Color Code On Uflex Oil Ring

(Oposite ring gap) Std to .019 not marked .020 to .039 Light blue .040 to .059 Light green .060 to .079 Purple Figure 3C-9. Assembling Rings with Ring Expander To check compression ring gap, place a piston in cylinder with top end of piston about 1 2 in. from top of cylinder. Place ring In cylinder bore squarely against piston and check gap with thickness gauge (see Fig. 3C-7). Use only standard size rings and piston in standard bore, and only matching oversize rings and piston in the same...

Info

KEY FOR WIRING DIAGRAM (RADIO-SPECIAL) A. FOUR WIRE CABLE - Red, green,black and yellow wires from switch and instrument panel base terminals 1, 4, 6 and 7. Right front cable in panel base to terminal box behind ignition coil. B. LOOM (one wire) - Green wire from generator signal light (28) (under panel) to REG terminal on generator. C. FOUR WIRE CABLE - Red, green, yellow and black wires from switch and instrument panel base terminals 1, 2, 3 and 46. Right rear cable in panel base to terminal...

Aligning Fuel Shutoff Valve Fittings

When a left tank has been repaired the fuel shut-off valve should be realigned using Gas Shut-Off Valve Tool, Part No. 96365-42. The tool aligns top and bottom holes and correctly spaces them so the fuel shut-off valve operates without binding. The tool consists of four parts 1. Aligning Bar 2. T-Handle 3. Spacing Handle 4. Stop Sleeve. Remove left tank from motorcycle and disassemble all fuel fittings. Shift spacing handle in aligning bar so larger portion marked aligning is through hole. Turn...

Fitting Pinion Shaft Bearing

The fitting of pinion shaft bearing is done in much Figure 3E-17. Pressing Flywheel into Crankcase Figure 3E-16. Pressing Bearing on Sprocket Shaft small end up over sprocket shaft, starting it squarely. Install the small bearing spacer and the sprocket shaft spacer. Place tool sleeve on spacers andpress bearing against flange on flywheel using the tool driver and handle as shown in Fig. 3E-16. Position flywheel assembly in vise with sprocket shaft up. Slip crankcase half (15), with outer race...

Assembling Cylinder Head

Replace valve and valve spring assemblies using Valve Spring Compressor, Part No. 96600-36. Position valve keys so spaces between key halves are equal. Spaces between key halves must face front and rear of engine on intake valves. Replace rocker arm assemblies making sure intake valve oiler is in place on intake rocker bearing, with oiler tube 3 32 in. from rocker arm. Rocker arms must be free or hydraulic lifters will not fill with oil. Replace rocker arm cover and reinforcing ring. Use new...

Fitting Piston Rings

Piston rings are of two types - compression (plain face) and oil control ring. The two compression rings are positioned in the two upper piston ring grooves with the stamped word TOP or a dot (.) upward. Rings are regularly supplied in the following over-sizes to fit standard oversize pistons .005, .010, Figure 3C-6. Measuring Ring Side Clearance .020, .030, .040, .050, .060 and .070 in. Compression rings must have proper side clearance in ring grooves. In new assembly this is .004 in. Check...

Lapping Connecting Rod Races

Connecting rod lower races that are likely to clean up within the range of oversize bearing rollers and are otherwise in serviceable condition, should be trued and sized with Connecting Rod Lapping Arbor, Part No. 96740-36, as shown in Fig. 3E-9. Turn lap in lathe at 150 to 200 rpm. Adjust lap by means of adjusting nut to a dragging but free fit in rod race. Clean lap before using, then apply fine lapping compound (No. 220 grit grinding compound mixed with oil) to lap. A loose or tight lap will...

Trouble Chart Engine

Note- Too frequently, spark plugs and or ignition coil are thought to be defective when engine starts hard, runs irregularly, or fails to start. Sometimes when a spark plug fails to function normally, it is the result of an accumulation of dirt on Sug core which becomes a conductor when damp or wet allowing spark to jump from cable terminal Z plug base, instead of across electrodes in combustion chamber. Under such a condition, wiping plug core clean with a dry rag will allow plug to function...

Fitting Rod Bearings

There are three ways to determine oversize rollers to use. All will result in properly fitted bearings if applied correctly. 1. Use a micrometer to measure the outside diameter of the crank pin at its center. Use an inside micrometer or telescoping hole gauge to measure the inside diameter of the rod races. Subtract the diameter of the crank pin from the inside diameter of the bearing race. Subtract from this figure the standard Figure 3E-6. Pressing Bearing Races Out of Crankcase Figure 3E-7....

Cleaning And Inspection

Wash all parts except lined discs in cleaning solvent and blow dry with compressed air. 1. A glazed surface which may be recognized by a smooth, shiny and sometimes darkened appearance. 4. Oil impregnated accompany glazing. Figure 4B-3. Positioning Clut' Actuating Lever Glazed and oil soaked discs may sometimes be reconditioned by soaking in white gas for several hours, blowing dry with compressed air and roughing with medium coarse sandpaper. Grooved linings and linings worn down near the...

