. Tighten caliper mounting bolts (3) t0 11 lbs torque REMOVING AND INSTALLING REAR WHEEL (Figure 2-8) Raise rear end of motoreycle high enough to permit re ‘moving wheel; support motoreycle by suitable blocking un- erneath frame. Locate and remove chain connecting link (1) and disengage chain from rear sprocket. Remove brake chain connecting link 3 brake rod adjusting nut axle ‘Axle spacer, lft side ‘Axle nut lockwasher ‘Anchor bolt Figure 2-9. Rear Wheel Removal ‘adjusting nut (2) from brake rod. Remove axle nut (6), axle rut lockwasher (7) and centering collar (6). With a soft hammer tap right end of axe (3) t0 loosen from ltt sido of frame. Remove axle from hub and frame assembly. Re- ‘move axle spacer (4) from left side, Slide wheel and brake assembly to extreme rear end of frame. Lift wheel up to pass brake drum over brake shoes. Remove whee! from motorcycle. ‘To reinstall rear wheel, reverse the disassembly proce: dure, Center brake shoes as described in “ADJUSTING REAR WHEEL BRAKE.” HUBS DISASSEMBLING AND ASSEMBLING FRONT WHEEL HUB (1972 AND EARLIER) Figure 2-10) Pry grease seal (1) from whee! hub. Remove retaining ring ) with Tru-are lock ring pliers, Tap ball bearing (3) inward the way against its seat in hub. Tis will move bearing (4) out far enough so that spacer (5) can be moved away ‘rom bearing (4). Then use a drift tap out bearing () from ‘opposite end of hub. Bearing (3) can now be tapped out from opposite end. 20 Clean and inspect alerts, paying particular atention to the wheel hub bearffe. If bearings have excessive side play or radial (up and Bown) play in the wheel hubs. hey Should boygplaced. If bearings have been removed from the huteMMarctully examine for yisible wear, heat dis ‘cloration or damage to inner arf outer races, Inspect brake shells or brake dis for scaring, fooving and worn running surfaces. Check spoke flanges for bent or dam- ‘aged condition. Recommended hub repair is replacement of worn or damaged pats Coan and pack both ball beorings with fresh Greate-All ‘grease, Press brake side ball bearing (4) against shovider in hub, shieldod side out. Install retaining ring (2) using Trasarc loc rng plas IMPORTANT Flat side of retaining ring must be toward bearing 1. Goaas oa Install bearing spacer (5). Press bal! bearing (3) against 2 Retaining ving shoulder in hub and tap grease retainer (1) in place. 3. Ball bearing DISASSEMBLING AND ASSEMBLING FRONT WHEEL ‘4, Ball bearing (rake sie) HUB (1973 TO 1977) (Figure 2-11) Ea see Remove ol sais (1), spacor (2, and bearing cones (3). Use ‘bearing puller to remove bearing cups (4. Spacer (5) may ow be removed. Brake ise oF 6A is secured to hub (9 Figure 2-10. Front Wheel Hub (1972 and Earlier) or 9A) with 6 bolts and lockwashers (8) or serews (BAL 1. Oits0ai a) 2 Spacer 3. Bearing cone (2) 4 Bearing cup (2) 5. Spacer 8. Brake disc (1973) 6A, rf Brake dise (1874 10 1977), Brake disc spacer (1973) Bolt and lockwasher (5 (1973) A. Hex socket screw (5) (1874 to 1977) 8.” Hub (1873) 9A. Hub (1974 to 1977) Figure 2-11. Front Wheel Hub ~ Exploded View (1973 to 1977), - 28 Clean and insect al parts. paying particule attention to the wee! hub bearings. W baring have exonsive se lay or redial (up ane down) payin th whee! Rube they ‘Should be replaced. bearings have been removed from the habe, careully examine for vie wear, heat {oloraton or damage te inner and outer races. Inspect rake shes or brake size for scoring pfooung nd worn running surfaces Check spoke flanges for Bent or da ‘ged canaiton. Recommended hub rps repocement of worn or damaged parts. Reassembly Is basicaly the reverse of cisassembly with the folowing exceptions: Apply aliberat amount ot Here Davidson Grease Alto bearing cones (3 lore assom Diy, Pres ol sais (1) into ub ues wth oer surone arcate lip of oi seal before inserting spacer (2) brake ‘diac (6 or 6A and brake cise spacer (7 ave Been das: before assem, Apply Harley Davidson Bearing Mount” Part No. 99625-77, to threads and ‘ighen bolts (to 35 bs torque or srows (A) 1 18 Bb torque Wen wee x aesemblodto moore, be ing end pay shoud be 0028 to O16 in. W end Baye not correct substtute a sighdy anger oF shorter spacer 895 (4 Sea (2 ‘Spacer ‘Bearing cone (2), Bearing cup (2 Spacer Brake cise (2) Screw (10) Hub Figure 2:72. Front whee! Hub DISASSEMBLING AND ASSEMBLING FRONT WHEEL HUBS (1978) Figures 2-12. 213), Remove oi seas), spacer (2 and bearing cones (3, Use 2 standard bearing puller to remove bearing cups (, Spacer (5) may now be removed. Brake discs (8) are se ured to nab ot whoo (8) with sows 7). Clean all paris in solvent and inept for damage or west Replace pers x necesary. If bearing cones o cups need replacing replace 65 set Inspect brake ccs for war Ing, scaring or worn running surfaces. Replace as neces ‘hry On spoked wheels sec spe lenges for Bat ot

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