Sun Powertiming Light Model Ptl-45

Order from Sun Electric Corp., Chicago, Order from Sun Electric Corp., Chicago, Sun Power Timing Light, Model PTL-45 For testing state of charge of storage batteries. Specific gravity of electrolyte can be corrected for temperature extremes by means of built-in thermometer. 96802-63 Battery Hydrometer -with Temperature Correction Feature Sun Power Timing Light, Model PTL-45 Clear plastic plug threads into crankcase timing hole for ac-l curate ignition timing with strobe timing light....

Starter Motor And Drive

REMOVING AND INSTALLING STARTER MOTOR WARNING Disconnect battery cables (negative cable first) to avoid accidental start-up of vehicle and possible personal injury. Disconnect solenoid cable from starter motor terminal. Remove attaching nuts and lockwashers (1, figure 5-26) which fasten starter motor housing (3) to studs on chain housing. Remove starter motor end support plate (not shown) from transmission. It may be necessary to loosen and raise battery carrier to provide clearance. Remove...

A

Testing Battery Capacity Never allow a battery to stand in a discharged condition. Start charging it at once at the recommended continuous charge rate. Be sure charger is properly connected and adjusted observing positive (+) and negative (-) polarity to battery. To determine the amount or condition of a battery charge, check solution in each cell with a battery hydrometer. When hydrometer reading is 1.200 or less, battery is considered discharged and should be removed from...

Spark Plugs

Types of Plug Base Deposits Spark plugs should be replaced every 2500 miles. Use only the replacement spark plugs listed on page 5-1. The 5R6 and 5R6A plugs have a resistor element to reduce radio interference originating in the motorcycle ignition system. Only resistor type plugs should be used with 1980 and later ignition systems. Disconnect spark plug cables from plugs by pulling on molded connector caps. Connection is the simple snap-on type. CAUTION Do not pull on wires since...

Inspection And Replacing Parts

Inspect lip of seal and replace if it worn or rough. Alsc replace the seal if there is any evidence of oil leakage intc the timer compartment. Whenever ignition components have been disassembled, such as during engine disassembly and reassembly, or if a strobe timing light is not available, approximate timing can be obtained by using the following procedure 1. Set sensor plate (8) so that sensor plate screws (6) are centered in the slots. Snug down the screws (6). 3. Adjust the advanced timing...

Figure 523D

Remove rotor screw (9) and rotor (10). 6. Seal (11), if defective, can be pryed out from ignition side of gearcase. Use care not to damage camshaft end while prying. 7. Disconnect ignition module wires from coil. 8. To remove ignition module (13) from the frame, remove two mounting bolts, and the screw securing the ground wire to the frame. This procedure will result in approximate timing and engine can be operated in an emergency for a short period of time. Advanced timing should be checked...

Figure 523C

Ignition timing should be checked every 2500 miles. Use a strobe flash timing light (timing gun) to view advanced timing of flywheel through accessory plastic view plug, Part No. 96295-65, screwed into timing inspection hole. Make sure view plug does not touch flywheels. Timing light leads should be connected to the front spark plug, ground and battery positive terminal. Start engine and set engine speed at 2000 rpm. Light will flash each time spark occurs. Loosen sensor plate screws just...

Troubleshooting

When the engine will not start, or when hard starting or missing indicates a faulty ignition system, proceed as follows 1. Disconnect spark plug cables from spark plugs. Check condition of plugs and cables. Clean or replace as necessary. 2. Insert a conductive adapter into spark plug cable nipple and establish a 3 16 in. gap between adapter and cylinder head. Turn on ignition and engine stop switches. Crank engine. Check to see if a spark is obtained across the gap. If a spark is obtained, the...

Installing The Alternator

Install a new O-ring on the engine groove. Assemble the stator to crankcase securing with two lockplates and four screws. Install the plug retaining plate and screws. After assembling stator to crankcase, use tool, Part No. 97225-55, to press rotor onto sprocket shaft so that it bottoms tightly against seal spacer. See Figure 5-16. 2. Attach the hoses to the inner primary housing and install the housing. 3. Attach the transmission to the inner primary using the four nuts and washers or two nuts...

