Gear Shaft Bearing Washfr

PISTON PIN BUSHING Rcom or horte to fit pitlon pin .001 loose. SET OF CONNECTING RODS, with cronk pin and roller beorlng complete (Include hem 14, 21 and 221. Forked treorl rod Side pfay .006 la .010 between flywheel wotheri (Item 24). Forked (rear) rod it No. 285-36 ond single end (front rod is No. 286-36. CRANK PIN ROLLER BEARING COMPLETE Fil this beorlng .001 ta .0012 loose. Bearing consist of 4 No. 301-40 retainers. It No. 304-40 long rollers ond 36 No. 304-40 short tolleri. (See FOOTNOTE...

Removing Handlebar Grip Sleeve Assembly

(C) back with slight pressure against screw while starting screw in handlebar end. This squares screw with end of grip sleeve, aligning threads. Always tighten screw securely. After throttle and or spark controls are completely assembled, connect control wire at carburetor and or circuit breaker. Adjust throttle control so throttle closes and opens fully with throttle control grip movement. There should be about 1 to IV2 between end of throttle control wire housing and throttle lever when lever...

Illus 102

THREE WIRE CABLE (fourth wire attached) Green wire red wire two black wires. B. LOOM COVERED METALLIC SHIELDED CABLE (two wires) No standard color. C. TWO WIRE CABLE Green wire red wire. D. LOOM (four wires) Black wire with red tracer red wire with yellow tracer red wire with black tracer black wire. 1. SWITCH TERMINAL Cable A red wire, from junction terminal (15). 2. SWITCH TERMINAL Cable C red wire, from junction terminal (17) black wire from speedometer light switch. 3. SWITCH TERMINAL...

Illus

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 marked). (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...

Illus 107

Note With this method of wiring, when spotlamps are turned ON, headlamp is automatically turned OFF and vice-versa. C. THREE WIRE CABLE Green wire red wire black wire. D. LOOM (four wires) Black wire with red tracer red wire with yellow tracer red wire with black tracer black wire. E. THREE WIRE CABLE (clamped on outside of right handlebar) Green wire red wire black wire. 2. SWITCH TERMINAL Green wire from junction terminal (39). 3. SWITCH TERMINAL Black wire from mudguard lamp (36). 17....

Instrument Panel Signal Lights

1946 and Earlier Models Green light in left side of instrument panel indicates whether or not generator is charging. Red light in right side of instrument panel indicates whether or not oil is circulating. 1947 Models Red light marked GEN in center of instrument panel indicates whether or not generator is charging. Red light marked OIL in center of instrument panel indicates whether or not oil is circulating. All Models When switch is turned ON preparatory to starting engine, both lights should...

Retainer Seat Asbestos

Asbestos Seat

VVhen fitting a new Piston, measure Piston with micrometer at bottom of skirt, front to rear (across thrust faces). Measure Cylinder bore with inside micrometer. Piston should be .001 to .002 smaller than cylinder. If a fit within these limits cannot be attained with parts and facilities xit hand, it is preferable to allow more clearance rather than less. Note Inside 'and outside micrometers used for Cylinder* Piston fitting should first be checked together to be sure they are adjusted to read...

High Speed Tips

Develop the habit of frequently snapping throttle shut for an instant when running at high speed. This draws additional lubrication to pistons and cylinders and helps cooling. In cold weather run engine slowly until it is thoroughly warmed up, to avoid possible damage to piston rings, pistons and other parts before oil is warm enough to circulate freely. A motorcycle run long distances at high speed must be given closer than ordinary attention to avoid overheating and possible consequent...

B

Pressure Regulating Valve Chamber Cap Screw Pressure Regulating Valve Adjusting Screw Pressure Regulating Valve Spring Pressure Regulating Valve (same as Items 8 and 16) Oil Feed Pump Body Check Valve Chamber Cap Screw (same as Item 14) Check Valve Spring (same as Item 15) Check Valve Oil Feed Pump Mounting Stud Nut Lock Washer Oil Feed Pump Mounting Cap Screw Oil Feed Pump Mounting Stud Nut Oil Feed Pump Mounting Stud Nut Oil Feed Pump Vane (same as Item 20) Oil Feed Pump Gasket Oil Scavenger...

