Lubrication

The engine is lubricated by a pressure system circulating oil from the tank through the moving parts and back to tank. For adequate lubrication the tank must contain an ample supply of clean oil at all times. Oil consumption varies from 250 to 500 miles per quart depending on the nature of service, solo or sidecar, fast or moderate driving, and how well the engine is kept tuned. If mileage is not within this range, see following engine overhaul section. Remove tank cap and check oil supply at...

Shock Absorbers

ADJUSTING REAR SHOCK ABSORBER SPRING The rear shock absorber springs can be adjusted to three positions for the weight the motorcycle is to carry. The average weight solo rider would use the extended spring position (off cam) when in low position (off cam), the cam lobes should be next to each other that is, single lobes and double lobes matched. If necessary, rotate the cam to line them up properly. A heavy solo rider might require the position with springs slightly compressed (first cam step)...

Handlebar

Handlebar controls for throttle and spark advance must operate freely. If a control becomes stiff and hard to adjust, parts must be removed and cleaned of caked grease, gum and dirt. A kinked control coil must be replaced if complete straightening cannot be accomplished. DISASSEMBLING HANDLEBAR CONTROLS (Fig. 2D-2) Disconnect control coil and wire at carburetor or circuit breaker. Loosen clip which secures spark control coil to upper frame tube. Insert a large screwdriver through hole in end of...

Cylinder Head

REMOVING CYLINDER HEAD ASSEMBLY (Fig. 3B-1) Remove spring cap retainers (1) on push rod covers by prying down on cover spring cap with screwdriver wedged between cylinder cooling fins and pulling spring cap retainers out. Remove five head bolts and washers (2) from each head. Lift cylinder head enough to slip out push rods (3) and push rod covers (4). Remove cylinder head (5). Remove cylinder head gasket (6). Mark push rods so that they will be reassembled in same position. ened tool that will...

Oil pump

The oil feed pump and scavenger (oil return) pump are gear type pumps housed in one pump body and located on rear of gearcase on right side of motorcycle. The feed pump incorporates an automatic bypass valve that reroutes surplus oil (above the amount needed to lubricate the engine) directly to the gear-case. This valve is preset and non-adjustable. Under normal operating conditions, the pump is a comparatively trouble free unit. The most common trouble with pump operation is the introduction...

Rear Fork

To disassemble rear fork, first remove following assemblies 1. Rear wheel (see Section 2C). 2. Rear brake side cover with connecting control linkage (see Section 2G). 3. Rear shock absorbers (see Shock Absorbers). See Fig. 2F-20. Turn back locking ear on pivot bolt lock washer (2) and turn out pivot bolt (1). Remove fork (3) from frame. With appropriate size arbor pin, push out bearing spacer (4), bearing seal (5) and bearing with outer race (6) from each side of fork pivot bearing. Clean pivot...

Engine Repair Procedure

When an engine needs repair, it is not always possible to definitely determine beforehand whether the engine can be repaired by disassembling only cylinders and heads, only gearcase or whether engine must be completely disassembled for crankcase section repair. Usually, only upper-end repair is needed and it is recommended procedure to first strip motorcycle for cylinder head, cylinder and piston repair as described in Stripping Motorcycle for Engine Repair, steps 1 through 10. After...

If Engine Starts But Runs Irregularly Or Misses

Spark plugs in bad condition, or partially fouled. 10. Spark plug cables in bad condition and 'leaking. 11. Spark plug gap too close or too wide. 12. Circuit breaker points out of adjustment or in need of cleaning. 13. Condenser connections loose. 17. Loose wire connection at one of battery terminals, or at coil or circuit breaker. 18. Intermittent short circuit due to damaged wiring insulation. 19. Water or dirt in fuel system and carburetor. 20. Gasoline tank cap vent plugged and tank air...

Use Genuine Replacement Parts

To insure a satisfactory and lasting repair job, follow the manual instructions carefully and use only genuine Harley-Davidson replacement parts. Behind the emblem bearing the words Genuine Harley-Davidson is more than half a century of designing, research, manufacturing, testing and inspecting experience. Jlooh 04. tluA. lUf*i cjjUalihf, This is your insurance that the parts you are using will fit right, operate properly and last longer. When you use genuine Harley-Davidson parts you use the...

Valve tappets and guides

Motorcycle Tappet

The tappet assembly consists of tappet, roller and hydraulic unit. The tappet and roller, under compression force from valve spring, follow the surface of the revolving cam. The linear motion produced is transmitted to the valve stem by the hydraulic unit, push rod and rocker arm. The hydraulic unit contains a piston or plunger and cylinder plus a ball check valve which allow the unit to pump itself full of engine oil to take up all play in the entire valve train. When hydraulic units are...

St1100 Fork Tool Compress

Harley Davidson Frame Drawings

To rough check a frame for correct alignment, see Fig. 2E-1. The dimensions shown will provide basic information to determine whether a frame is enough out of alignment to require a major realigning job or replacement. Straightening a badly bent frame requires special tools and fixtures for holding, bending and gauging. If frame straightening facilities are not available locally, damaged frames may be returned to the factory for repair through authorized Harley-Davidson dealers only . Replace...

Cylinder

DISASSEMBLING CYLINDER AND PISTON Fig. 3C-1 Strip motorcycle as described in Stripping Motorcycle for Engine Repair, Section 3A, steps 1 through 10. Remove cylinder head as described in Disassembling Cylinder Head, Section 3B. Figure 3C-1. Cylinder - Exploded View Remove all cylinder base stud nuts and washers 1 except one on rear cylinder using Cylinder Base Nut Wrench, Part No. 94585-30. Raise front cylinder and piston enough to permit placing a cloth over crank-case opening. This will...

If Brake Does Not Hold Normally

Brake shoes improperly adjusted. 105. Brake linings impregnated with grease as a result of over-lubrication. 107. Brake drum badly worn or scored. 108. Master cylinder low on fluid. 109. Brake line contains air bubbles. 110. Master or wheel cylinder piston worn. Chain adjustment must be checked at 2000-mile intervals. Rear chain requires more frequent attention than front, or primary chain. As chains stretch and wear, they run tighter at one spot than another. Always adjust free movement...

If Engine Fails To Start

Discharged battery or loose or broken battery terminal connection. Check by turning light switch ON. 28. Spark plug cables in bad condition and leaking. 29. Badly oxidized ignition circuit breaker points. 30. Circuit breaker points badly out of adjustment. 31. Loose wire connection at one of battery terminals, or at coil or circuit breaker. 34. Clutch slipping and starter not turning engine over. 35. Sticking valves, or tappets too tight. 36. Engine flooded with gasoline as a result of...

Wheels

Good handling of a motorcycle at any speed will result in maximum tire mileage. Tires must be transposed at regular intervals for best performance and long life. The larger the tire size and higher the average road speed, the more essential it is that wheels and tires be given proper attention. A tire kept in continuous solo motorcycle front end service long enough to allow tread to wear irregular and peaked, may cause high speed weave, especially if over-Inflated. At regular intervals of...