Alternator

The alternator consists of two main components the rotor (magnetic field) which is mounted on the engine sprocket shaft, and the stator (armature) which is bolted to the engine crankcase. The rotor is circular in shape with an outer flange that extends over the stator. On the inside of the flange there are twelve (12) magnets in a plastic ring. The stator consists of twelve (12) coils, each wound over a laminated iron core. The coils are positioned radially around the engine crankshaft and...

Transmission Neutral Switch

This switch (figure 5-6) is threaded into the transmission top cover. Switch plunger is depressed by a nub on the shifter drum or shifter gear only when the transmission is in neutral to complete the circuit. A variable number of spacing washers are used to close the circuit only when transmission is in neutral. Switch is permanently assembled Figure 5-5. Handlebar Switch Assemblies and if it fails to close the circuit when operating plunger is depressed, it must be replaced. Solenoid switches...

Stoplight Switch

To replace stoplight switch in right handlebar assembly (figure 5-5), remove cover (2) and rubber cap (9). Disconnect wires and unscrew switch (10) and washer (11) from housing. Switch must be replaced as a unit. The rear stoplight switch is located in the rear brake hydraulic line. The stoplight switch is a normally open type switch which closes with hydraulic pressure. The switch parts are not serviceable and must be replaced as a unit. Connect a test light of at least 21 CP (12v) between the...

Handlebar Switch Assembly

The left handlebar switch assembly, figure 5-5, contains a rocker arm switch (headlamp HI-LO beam) and two pushbutton switches (horn and left turn signal). The right handlebar switch assembly contains a rocker arm switch (RUN-OFF) and two pushbutton switches (engine start and right turn signal). Individual rocker arm and push button switches can be replaced if defective. To replace individual switches, remove four screws (1, figure 5-5) and pull off cover (2) assemblies. Remove screws (3) and...

Shifter Forks

The disassembly and assembly procedure is the same for early and late style transmissions. However, on late 1979 and later transmissions, the shifter fork assemblies are reversed on the shifter shaft, that is, the side with the nuts (5) face the center of the shaft. See Figure 4-16. REMOVING SHIFTER FORKS (Figure 4-16) Remove shifter cover and transmission side cover as described in Removing Shifter Cover. Shifter fork shaft (2) is held in position by lock ring (1). With lock ring (1) removed,...

Shifter Cover Plate Shifter Late 1979 And Later

REMOVING SHIFTER COVER (Figure 4-15A) Remove transmission from chassis as described in STRIPPING MOTORCYCLE FOR TRANSMISSION REPAIR. Remove five bolts (1) and washers (2). The shifter cover (3) is registered on two dowel pins. Lift the shifter cover off and remove gasket (4). The bolt located in the left-side rear mounting hole (see arrow) can only be loosened to remove the top cover (3). To remove bolt from cover, it is necessary to remove the shifter shaft cover (11). DISASSEMBLING SHIFTER...

General

The Bendix type drive shaft and gear assembly, located in starter housing between starting motor (figure 4-5) and clutch ring gear, provides automatic means of engaging the starter shaft drive pinion with the ring gear on the clutch sprocket for cranking the engine and for disengaging the drive pinion from the ring gear after the engine starts. When the starter motor is not operating, the drive shaft worm pinion is disengaged from the ring gear. When the starter switch button closes starting...

Assembling Clutch Figure

Assemble clutch in approximate order of disassembly. If parts 1, 2, 4, 5 and 6 have been disassembled, preassem-ble them on clutch hub as follows Place clutch releasing disc (6) on hub. Position springs (5) on pins and studs. Place spring collar (4) over springs. Note that stud holes are arranged so it fits in only one position. Turn adjusting screw lock nut on adjusting screw until head is flush, then turn into pressure plate with 1-3 4 in. washer under nut. Remove this assembly from hub....

Cleaning and Inspection

Wash all parts except friction 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. 3. Lining worn down to 1 32 in. or less. 4. Oil impregnated linings which will sometimes accompany glazing. Glazed and oil soaked linings may sometimes be reconditioned by soaking in solvents of various types for several hours, blowing dry with compressed air and roughing with medium coarse sandpaper. This...