Illus 117 Left Side Of Transmission Stripped

Remove clutch control rod by loosening lock nut at pedal connection and turning rod out of connection. 2. Remove left footboard and studs only. 3. Remove outer front chain guard after removing screws and lock washers which secure it to inner chain guard. 4. Disconnect shifter rod from transmission lever after removing cotter pin and plain washer from end of rod. 5. Remove engine sprocket nut (right thread) using Harley-Davidson special wrench, Part No. 12645-26. It will be necessary to strike...

Engine Lubrication

Engine lubrication is a circulating system. A gear-type feed pump (OJH.V. Engine) or a vane-type feed pump (Side Valve Engine), draws oil from the tank and delivers it to crankshaft under pressure. Pressure can be regulated. A gear-type scavenger pump returns oil from engine base to tank. OJi.V. Engine Refer to schematic diagram of oil pump, Illus. 23, and engine oiling system, Illus. 22. Side Valve Engine, 1940 and Earlier Models Refer to schematic diagram of oil feed pump, Illus. 25, and...

Truing Rim Sideways And Centering Wheel

Remove wheel lay wi , on its side. (See Removing Front Wheel, Removing Rear Wheel and Removing Sidecar Wheel, Page 147. 2. Remove valve cap and valve core to free all air from tube. Remove valve stem nut (18 rim). 3. Loosen both beads from rim flanges by stepping on sides ot tire or by using a tire tool. Stand or kneel on tire opposite valve to push bead into rim-well. 4. Using tire tools (not sharp instruments) start upper bead over edge of rim at valve. Don't use force when starting bead over...

Ignitionlight Switch Disassembled

(To identiy Items, Refer to Illus. 101) See Item 24, under Illus. 102, 103 and 105 for information on switch operating positions. 1. After removing instrument panel cover, disconnecting wires and removing switch from panel, a faulty switch can be disassembled for inspection and repair as follows 2. All switch part positions mentioned below apply with switch upsidedown. Switch must be in OFF position and unlocked. 3. Grasp end of center pin (6) with pliers and pull and move sideways to release...

Xi

On a grinder, maintaining original pad curve. Worn and flattened ball studs must be replaced, otherwise satisfactory tappet and push rod adjustment cannot be made and upper end push rod trouble is likely to be experienced. Oil seals and oil seal retaining washers must be assembled on rocker arms before arms are installed in housings. 1940 and earlier Models One of the larger oil seals has no fabric on either side and is to be installed on rear exhaust rocker arm, either side of seal facing ball...

Visual Check Of Fork Side Relative Alignment

Sketch (Illus. 148) shows a satisfactory method of rough checking a frame that is not visibly badly damaged but there is doubt as to its possible alignment. This check will determine whether or not frame is far enough out of alignment to require either a major re-aligning job or replacement. Straightening a badly bent frame requires special tools and fixtures for holding, bending and gauging. The straight edge must be perfectly straight and can be either a 1 rod, or a rectangular bar 1 wide and...

Removing And Installing Oil Feed Pump With Engine Installed In Chassis

(To Identify Items, Refer to Illus. 57 Also Refer to Illus. 21) 1. Remove oil feed pipe and install nipple cap. Part No. 3583-15, on oil tank feed pipe nipple to prevent oil from running out, or drain tank. Disconnect oil feed pipe from oil pump nipple. 2. Oil pump is secured to engine gear case cover by one cap screw (11) and three nuts (9, 12 and 13). Two of the nuts are extra long to provide wrench clearance, and their location should be noted so they will be put back on same studs when...

Illus 109

These notes apply to carburetors which have been in service for some time and have become dirty, full of crust in the throttle barrel, and are found to be difficult to get adjusted properly. Usually the effect of excessive dirt or crust formation in the carburetor throttle barrel, around the throttle disc and in the fuel mixture passageways, is to cause the carburetor to have a lean spot off idle. This crust should be removed, particularly when a lean spot comes in at speeds off idle up to...

Replacing Front Brake Control Cable

Remove control cable lower clevis clamp nut and pull cable out of clevis. Next, remove cotter pin and flat washer from handlever hollow pin and pull pin out of lever. Control cable can now be pulled out of housing. Insert new control cable in housing (at handlever end). Make sure lower end of cable is inserted through adjusting sleeve. Apply grease or engine oil to new cable as it is being inserted. Handlever hollow pin must be reassembled before lower end of cable is connected. Narrow slot in...