Illus 64 1948 1954

TIMING GEARS WITH MARKS IN CORRECT ALIGNMENT (O.H.V. ENGINE) 1. Pinion gear. Gear and shaft are spline engaged and gear is a slip fit on shaft. 2. Cam gear. (Steel spacing washer behind this gear). 4. Circuit breaker drive gear. (Spacing collar in front of this gear). 5. Intermediate gear (not itiarked). (Spacing collar in front of this gear). 6. Generator drive gear (not marked). 7. Oil pump drive gear (not marked) secured on end of pump drive shaft with key and spring ring. Installing Timing...

Pump Changes

It is not necessary to remove complete oil tdubid from engine in order to make these changes. Refer to 1948 Big Twin warts catklog, page 23. Remove pump cover and governor rotor part Nos. 682-41 and 687-41C, and also remove cover plate Np. 683-41. Discard governor rotor and cover pl.-te. Install new cover plate 683-49. You will note that new cover plate blocks off the holes in pump body and cover that formerly passed oil to and from the governor. (If a new cover nlate 683- 9 is not available...

Illus 53 Truing Flywheel Mainshafts

Bear in mind that, while a straight edge across rim faces is used when assembling flywheels to keep them as near as possible true with each other, final truing is a matter of truing sprocket shaft and pinion gear shaft to perfect alignment with each other, rather than truing flywheel rims. Install wheel assembly in truing device (Harley-Davidson truing device. Part No. 11962-X) and adjust so that centers are just snug (wheels must turn freely). If flywheel assembly is either loose between...

Clutch And Gear Shifter

Need for attention to clutch and control is indicated ne dfirst warning or indication of shifter control fcorrect adjustment is transmission W out Tengaginient when accelerate, u de heavy pull. This warning must not be dis regarded. Cheeking and Adjusting External Gear Shifter Control 1 See that control joints from transmission gear siiher lever to gear shifter handlever are well oiled and free-working. 2. Check handlever center pivot bolt nut for tightness. 3. Observe whether there is binding...

Disassembling Crankcase

Remove cylinder heads as described in Disassembling Cylinder Head, Remove cylinders as described in Disassembling Cylinder,' Remove gearcase parts as described in Disassembling Gearcase, See Crankcase, above for checking procedure before starting crankcase disassembly. Refer to Fig. 3E-1 and proceed as follows Remove crankcase bolt (1), stud (2), crankcase breather stud assembly (3) or (3A), stud (4), top and right crankcase studs (5) and two lower crankcase studs (6). It is necessary to remove...

Removing Sidecar Wheel

Raise wheel by blocking up under sidecar chassis. Loosen nut that secures fender front bracket to sidecar step lug. Loosen the fender inner brace clip bracket nut. Remove outside axle nut, lock washer and outer brace. Hinge fender forward, taking care to provide slack for taillamp wiring. Remove extension nut, axle nut and washer. Pull wheel from axle with brake drum attached. Detachment of wheel from brake drum is necessary only when wheel or brake drum is to be replaced or wheel interchanged....

Replacing Rear Wheel Sprocket

To replace a worn rear wheel sprocket remove wheel from motorcycle as described In Removing and Installing Rear Wheel. Disassemble brake drum from wheel. Chisel heads off all rivets and dowel pins from brake shell side and punch them out. lithe rivet holes are not worn, use the rivet holes again. If the rivet holes are found slightly worn or elongated and drum is in good condition, drill a new set of rivet holes in drum flange midway between original dowel and rivet holes. To drill new rivet...

Disassembling Front Fork

Prepare for disassembling by raising front end of motorcycle on stand or suitable support, so wheel is off the floor. Remove front and side fork trim panel or headlamp housing. Remove headlamp. Disconnect at terminal strip the two headlamp wires and all wires that pass through handlebars. Disconnect throttle and spark advance cables from carburetor and circuit breaker. Remove front wheel as described in Section 2C. Remove front brake hand lever bracket and coil clip on fender. Turn off front...

Replacing Front Fork Slider Bushings

The front fork slider bushings 25, Fig. 2F-3 may be replaced using three special tools. 1. Part No. 96255-50, Fork Slider Bushing Puller. 2. Part No. 96285-50, Bushing Driver and Guide. 3. Part No. 96300-50, Bushing Reamer and Pilots. REMOVING SLIDER BUSHINGS. Position fork slider in vise as shown in Fig. 2F-6. Remove spring ring, steel retaining washer and felt wiper from slider upper end. Pry out oil seal with large screwdriver. Install Fork Slider Bushing Puller, Part No. 9625550, so the...

