Product

General Specifications 1948-1954.. 4

General Specifications 1955-1957.. 6

Lubrication Chart 8

Signal Lights 9

Starting Engine 9

Stopping Engine 9

Running in New Engine 9

High Speed Tips 10

Trouble Shooting Charts 10

engine 10

generator 11

carburetor 11

transmission 11

brakes 12

General Lubrication 12

Lubrication Chart 13

Servicing Air Cleaner 14

Initial Servicing of New Motorcycle. 14

first 250 miles 14

first 750 miles 14

first 1500 miles 15

Regular Interval Inspection &

Maintenance 15

Care & Lubrication of Drive Chain. 16

adjusting drive chain 16

adjusting front chain 16

adjusting rear chain 16

lubrication front chain 16

lubrication rear chain 17

repairing drive chain 17

Clutch & gear shifter 18

Compensating sprocket (early style). 18

Chassis

Wheels 20

general 20

removal 20

removal (side car) 21

servicing wheel hubs 22

replacing rear wheel sprocket ... 23

spoking wheels 23

truing wheels 24

removing & installing tires 25

Shop Data wheels 2®

Servicing Handlebar Controls 28

early model 28

late model 29

Removing & Installing Forks 29

springers 31

Fork Frame & Handlebar Alignment. 34

rough check for fork alignment... 34

rough check for frame alignment. 34

frame alignment diagram 35

springer shock 36

Glide Forks 37

general 37

changing oil 37

glide fork diagram 39

glide fork diagram (adjustable) .. 40 disassembling fork sliders & tubes 41

adjusting steering damper 41

adjusting fork trail (adjustable)... 42

disassembling front fork 42

steering head bearings 43

replacing slider bushings 43

inspecting & servicing fork 44

straightening fork tubes 44

straightening fork stem & bracket assembly 45

assembling fork 46

assembling fork (adjustable) ---- 47

Brakes 48

disassemble front brake (glide) .. 48 inspection & servicing (glide) ... 48 assembling front brake (glide) ... 48 adjusting front brake cable (glide) 48 adjusting front brake shoes (glide) 48

glide brake diagram 49

springer brake diagram 49

rear brake diagram 50

adjusting rear & springer brakes. 51 servicing rear & springer brakes. 51

Servicing Saddle Spring Post 52

Engines general 54

engine diagram 55

lubrication 56

winter lubrication 57

changing oil 57

oil pressure signallight 57

operating oil pressure 57

oil filter 57

pressure oil system 58

return oil system 59

engine repair procedure 59

pressure oil system diagram 61

return oil system (early) 62

return oil system (late) 63

disassembling cylinder & piston.. 64

refinishing cylinders 65

fitting piston rings 66

connecting rod bushings 67

straightening connecting rods ... 68 assembling cylinder & piston ... 69

Shop Data cylinder reboring & piston fitting.. 70 pistons & rocker arms 72

removing cylinder head assembly. 73 disassembling cylinder head 73

replacing valve guides

cylinder head diagram

replacing valve seats 'J>

grinding valve faces & seats

lapping valve faces & seats 7b assembling cylinder head «>

adjusting tappets

Shop Data valve guides IT

installing high lift cam

intake valve guides £9

valve guide sizes

exhaust valve rotating mechanism 81

valve spring testing information.. 82

FLH valve springs S3

hydraulic pushrods °4

adjusting hydraulic pushrods--------85

servicing hydraulic pushrods--------86

misc. clearances & oil pressure.. 89

servicing oil pump 90

installing oil pump 91

Shop Data oil control 92

oil pump charges 94

late oil pump 96

oil pump flow diagram 97

1948-1954 Lower End Diagram 98

Disassembling Lower End "

installing timing gears 100

installing timing gear case cover. 100 1948-1954 gear & crankcase data procedures 100

truing & sizing main bearing races 101

fitting main bearings 102

servicing flywheels & installing crankpan 102

truing & sizing connecting rod lower races 102

determining correct lower bearing fit 103

assembling connecting rods &

flywheels 103

truing flywheels 104

assembling crankcases 105

installing generator 106

Shop Data removing & replacing pinion shaft gear 1P7

crankcase drilling procedures ...109 connecting rod roller & retainer size chart 111

engine fitting specifications 112

servicing pinion shaft rollers ... .113 pinion shaft assembly diagram.. .114 1955-1957 oil pump diagram . . . .115

1953-1957 Valve Tappets & Guides. .116

1954-1957 Gear Case Diagram ----118

1954-1957 Gear Case Timing Cases. 119

1955-1957 Crankcase 122

1955-1957 Complete Lower End

Procedures 122-130

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