Checking Adjustment Of Shifting Members

Checking Adjustment of Shifter Clutches and Sliding Gear (To Identify Items, Refer to Illus. 121,122 and 123) 7. Check adjustment of shifter clutches and sliding gear with Harley-Davidson special gauge. Part No. 12074-39 (see Illus. 127 and 128). Complete instructions for checking and adjusting shifter clutches and sliding gear are included with gauge. 4 Speed Transmission Shifter clutch (36) must be centered between gears (18) and (39), and shifter clutch (68) must be centered between gears...

Illus 87 Disassembling Generator

End cover and brushes have already been removed for previous checking and testing. 2. Disconnect field wires. Closely observe how field coil wires are arranged to keep them in the clear so they will not be damaged by armature. One is pulled between generator frame and frame end screw, and one is brought over the outside of aluminum frame end. Also, excess slack is avoided by winding wires together, where they cross at brush holders. The arrangement of wires shown in Illus. 88 applies to three...

Removing And Installing Forks

Spring fork only can be removed and replaced, or complete fork assembly (spring and rigid fork) can be removed and replaced as a unit. 1. Set motorcycle on rear stand. 2. Remove spring rod lock nuts (acorn-type). 3. Sit on front mudguard, or otherwise provide weight, to compress fork cushion (lower) springs. The spring rod larger nuts can then be easily removed, freeing upper recoil and upper bumper springs for removal. 4. Free lower end of horn assembly from horn bracket on mudguard. 5. If...

Pinion Gear

Ler. from .landord lo .001 over.ile in .lep. of .0002 . kiohi tltwnetl q1wsi eng dim FOOTNOTE NO. 1 Referring to Item 22 Diameter of .landord roller is 1B75 . Complete bearing, are avoiloble with FOOTNOTE NO 2_Referring to llem 6 ond 28 Diameter of standard railer i. .250 . Complete bearing, are avoiloble wilh rollers from .001 sindersite to .001 oversiie In .lep of .0002 . Installing Timing Gears O.H.V. Engine Before installing timing gears, install on pinion gear shaft in the following carder...

Reamer Assembled To Ream Rear Intake Cam Gear Shaft Bushing After Case Cover Is Installed On Crank Case

This large flange bushing must be pressed into gear case cover until outer face of bushing is just flush with machined surface of -case cover to provide correct seating and clearance for oil pump. Use a smooth surfaced disc or plate a little larger than flange when pressing bushing into case cover to insure flush fit. After new bushings have been pressed in they must be dowel pinned to prevent them from turning, by drilling a hole with a number 31 drill, 9 32...

Illus 112

Ings, use Harley-Davidson special tool set. Part No. 12012-44D. Complete instructions for renewing bushings are included with tool set. See Illus. 113, 114, 115 and 116. Throttle disc renewal is not usually necessary. If found worn or damaged to the extent of requiring renewal, be sure to install a new one with the same identification number stamped in face of disc. To identify disc see Carburetor Specifications, Page 125. With disc correctly installed and in closed position, number will be...

Illus 126 Removing Starter Clutch

Note Instructions fo - rer-oving starter clutch are included with Harley-Davidson starter clutch and mainshaft ball bearing puller. Part No. 12737-43. Removing Shifter Fork and Shaft Assembly To Identify Items, Refer to Illus. 123 7. Shifter fork shaft 98 , is held in position by a set screw 99 , head of which will be found in top cover joint face of transmission case at right end of shaft . With set screw removed, shaft can be driven out by means of a drift inserted in hole provided for that...

Summary Of Engine Specifications

Engine 61 3.3125 74 3.4375. Side Valve Engine 74 3.3125 80 3.422. PISTON CLEARANCE IN CYLINDER .001 to .002, measuring piston at bottom of skirt front to rear. Piston shapes to cylinder and acquires more clearance alter short time in service. Measure cylinder about W bom top of bore, front to rear. Warning This fitting clearance applies only to genuine Harley-Davidson taper-cam ground piston, which is smaller at top -of skirt underneath lower ring, than at bottom...

Starting Engine

When starting engine, gear shifter handlever must be in neutral and clutch fully engaged. Spark should be fully advanced or nearly so. Note Choke lever positions are as follows O.H.V. Engine Choke lever all the way down, choke is closed choke lever all the way up, choke is open. Side Vaive Engine Choke lever all the way up, choke is closed choke lever all the way down, choke is open. All Models Starting Cold Engine Set choke lever in fully-closed position, open throttle wide, and with ignition...