Fuel System

Throttle stop screw 17. Throttle lever 48. High idle cam Figure 3-46. Carburetor -1979 and Earlier Fuel from gas tank passes through inlet valve (21) into float chamber (29). The fuel entering causes float (23) to rise until it shuts off fuel valve, stopping flow at a level pre-de-termined by float level setting. Figure 3-48. Fuel Supply System Low Speed System (Figure 3-49) The low speed system functions at idle, low and intermediate speeds when the throttle valve...

Service Manual

Harley-Davidson motorcycles produced after January 1, 1978, conform to all applicable U.S.A. Federa Motor Vehicle Safety Standards and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture. To maintain the safety, dependability and emission control performance it is essential that the procedures, specifications and service instructions in this manual are followed. Any substitution, alteration or adjustment of emission system components outside of factory...

Foreword

This service and repair manual has been prepared with two purposes in mind. First, it will acquaint the reader with the construction of the Harley-Davidson product and assist him in performing basic maintenance and repair. Secondly, if will introduce to the professional Harley-Davidson mechanic the latest field-tested and factory-approved major repaii methods. We sincerely believe that this manual will make your association with Harley-Davidson products more plea sant and profitable. Your...

Section 1 Productpage No

Vehicle Tire Servicing a New Motorcycle 1-3 Regular Service Intervals 1-4 Electrical Harley-Davidson Oil 1-9 Chain Saver, Chain Spray 1-9 Brake Harley-Davidson Loctite Products 1-9 Lubrication Electrical System 1-13 Check List Front Rear Wheel Spoking Wheels -16 Inch 2-9 Spoking Wheels-19 Inch 2-10 Truing Spoked Wheel 2-11 Checking Cast Rim Runout 2-13 FL Front FX Front Straightening Fork Tubes 2-27 Rear Shock Absorber 2-29 Rear Rear Brake Pedal Adjustment 2-33 Disc Brake Rear Brake Master...

Section 3 Engine contd PageNo

Disassembling Clutch 4-3 Cleaning and Assembling Disassembling Starter Shaft and Solenoid 4-7 Assembling Starter Shaft and Solenoid 4-7 Disassembling Kick Starter 4-9 Cleaning, Inspection and Repair 4-9 Assembling Kick Starter 4-9 Disassembling Starter Clutch 4-9 Cleaning, Inspection and Repair 4-9 Assembling Starter Clutch 4-10 Adjusting Shifter Linkage 4-11 Replacing Main Drive Gear Oil Seal 4-11 Early 1979 and Earlier 4-13 Late 1979 and Later 4-16 Shifter Forks Transmission Case 4-19 1978...

Engine

CRANKING MOTOR DOES NOT OPERATE OR DOES NOT TURN ENGINE OVER 1. Engine run switch in Off position. 3. Discharged battery or loose or corroded connections (solenoid chatters). 4. Starter control circuit, relay or solenoid defective. 5. Electric starter shaft pinion gear not engaging. ENGINE TURNS OVER BUT DOES NOT START 3. Gasoline valve or filter clogged. 4. Discharged battery or loose or broken battery terminal connections. 6. Spark plug cables in bad condition and leaking or cable connections...

Lubrication System

Oil feed pump not functioning. 4. Restricted oil lines or fittings. ENGINE USES TOO MUCH OIL OR SMOKES EXCESSIVELY 1. Breather valve incorrectly timed. 2. Piston rings badly worn or broken. 3. Chain oiler adjusting screw adjusted for an excessive amount of oil. 4. Insufficient chain case vacuum. ENGINE LEAKS OIL FROM CASES, PUSH RODS, HOSES, ETC. 2. Imperfect seal at gaskets, push rod cover, washers, etc. 3. Restricted oil return line to tank. 4. Restricted...

Transmission

Transmission oil too heavy (winter operation). 4. Shifter forks (inside transmission) sprung. 5. Corners worn off shifter clutch dogs (inside transmission). 1. Shifter rod improperly adjusted. 2. Shifter forks (inside transmission) improperly adjusted. 3. Shifter engaging parts (inside transmission) badly worn and rounded.

Clutch

Clutch controls improperly adjusted. 2. Insufficient clutch spring tension. 3. Worn and or soaked friction discs. 1. Clutch controls improperly adjusted. 2. Clutch spring tension too tight. 4. Clutch shell keys or hub studs badly worn. 1. Clutch hub friction disc rivets loose. 2. Friction discs or steel discs worn or warped.

