Section 1 Productpage No

Specifications

Dimensions 1-1

Capacities 1-1

Engine 1*1

Vehicle Identification 1-1

Transmission 1-2

Tire Data 1-2

Service

Servicing a New Motorcycle 1-3

Regular Service Intervals 1-4

Torque Requirements

Wheels 1-7

Brakes 1"7

Forks 1-7

Handlebar 1-7

Engine 1-7

Transmission 1-8

Electrical 1-8

Fluid Requirements

Harley-Davidson Oil 1-9

Harley-Davidson Chain Grease,

Chain Saver, Chain Spray 1-9

Gasoline 1-9

Brake Fluid 1-9

Harley-Davidson/Loctite Products 1-9

Locating Troubles

Engine 1-11

Lubrication System 1-12

Electrical System 1-13

Carburetor 1-13

Transmission 1-13

Clutch 1-13

Brake 1-14

SECTION 2 - CHASSIS Drive

Chains 2-1

Wheels

General 2-5

Check List 2-5

Front Wheel 2-5

Rear Wheel 2-6

Wheel Hubs 2-6

Spoking Wheels -16 Inch 2-9

Spoking Wheels-19 Inch 2-10

Truing Spoked Wheel 2-11

Checking Cast Rim Runout 2-13

Tires 2-14

Handlebar Throttle Control

General 2-15

Frame

General 2-17

Forks Page NO.

General 2-19

FL Front Fork 2-23

FX Front Fork 2-24

Straightening Fork Tubes 2-27

Rear Shock Absorber 2-29

Rear Fork 2-30

Brakes

General 2-33

Rear Brake Pedal Adjustment 2-33

Disc Brake Calipers 2-34

Rear Brake Master Cylinder 2-38

Seat

Solo Saddle 2-39

Comfort Flex Seat 2-40

TOOlS 2-43

SECTION 3 ■ ENGINE

General

Specifications 3-1

Description 3-1

Lubrication 3-2

Repair and Diagnostic Procedure 3-4

Cylinder Head

Removing 3-7

Disassembling 3-7

Cleaning and Inspection 3-7

Repairing Rocker Arms and Bushings 3-7

Replacing Valve Guides 3-9

Reconditioning or Replacing Vavle Seats 3-9

Grinding Valve Faces and Seats 3-9

Lapping Valve Faces and Seats 3-10

Installing and Adjusting Push Rods 3-11

Checking Push Rod Adjustment 3-11

Cylinder and Piston

Disassembling Cylinder and Piston 3-13

Cleaning and Inspecting 3-13

Refinishing Cylinders 3-13

Fitting Piston Rings 3-14

Piston Pin Bushing 3-16

Assembling Cylinderand Piston 3-17

Gearcase

Oil Pump 3-19

Valve Tappets and Guides 3-21

Gearcase Cover and Timing Gears 3-22

Crankcase

General 3-27

Disassembling Crankcase 3-27

Flywheels 3-28

Assembling Crankcase 3-34

Fuel System

Carburetor 3-37

Air Cleaner 3-43

Fuel Tank 3-45

Fuel Supply Valve 3-45

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