Removing Assembled Engine From Chassis For Complete Overhaul

When it is obvious that engine needs a complete overhaul, rather than possibly only an upper-end job, proceed as follows If motorcycle is used with sidecar or package truck, remove it. 1. Disconnect battery ground connection. 2. .Remove instrument panel cover 1946 and earlier Models require removal of speedometer lamp switch knob, front hexagon head screw, two side screws and cover side plate 1947 Models require removing cap screw and cover side plate. 3. Disconnect shifter lever bottom bolt....

Running In New Engine

Don't run new motorcycle faster than 35 miles per hour the first 250 miles 40 miles per hour the second 250 miles 45 miles per hour sidecar or 50 miles per hour solo the next 500 miles. Avoid running at or near top speed for long distances below 2000 miles. After a new motorcycle has been run 500 to 1000 miles it needs to be thoroughly checked over and any loose screws and nuts tightened. Particular attention must be given to those that secure engine and transmission also to wheel mounting...

Three Brush Generator

Remove steel and fibre washers from armature shaft 18, 19 and 20 . 9. Take generator out of vise and remove frame end screws 8 and 12 . If gasket is still on end of generator frame, it will have to be removed to uncover the heads of these screws. Before turning screws all the way out leave at least two threads engaged , tap them lightly to drive aluminum frame end 21 off frame 10 . 10. Remove armature 15 from frame by tapping drive end of shaft lightly with a soft hammer. 11. Drive end...

Servicing Handlebar Controls

To Identify Items, Refer to Iilus. 19 To lubricate control parts, or to replace a throttle or spark control wire, or a damaged control wire housing, proceed as follows Disconnect control wire at carburetor or circuit breaker. Insert a large heavy screw driver through hole in end of grip as shown in Illus. 18 and turn out end screw A by using a wrench on screwdriver. Sometimes this screw is difficult to remove. In this case, insert a punch in slot in screw and strike it two or three sharp blows...

Spark Plugs

After a new engine has gone through its run-ning-in period, colder than the original plugs may be needed, especially as concerns O.H.V. Models. The type of plug required depends on compression TStio and how hard engine is driven. This cannot be determined by compression ratio alone, as some high compression engines see very moderate service, and some low compression engines are driven very hard. 2. If, in an engine in average good condition as concerns valve seating, compression, timing,...

Oil Bath Type Cleaner

A few motorcycles are in service equipped with an oil bath type air cleaner. Clean and refill air cleanerapil gt cup at .leasUeach time engine oil tank frequently under dusty,conditions. ' Remove oil cup and gt baffle, thoroughly clean them and refill to indicated level with same grade of new oil as used in engine. Do not fill oil cup above indicated oil level as a higher level will restrict passage of air through cleaner and upset carburetion to the extent that engine may not start at all, or...

Fitting and Adjusting

All Holler Bearings .0006 to .001 .0008 preferred. Mainshatt in Main Drive Gear Bronze Bushing .002 to .003 loose .0025 preferred. Countershaft Gear Endplay .008 to .012 .010 preferred. Main Drive Gear and Sprocket Assembly Endplay .005 to .014 .010 preferred. See Item 12 under Transmission Assembly Main Drive Gear Group, Page 131. Shiiter Cam Endplay Free to .005. If when installing new shifter cam or new transmission cover, cam is tight endways, file boss in case. If cam has too much endplay,...

General Lubrication

Note If predominating service conditions are either wet or muddy, or very dusty, the 750 and 1500 mile greasing intervals should be reduced to 500 and 15 Every 5000 miles, or at least once a year, pack generator commutator end bearing with high melting point grease Harley-Davidson grade A grease . See Lubricating Commutator End Armature Bearing, Page 105. 16 Lubricate front wheel brake handlever and control cable every 750 miles or whenever operation of brake indicates lubrication is necessary....

Removing Generator End Mounting Screws

Disconnect wires from generator switch and relay terminals. 2. Remove the two long screws, through timing gear case cover, that secure end of generator against gear case see Illus. 81 . 3. Remove nut, lock washer and convex washer from end of strap that clamps generator in its cradle on crankcase see Illus. 82 . 4. Side Valve Engine Lift strap high enough to permit raising generator so oil centrifuge on end of generator gear or on armature shaft will clear adjacent gear and allow generator...