Replacing Valve Guides

Replacing valve guides 24, Fig. 3B-1 if necessary, must be done before valve seat and face are ground since the valve stem hole in valve guide is the basis from which all face and seat grinding is done. Figure following name of part indicates quantity necessary for one complete assembly. 7. Cover reinforcing screw 12 12. Rocker arm bearing stud nut 8 14. Rocker arm bearing top half 2 16. Rocker arm bearing bottom half 2 17. Exhaust valve stem pad FL model only 19. Upper valve spring collar 2...

Disassembling Engine For Complete Overhaul

After Removing From Chassis Completely Assembled 1. Remove upper-end parts as outlined under Disassembling Engine for Top Overhaul Only O.H.V. Engine 2. Remove pistons. See Piston and Pin, 3. Remove generator as outlined under Removing Generator, 4. Remove circuit breaker assembly from crank-case Free low tension wire from clip on crank-case if wire is shielded, disconnect metallic shielding from crankcase stud. Remove relay and relay bracket. Remove two cap screws 9 and then circuit breaker...

Left Crankcase Assembly

Using sprocket shaft as gauge to determine bearing fit Servicing Flywheels and Installing Crank Pin First give attention to flywheel washers 24 , Illus. 62 or 63. If washer in either flywheel is worn and grooved to any extent, it should be renewed. This hardened steel washer fits into recess in flywheel face around crank pin hole and takes side thrust of connecting rod lower end and bearing. Washer is a close fit in recess and is secured by punching flywheel metal tight against it at several...

Roller Bearing Roller Guide

Here is a handy chart, giving information on roller bearing rollers. It is suggested that this data be kept in a prominent place so that it can be referred to on a moment 's notice. Rollers .250 and .1875 are used in retainers. Needle rollers .152, .125, .114 and .0625 are used without retainers. Rollers .250, .1875 and .152 are furnished from .001 undersize to .001 oversize in steps of .0002. Rollers .125 and .114 are furnished only .0004 and .0006 oversize. Rollers .0625 are furnished only...

Hardwood Wedge

Truing Flywheels on Truing Stand hammer to realign wheels. To prevent flywheel assembly from turning in vise while tightening nut, insert a rod 5 in. long and about 1 2 in. in diameter through holes in flywheels and between vise jaws so that rod bears against some part of the vise. When nut is fairly tight, install flywheel assembly in Flywheel Truing Device, Part No. 96650-30. Adjust so centers are snug. Wheels must turn freely but shafts may not be loose in centers. If flywheel...

Straightening Fork Stem And Bracket Assembly

Straightening a fork stem and bracket assembly requires a great deal of skill, experience and several tools and fixtures. Special tools necessary include Fork Tube Straightening blocks, Part. No. 96246-50, four blocks are needed Bending Bar, Part No. 96806-40 Fork Stem and Bracket Aligning Gauge, Part No. 96245-51. In addition, the following pieces of bar stock are needed Two bars, 1-5 8 in. diameter, about 12 in. long two bars 1 in. x 4 in. x 12 in. approximately assorted pieces of rectangular...

Connecting Rod Bushing

When connecting rod bushing is tight in rod but is worn to excessive pin clearance .002 in. or more it is possible to service by reaming oversize and fitting an oversize pin. However, it is recommended that a new bushing be installed and reamed to fit a standard pin, except when piston to be used had previously been fitted with oversize pin, or pin is loose in bosses, necessitating fitting with an oversize pin. The objection to fitting upper end oversize is that considerably more time is...

Lc35f

M-35S M-36 M-U U-lllF M-lOL M-iilLF M-US M-51 M-51F M-51L J -5lLF M-75 M-75F 1 1 1 If if if If If if 7 8 7 8 7 8 1-1 16 1-1 16 1-1 16 1-1 16 1-5 16 1-1 16 1-1 16 1-1 8 1-1 8 1-1 8 1-1 8 1-1 8 1-1 16 1-1 16 1-1 8 1-1 8 1-5 16 1-1 16 1-1 16 1-1 8 1-1 8 1-5 16 1-5 16 Small Idle Hole Nearest Manifold Flange 70 70 70 70 70 72 70 70 70 72 72 72 72 70 70 70 70 72 70 70 70 70 72 72 Farthest From Width Manifold Flange Drill Size .009 .009 .009 .009 .009 .009 .009 .0155 .009 .009 .009 .0155 .0155 .0155...

Truing And Sizing Pinion Shaft Main Bearing

Before fitting new pinion shaft main bearings, lap bearing race in crankcase to true it and remove traces of -wear shoulder at sides of roller paths. Using Crankcase Main Bearing Lap, Part No. 9671854, consisting of lapping shaft, handle, lapping arbor and guide sleeve Fig. 3E-14 . A race that is worn beyond limits of oversize bearings must be replaced. To remove worn bearing race, remove two bearing race lock screws 17, Fig. 3E-2 from inside of case. Heat case to 275 - 300 degrees F. Heating...