Brake

Brake line contains air bubbles. 3. Master or wheel cylinder piston worn or parts defective. 4. Brake pads impregnated with grease or oil. 5. Brake pads badly worn (1 16 minimum lining thick ness). 6. Brake disc badly worn or warped. 7. Brake fades due to heat build up - brake pads drag ging or excessive braking. 8. Brake drags-insufficient brake pedal or hand leve free play.

Checking Cast Rim Runout

The die-cast wheels should be checked for lateral and radial runout before installing a new tire or tube. 1. See Figure 2-18A. Install arbor in the wheel hub and place wheel in the truing stand. To check rim lateral runout, place a gauge rod or dial indicator near the rim bead. If lateral runout exceeds 3 64 in., replace the wheel. 2. See Figure 2-18B. Check for radial runout as shown here. Replace the wheel if runout exceeds 1 32 in. Figure 2-18B. Checking Cast Rim Radial Runout

Tires

Tires should be inspected for punctures, cuts, breaks and wear at least weekly if in daily use, or before trips if used occasionally. Whenever a tire is replaced, the tube should also be replaced. Inner tubes should be patched only as an emergency measure. Replace the damaged tube as soon as possible. Inner tubes must be used with all Harley-Davidson cast and laced wheels. Rim bands must be used on laced wheels. Some rear tires have arrows molded into the tire sidewalk These tires should be...

Handlebar Throttle Control

Control must operate freely and carburetor throttle must return to closed (Idle) position with friction adjusting screw (10, figure 2-22) backed off. If control becomes stiff and does not return properly, it should be disassembled, cleaned and inspected. DISASSEMBLING THROTTLE CONTROL (Figure 2-22) To disassemble and inspect throttle control assembly, remove the two screws (1) holding the upper throttle clamps (2) to the lower throttle clamp (3). Unhook ferrule (4) from ball on end of cable (5)...

Brakes

The front and rear brakes are fully hydraulic disc brakes and require little maintenance. Every 1250 miles, check master cylinders for proper fluid levels and check brake pads and discs for wear. If brake pads are worn to 1 16 in. or less they should be replaced. Minimum brake disc thickness is stamped on the side of the disc. When filling master cylinders, use only D.O.T. 5 Hydraulic Brake Fluid which is approved for use in hydraulic brake systems. When removing master cylinder filler plug or...

Specifications

Fit in guide (IN) 1979 and earlier 0018 - .0038 in. 1980 and later .0020-.0040 in. Spring (outer) 104-120 lbs. at 1-3 8 in. (closed) Free length 1-31 32 in. (inner) 26-32 lbs. at 1-3 16 in. (closed) Free length 1-23 64 in. Tappet adjustment Hydraulic tappet unit compressed 1 8 in. from fully extended position. Fit in bushing 0005 - .002 in loose End clearance 004 - .025 in. Fit in cylinder 001 - .002 in. loose Ring gap 010 - .020 in. Compression ring side...

Description

The engine is a two-cylinder, four-cycle, air cooled, overhead-valve, V-type engine. It has three major component assemblies cylinder, crankcase and gearcase. Cylinder assemblies include cylinder head, valves, rocker arms and piston. Cylinders mount on the engine crankcase in a 45 degree V, with both connecting rods connected to a single crank pin. The reciprocating, linear motion of the piston in the cylinder is converted to circular motion in the crankcase. The built-up crankshaft consists of...

Installing and Adjusting Push Rods

Before installing or adjusting push rods, remove and clean all hydraulic tappets. Make sure each tappet is clean and free from oil before installing it in the guide. See Valve Tappets and Guides. 2. See Figure 3-7. Remove the spark plugs and turn the engine until the front piston is at the top of its compression stroke. With front piston in this position the advance timing mark (1) will align with the timing inspection hole. Advance timing mark Retard position of piston top center mark on...

Adjusting Shifter Linkage

The foot shift linkage normally requires adjustment only to compensate for wear or when transmission has been moved. Only the shifter rod needs adjustment to maintain correct pedal position and prevent interference with crankcase. Remove cotter pin and clevis pin, securing the shifter rod to the shifter cover. Loosen the locknut and adjust the threaded ends on rod. Adjustment is important, as any interference will prevent full movement of foot lever and full engagement of shifting...