Servicing Saddle Spring Post

To Identify Items and Part Numbers, Refer to Illus. 20 Spring combinations with part numbers that make up saddle spring post assemblies, Part Nos., 3122-36, 3123-36, 3121-36, 3123-36A, 3125-36, are listed. New motorcycles are furnished with standard saddle spring post assembly unless other than standard is specified on order. The illustration shows following parts of saddle spring post assembly 1. Spring tension adjusting nut. After raising saddle, remove saddle post clamp nut 5 , which is...

Using Sprocket Shaft As Gauge To Determine Bearing

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 points around outer edge of washer. To remove washer, it...

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 plug core which becomes a conductor when damp or wet, allowing spark to jump from cable terminal to 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 And Reassembling Engine

First thoroughly wash all parts in gasoline or solvent and inspect them for wear and damage. Clean out oil passages in pinion shaft, right flywheel a amp d timing gear case cover, with a piece of wire, and compressed air. Clean dry shellac from crankcase center joint and register, with a scraper. Do this carefully to avoid any deep scratches that may allow oil leakage when cases are reassembled. Clean outside of cylinder and head with wire brush to remove dirt, rust, etc., getting in between...

Undercutting Commutator Mica

After undercutting is completed, again smooth commutator with No. 00 sandpaper. It is also advisable to repeat growler check for short as there is a possibility of developing a short during the turning and undercutting operations. If so, it can very likely be corrected by more thorough cleaning between segments and at ends of commutator. To Identify Items, Refer to IUus. 79 or 80 1. If one or both field coils have to be reassembled, do this first. Remember that field coils 13 and 17 are not...

Removing Lock Ring From Piston

In removing piston pin, first remove lock ring from end of pin that is slotted. Slot permits getting a screwdriver underneath lock ring and forcing it off. Use end of special tool specified below as a rest for screwdriver see Illus. 73 . Pin can then be driven out of piston. Use a drift of proper size to avoid damaging end of pin and piston boss and strike light hammer blows to avoid bending connecting rod. If piston pin is to be used again, examine lock ring on unslotted end of pin and if ring...

Installing Piston Pin Lock Ring

All pistons, including 61 O.H.V. pistons in the lower oversize steps, have two horizontal lots, one front and one rear, in bottom ring groove. 61 O.H.V. piston in the larger oversize steps is slotted horizontally and also has a vertical slot in one thrust face. Piston with only the horizontal slots may be installed with either thrust face to the front. Piston with vertical slot in one thrust face must be installed with that thrust face to the front. Pistons obtained from the factory, standard...

Truing And Sizing Connecting Rod Lower Race

Determining Correct Lower Bearing Fit See Checking Connecting Rod Lower Bearing for Excessive Wear and Looseness, Page 40, for information on checking lower bearing in connection with top overhaul and how much looseness may be allowed before bearing must be refitted. After lapping lower races of used rods as necessary, to smooth and true them, or replacing rods with a set with new lower races, install set of rollers and retainers on crank pin rollers must always be new. Check fit of rods on...

Inserting Spokes In Wheel

Front, Rear and Sidecar 5.00 x 15 Whc-ei and 4.00 x 18 Wheel Spoke holes in hub flanges are in two around flange ten inner row holes and ten outei row holes in each flange. All spokes must be inserted from inside of flange. 1. Place hub on bench with brake drum end of hub up. 2. Insert spokes in ten inner spoke holes of brake side flange. 3. Swing loose end of spokes counter-clockwise as far as hub will allow without turning hub. 4. Place rim over hub with tire valve hole 90 to 180 from hub...

Timing Ignition By Piston Position

Check point gap 3 with breaker lever fibre block on highest point of cam. Gap should be .022. Adjust by loosening the two lock screws 2 and shifting adjustable contact plate. Measure gap with accurate thickness gauge before and after tightening lock screws. Turn engine in direction in which it runs, until front piston is 7 16 O.H.V. Engine , or 11, 32 Side Valve Engine , before top dead center on compression stroke. With piston in this position, adjust circuit breaker so narrow cam the one with...

Straightening Bent Or Twisted Connecting

Kets between carburetor and manifold. Install lock washers and carburetor-manifold screws and tighten screws securely. If these screws are not tight, an air leak will result, causing carburetion to be erratic. Attach carburetor support bracket and tighten securely. Disassemble gasoline strainer clean thoroughly before installing. Installing Cylinders Side Valve Engine Lubricate cylinder walls, pistons, pins and rod upper bushings generously with engine oil. Also pour about V pint of oil onto...

Circuit Breaker Head Disassembled

Installing Circuit Breaker and Timing Ignition O.H.V. Engine Refer to Illus. 66 also see Timing Ignition By Piston Position, Page 86. Turn engine in direction in which it runs until tappets indicate front cylinder is on compression stroke directly after front intake valve closes . Continue turning engine slowly until flywheel timing mark is at rear edge of inspection hole in left crank-case. If front cylinder head is off circuit breaker completely assembled, can be installed. Be sure ground...

Regular Interval Inspection And Maintenance

After schedule of initial servicing of new motorcycle has been completed, this maintenance schedule is then to be followed at regular intervals not exceeding 1500 miles. 1. Check condition of oil in tank to determine if oil change is needed. 2. Lubricate all points indicated for 750 mile attention on Lubrication Chart. 3. Lubricate wheel hubs at 1500 mile intervals as indicated on Lubrication Chart. 4. Oil all control joints, namely, clutch, gear shifter, brakes, front brake control wire, and...

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 . Page 37. 2. Remove pistons. See Piston and Pin, Page 88. 3. Remove generator as outlined under Removing Generator, Page 97. 4. Remove circuit breaker assembly irom crank-case Free low tension wire from clip on crank-case if wire J3 shielded, disconnect metallic shielding from crankcase stud. Remove relay and relay bracket. Remove two cap screws...

Wheels Hubs And Tires

Wheels normally require little attention other than ample lubrication of hubs. See Lubrication Chart, Page 9. Occasionally, set motorcycle on rear stand, block up front end of motorcycle to raise front wheel, and check adjustment of hubs. Adjustment is all right when only a small amount of side shake can be found at rim of wheel. Also check spokes and tighten any found loose. Set motorcycle on rear stand then raise front end of motorcycle high enough to permit removing wheel support motorcycle...

Adjusting Valve Tappets

Engine To get the maximum power and best all-around performace from an engine, keep valve tappets properly adjusted. They must be adjusted after grinding valves, and should be inspected and, if necessary, adjusted about every 1000 to 1500 miles thereafter. The need of attention to tappet adjustment is indicated by excessive clicking and noise that develops with too much overhead rocker arm play, or in other words, too much clearance between valve rocker arms and...

Initial Servicing Of New Motorcycle

At the first 250 miles, check front chain to make sure it is receiving required amount of oil for ample lubrication. If necessary, readjust chain oiler. See Lubricating Drive Chains, Page 12. Note If motorcycle is equipped with rear chain oiler, instructions that apply to checking front chain lubrication, also apply to rear chain. 2. Check adjustment of chains. Readjust if needed. 1. Drain oil tank and refill with fresh oil. Thereafter, in average service change oil at intervals not...

Lubricating Drive Chains

Front chain is automatically lubricated by engine oil pump. Chain oiling is adjustable and occasional readjustment may be needed to meet lubrication requirements of varied operating conditions. As nearly everyone knows through experience, the good performance and life of a front chain depends entirely upon its ample lubrication. The quantity of oil required for ample lubrication is very slight. However, oiling must be constant. If oiling fails for a period of only a few hours or a few hundred...

Truing And Sizing Main Bearing Races

Securely tightened as in final assembly this is to assure perfect alignment between left and right races in assembly. Lap first one side and then the other, guiding lap by means of pilot bushing in opposite race. Adjust lap snugly in race and use only a light application of fine lapping compound. A loose lap and the use of excessive amount of compound results in tapered bearing surface. When fitting main bearings, the shafts that are to be used when flywheels are reassembled can be used as...

Testing Regulating Field Coil Standard And Radio Three Brush Generator

Harley Generator Test

Standard Generator from 1.4 to 1.9 amperes Radio Generator, 1.9 to 2.3 amperes. If ammeter shows no reading, field coil is open see that terminal connections are tight and field coil wires are not broken at terminals . If reading is appreciably higher than Standard Generator 1.9 amperes Radio Generator, 2.3 amperes, field coil is shorted internally. 4. With test point A still on relay terminal, ground other test point by moving it to generator frame as indicated by dotted line C. Ammeter should...