Ignition Coil

The ignition coil is a pulse type transformer that transforms or steps up low battery voltage to the high voltage necessary to jump the electrode at the spark plug in the cylinder head. Internally the coil consists of primary and secondary windings with a laminated iron core and sealed in waterproof insulating compound. The ignition coil cannot be taken apart or coil repaired. If the ignition coil is defective, it must be replaced. CAUTION On 1980 and later models, use only ignition coils...

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 should be approximately 250 to 500 miles per quart depending on the nature of service, solo or sidecar, fast or moderate driving, how well the engine is Kept tuneo, ana cnain oner adjustment. n mneaye is noi within this range, see following engine overhaul section. Remove...

Chassis

Spoke Screwing Harley

Wheels Handlebar Throttle Seat Tools Figure 2-1. Adjusting Front Chain Figure 2-2. Adjusting Rear Chain Chain adjustment must be checked at regular intervals of 1250 miles. As chains stretch and wear, they run tighter at one spot than another. Always adjust free movement at tightest spot in chain to allow specified play midway between sprockets. Do not adjust tighter. Running chains too tight will result in excessive wear. Inspect chains frequently for cracked, broken, or badly worn links. The...

Troubles

Spark plugs in bad condition or have improper gap or are partially fouled. 2. Spark plug cables in bad condition and leaking. 4. Loose wire connection at one of the battery terminals or at coil. 5. Carburetor controls not adjusted correctly. 7. Engine and transmission oil too heavy (winter operation). 8. Timing advance weight sticking in advanced position (1979 and earlier). 9. Ignition not timed properly. 10. Gasoline tank cap bent or plugged, or carburetor fuel line closed off restricting...

Starter

To separate gear (19), shifter collar (20), and spacer (21) from shaft (22). To remove starter shifter lever (25), it is necessary to either remove inner chain housing (See Stripping Motorcycle for Transmission Repair) or remove oil tank. Remove screw (24) and lever (25) from chain housing. Remove starter shaft housing (29) from chain housing studs as follows Remove starter motor and housing as an assembly by removing nuts and lockwashers (23) from chain housing studs. (See Starter Motor,...

Transmission Case

Remove transmission from chassis as described in Strip ping Motorcycle for Transmission Repair. Remove shifter cover. Slide shifter forks together so thai two gears engage, locking transmission. Remove kick starter clutch as described under Kick Starter. If main drive gear is to be removed from transmission, remove rear chain sprocket nut (left hand thread) and sprocket while transmission is locked. Remove shifter forks as described under Removing Shifter Forks. DISASSEMBLING COUNTERSHAFT...

Tools

Special pliers for removing and replacing retaining rings. Special pliers for removing and replacing retaining rings. Used to install press-fit connecting link sideplate supplied with replacement chains. 96219-50 Frame Head Bearing Adjusting Cone, and Lock Nut Wrench 95020-66 Rear Chain Connecting Link Press Tool Removes press fit roller pins from all chains. Removes press fit roller pins from all chains. Adjustable stand for truing spoked wheels. Includes arbor. 95515-30A Arbor for wheels....

Cylinder Head

Before removing cylinder head assembly, strip motorcycle as described in Stripping Motorcycle For Engine Repair. Disconnect overhead oil feed line (1) and cylinder interconnecting oil line (4) at fittings. Remove spring cap retainers (8) on push rod covers by prying down and out on cover spring cap with screwdriver. Crank engine until valves are closed. Remove five head bolts (5) from each head. Lift cylinder head enough to slip out push rods (6) and push rod covers (7). Mark push rods so that...

Prestolite Starter Motor

DISASSEMBLING AND ASSEMBLING (Figure 5-27 Remove thru bolts (1) with washers and lockwashers (2). Remove commutator end cover (3) holding brush plate (4) in place if necessary. End cover is marked with a double line next to the motor terminal. Also brush holder has a positioning notch which registers on the motor terminal insulator. See figure 5-28. Parts must be located correctly when reassembled. 1. Attaching stud nuts and 3. Starter shaft housing lockwashers (2) 4. Thru-bolt (2) Figure 5-28....