Removing And Installing Oil Pump With Engine Installed In Chassis

To Identify Items, Refer to Illus. 56 1. Remove stop lamp switch and oil pressure switch. Remove oil return pipe. Remove oil feed pipe and install nipple cap. Part No. 358315 on oil tank feed pipe nipple to prevent oil from running out, or drain tank. 2. 1940 Model pump is secured to crankcase by six nuts after removing the six nuts, remove pump cover and gasket 1941 and later Model pump is secured by one cap screw, one flat head screw and five nuts, one of the nuts is extra long to provide...

Illus 34 Measuring Piston

Standard piston or piston of the same oversize to which the cylinder was last refinished should be fitted to reduce clearance and effect reasonably quiet operation. See Emergency Piston and Ring Service, Page 87. If, in completely overhauling engine and putting it in like-new condition for a long period of further service, cylinders show more than .002 wear, they should be refinished to the next oversize step and fitted with new pistons. When refinishing cylinders oversize, first add to...

Legend For Illus 22 And 23ohv Engine Oiling And Breather System

Harley Davidson Knucklehead Diagram

Maximum oil pressure regulating valve. D. Governor rotor with centrifugal valve which controls oil pressure at low and intermediate speeds. E. Front chain oiler adjusting screw. F. Scavenge section of oil pump. G. Pinion gear shaft through which oil is forced to connecting rod lower bearings, from which it splashes to cylinder walls, pistons, main bearings, etc. H. Timed Rotary crankcase breather valve. Rotary breather valve is timed to open on downward stroke of pistons, allowing crankcase...

Adjusting Carburetor

To Identity Items, Refer to Illus. 108 Before attempting to correct faulty engine performance, attention should be given other items which have a direct bearing on, and can affect carburetor adjustment as well as engine performance. A. See that throttle and spark controls are correctly adjusted. B. Remove drain screw from bowl of carburetor. Drain and flush bowl to eliminate dirt and water. C. Drain and flush gasoline strainer. D. Check air cleaner to be sure passage of air through cleaner is...

Adjusting Drive Chains

Inspect the adjustment of chains at least every week and adjust them if necessary. Adjustment of front chain can be checked through inspection hole provided in chain guard. Chains must not be allowed to run loose enough to strike guards or other chassis parts, because when that loose, they cause motorcycle to jerk when running at low speed, and there is excessive wear of chains and sprockets. The rear chain requires more frequent adjustment than front chain. As chains stretch and wear in...

Installing New Connecting Rod Bushing

When installing new upper end bushings in rods disassembled from engine, an arbor press, if available, is usually used to press out old bushings and press in the new. When renewing bushings in connection with only a top overhaul, use Harley-Davidson special tools as shown in Illus. 78 bushing tool. Part No. 12057-X, and connecting rod clamping fixture. Part No. 12058-X. Be careful to start new bushings with oil slot in alignment with oil slot in rod. Ream new bushing to size, or preferably,...

Greasing Commutator End Armature Bearing

Lubricating Commutator End Armature Bearing To Identify Items, Refer to Illus. 79 or 80 Also Refer to Illus. 98 To lubricate bearing 42 it is necessary to first remove end cover 54 . Then bearing can be oiled through hole in outer grease retainer 52 or outer grease retainer can be shifted to expose bearing and permit greasing as follows Take out two of the three outer grease retainer screws 53 and loosen the third screw slightly to permit shifting outer grease retainer to one side. Pack bearing...

Disassembling Engine For Top Overhaul Only

If motorcycle is used with sidecar or package truck, remove it. First perform operations 1 to 8 inclusive, under Removing Assembled Engine From Chassis for Complete Overhaul, Page 41. 9. Remove oil pipe at rocker arm housings and gear case cover. 10. Remove manifold and carburetor If motorcycle is eguipped with oil bath air cleaner, disconnect air intake hose connection fitting from carburetor and leave attached to hose. Remove air cleaner bracket together with oil bath air cleaner and hose....

Removing Generator Strap

Testing Field Coils and Brush Holders Without Disassembling Generator CAUTION Overloading ammeter, due to short circuit or otherwise, will damage it. Overload is indicated by needle going beyond range of calibrated scale direct short is indicated by needle swinging violently to extreme limit of its travel. In either case, contact must be broken instantaneously to avoid damaging or burning out ammeter. Therefore, in making the following tests with ammeter, first make only a momentary contact to...

Adjusting Oil Feed Pump

Standard factory setting of maximum pressure adjusting screw is as follows 1940 OJi.V. Model To identify item 14 , refer to Illus. 56 . End of adjusting screw 14 3 e from outer end of valve chamber. Average maximum oil pressure at this setting is about 15 lbs. 1941 to 1947 OJH.V. Models To identify item 14 , refer to Illus. 56 . End of adjusting screw 14 from outer end of valve chamber. Average maximum oil pressure at this setting is about 30 lbs. 1940 and earlier Side Valve Models To identify...

Electrical System

Electrical system is a 6-volt, one wire ground return system with negative ground. Three-brush generator is regulated by the third or regulating brush and lamp load. Lamp load regulation is accom- Slished by connecting shunt field winding in the ghting circuit. When lamps are turned ON this field is energized and generator output is increased to carry load of lighting eguipment. Two-brush generator is regulated entirely by current and voltage regulator. Generator models are identified as...

Illus 140 Wheel Hub Assembly

Grease retainer 21 and pull out inner sleeve 16 . Rollers and retainers can then be taken out. It is necessary to remove spring lock ring 20 and washer 19 before brake side bearing can be removed. When trying for roller bearing clearance .001 to .0015 , bearings must be free from grease or oil. After correct size rollers have been selected, reassemble hub in reverse order of disassembly. When reassembling hub, apply a thin coating of Harley-Davidson grade A grease to rollers, races and thrust...

Illus 99 Cutout Relay

With one test point on GEN terminal, and other test point on relay armature, test lamp should light. If it does not, it indicates an open circuit in series current coil. If relay passes above tests, and generator is known to be OX, but points do not close, it is an indication that series coil is grounded, or voltage coil grounded prematurely. It is not practical to disassemble relay for repairs. A relay worn or damaged beyond adjustment service should be replaced. Cut-out relay must be grounded...

Illus 35 Reaming Valve Guides

Install new valve guides by inverting cylinder and pressing or driving guides into guide holes until shoulder on guide is tight against cylinder. New valve guides are reamed to correct size. However, when guides are pressed into cylinders they may close up slightly also the ends may be burred. Therefore, after new guides are in place, they should be sized and cleaned up with Harley-Davidson special reamer, Part No. 11894-30. See Illus. 35. It is of prime importance that valve guides fit tightly...

Checking Connecting Rod Alignment With Squaring Plate

If rod proves to be out of alignment, it can be straightened by means of a bar inserted through piston pin, as shown in Illus. 71. Use bar of largest diameter that can be inserted through pin. The manner in which piston seats on squaring plate indicates as follows 1. Piston high on same side, both crank pin positions rod is bent. 2. Piston high on opposite sides as crank pin position is changed rod is twisted. 3. Piston sguare or nearly square with crank pin in one position and high on one side...

Illus 138 Rear Wheel Removed

Raise wheel by blocking up underneath sidecar chassis. Loosen nut that secures front lower end of mudguard to sidecar step. Loosen nut several turns that secures mudguard inner brace clip to bracket. Remove nut that secures mudguard outer brace clip to axle extension nut, and hinge mudguard forward, making sure lamp wiring if sidecar is equipped with lamp has sufficient slack. Remove extension nut, washer and axle nut. Wheel can now be pulled off axle with brake drum attached. Detachment of...

Line Reaming Pinion Gear Shaft Bushing

Note Illustration shows installation of reamer guide in crankcase to guide reamer when reaming bronze pinion shaft bushing in gear case cover. Cover must of course, be installed on right crankcase before starting the reaming operation. While illustration shows reaming Side Valve Engine pinion gear shaft bushing, same procedure is to be followed when reaming O.H.V. Engine pinion gear shaft bushing. Valve Tappets and Valve Tappet Guides Note Remove tappet guides and tappet assemblies if only for...

Meavjring Thickness Of Flywheel Thrust Washer

When a set of collars has been selected ana installed on flywheels, install flywheel assembly into right crankcase. Install sprocket shaft roller bearing assembly and bearing washer m sprocket shaft in the order shown in Illus. 62 or 63, and install left crankcase. No gasket is used on crankcase center joint, and joint should not as yet be coated with gasket cement or sealer. Insert stud at top center of cases and two studs at bottom of cases. Install and tighten nuts, to clamp cases securely...

Illus 53 Truing Flywheel Mainshafts

Harley Davidson Knucklehead Engine

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 centers...