Disassembling And Assembling

REMOVING IGNITION TIMER COMPONENTS (Figure 5-21) Remove ignition timer cover screws (1), cover (2) and ignition module (3). Remove timer plate screws (4) and washers (5). Remove trigger rotor bolt (6) and pull trigger Figure 5-21. Ignition System Components 19781 to 1979 22. Ignition coil terminal (FL) 22A. Ignition coil terminal (FX) Figure 5-21. Ignition System Components 19781 to 1979 rotor (7) from advance assembly (8). Remove advance assembly from gearcase cover. To remove sensor (9) and...

Ignition Components Figure 523D

Assemble ignition module (13) to front frame mounting bracket. Make sure that the black ground wire is secured to the bracket. 2. Connect ignition module wires to ignition coil as shown in the wiring diagrams. 3. If seal (11) was removed, install new seal (11) in gear-case, lip side to ignition side of gearcase. Seal (11) must be pressed into gearcase until it stops. A seal that is not all the way in may leak. 4. Apply Loctite Lock 'N Seal, Part No. 99625-77 to rotor bolt (9). Install rotor...

Shifter Cover Drum Shifter Early 1979 And Earlier

Remove transmission from chassis as described in Stripping Motorcycle for Transmission Repair. Remove the 12 screws securing shifter cover to transmission case. Shifter cover is registered on two dowel pins. Two of the screws are extra long. Notice that the screw in hole nearest the dowel pin on right side of transmission is vented to relieve gear box heat expansion pressure. This screw must be installed in the same hole when assembling shifter cover or transmission oil may be forced into...

Oil Pump

Image Tappet Screen 1998 Fxdwg

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 relief valve that re-routes surplus oil above the amount needed to lubricate the engine directly to the oil tank. A check valve ball is located ahead of the pressure regulating valve to prevent oil drainage from tank, and to operate the pressure switch. Under normal operating conditions, the pump is a...

Checking Push Rod Adjustment

Push rod adjustment may be checked using the Push Rod Adjustment Gauge, Part No. 94438-79. 1. With the appropriate piston at the top of the compression stroke see INSTALLING AND ADJUSTING PUSH RODS , raise the push rod cover to expose the hydraulic lifter. 2. See Figure 3-7B. Place the gauge on the lifter as shown. The top of the lifter should be even with the top of the gauge. 3. If gauge and lifter do not line up, follow the procedure for INSTALLING AND ADJUSTING PUSH RODS. Figure 3-7B....

Replacing Main Drive Gear Oil Seal

Main Drive Gear Oil Seal Tool, Part No. 95660-42, Figure 4-8 enables removing worn or damaged oil seal and installing new seal without removing or disassembling transmission. It may be used on transmission removed from chassis as well. To use, transmission must be assembled with the exception of clutch and transmisison sprocket. Shift transmission into low gear and lock rear wheel to prevent parts from turning while disassembling. Remove inner primary cover, compensating sprocket, front chain,...

Headlamp

The headlamp is a sealed beam type, specially designed and made for Harley-Davidson motorcycles. When replacement is required, use only the prescribed sealed beam unit. Do not attempt to use an automobile sealed beam unit because the current requirements for a motorcycle are much less and damage to battery or alternator may result. If either filament burns out, or the lens breaks, the entire unit must be replaced. 1. Loosen door screw enough to remove headlamp door. Remove three retaining ring...

Kick Starter

Exploded View Harley Speed Clutch

DISASSEMBLING KICK STARTER Figure 4-7 Remove kick starter assembly from gear box as follows Place oil drain pan under transmission. Remove starter cover nuts 1 and plain washers 2 . Loosen clutch adjusting screw 2, Figure 4-4 . If transmission is in chassis, remove clutch lever rod from left end of clutch release lever. Remove exhaust pipe and other components mounted on transmission cover studs. Cover assembly with clutch release lever assembly is then free to be pulled off mounting studs....

Torque Requirements

GENERAL FASTENER TIGHTENING SPECIFICATIONS Torque specifications for specific components are listed below. For all other fasteners, use the values listed in the table below. Torque figures are in ft-lbs except those marked with an asterisk which are in in-lbs. Use SAE 2, 5 and 8 values when grade is known, with nut of sufficient strength. SPECIFIC FASTENER TIGHTENING SPECIFICATIONS The following is a list of torque specifications for specific components. The values given are in ft-lbs unless...

Repair And Diagnostic Procedure

1978 Shovelhead Primary Starter Bushing

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 9. After...

Prestolite And Hitachi Starter Motors

Due to the internal wiring and connections of the Prestolite frame and field assembly, there is no satisfactory field test to determine grounded or shorted field coils. If field coils are required on either Prestolite or Hitachi motors it is necessary, due to the method of installing field coils in this assembly, to replace the frame and field assembly. To tesl for field coils, using a test lamp, place one probe of test light against the frame. Place the other probe against each of the brushes...

Disc Brake Calipers

All late 1980 FL and FX motorcycles above VIN 26625-JO have quad 4-sided seal calipers installed on both the front and rear brake systems of the FL and the rear brake system of the FX models. Instead of the spring retractor system, used on 1978 to early 1980 models, the caliper features a square cross section seal. To identify front and rear and make the square seal calipers distinguishable from the old style spring retractor units, the front caliper assembly is marked with an additional letter...

Table Of Contents

Wiring Motorbike Colour Codes Diagram

General Lamps Charging Ignition System 1979 and Ignition System 1980 and Ignition Spark Starter Tools Spark timing 35 BTC fully advanced 1979 and earlier 0.004 to 0.006 in. 1980 and later not applicable 14 mm Gap 0.038 to 0.043 in. 1979 and earlier Harley-Davidson No. 5A6A Standard Harley-Davidson No. 5R6A Resistor type 1980 and later Harley-Davidson No. 5R6A Note Harley-Davidson No. 5A6 plug may be used in place of a No. 5A6A plug and a 5R6 plug can be used in place of a 5R6A plug if regapped...

Cylinder And Piston

DISASSEMBLING CYLINDER AND PISTON Figure 3-8 Strip motorcycle as described in Stripping Motorcycle for Engine Repair. Remove cylinder head as described in Disassembling Cylinder Head. Remove all cylinder base stud nuts and spacers 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 crankcase opening. This will prevent dirt or pieces of broken ring from falling into crank-case. With piston at...

Carburetor

Location Baffles Plate Carburetor

The Keihin carburetor is a horizontal, gravity fed type with a float operated inlet valve, an accelerating pump, a throttle stop screw for low idle speed adjustment, and choke system with a high idle speed adjustment. The high idle speed cam operates in conjunction with the choke to progressively raise the idle speed as the choke disc closes. CAUTION This carburetor has been designed to control exhaust emissions. Any carburetor modifications or adjustments other than specified in this section...

Disassembling Crankcase

Flywheel Truing Stands

Remove cylinder heads as described in Disassembling Cylinder Head. 2. Remove cylinders as described in Disassembling Cylinder and Piston. 3. Remove gearcase parts as described in Disassembling Gearcase. Check flywheel end play as described previously. Refer to figure 3-30 and proceed as follows 4. Remove crankcase bolts and studs 1, 2, 3, 4, 5 , It is necessary to remove only one stud nut and slip stud and other nut out opposite side of crankcase. Refer to figure 3-31 and continue...

Rectifierregulator

The rectifier-regulator, manufactured by Tympanium, is a series regulator with a shunt control. The circuit combines the functions of rectifying and regulating. Figure 5-11 shows the schematic diagram. The circuit essentially is a full wave bridge made up of two SCR's Silicon Controlled Rectifier and two diodes SCR1, SCR2, D1 and D2. Each SCR has a control gate which turns it on or off makes it conduct or not conduct . When the alternator voltage is too high, both SCR's turn off, the current...

Harley Davidson Shovelhead Connecting Rod Bushing Reamer

Motorcycle Mechanics Institute

Late Style Compression Ring Figure 3-11A. Late Style Compression Ring Ring gap space between ends must also be as specified, see Specifications, Section 3. To check 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 squarefy against piston and check gap with thickness gauge see figure 3-12 , Use onfy standard size rings and piston in standard bore, and oniy matching oversize rings and piston in the same...