Disassembling Side Valve Engine

(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. Disconnect spark control wire at circuit breaker and free spark control wire housing from front cylinder base stud.

10. Free front exhaust pipe clamp and work pipe as far out of cylinder as possible. If motorcycle is used with sidecar, or package truck, lower front connection socket tie rod must be removed to free front exhaust pipe.

11. Remove cylinder heads: Use Harley-Davidson special wrench. Part No. 12047-30H.

12. Remove manifold and carburetor: If motorcycle is equipped with oil bath air cleaner, disconnect air intake hose connection fitting from carburetor and leave attached to hose. Loosen hose at air cleaner and remove hose with fitting. Remove nut securing carburetor support bracket to crank-case top center bolt. Unscrew manifold nuts, using Harley-Davidson special wrench. Part No. 12002-30, and remove manifold with carburetor attached.

13. Clean crankcase around cylinder bases and valve covers to prevent dirt from falling into crankcase when lifting cylinders.

14. Raise valve covers: Lift cover spring ring with Harley-Davidson special tool. Part No. 11959-39 and latch ring in slots in upper spring cover. Keeper can then be removed and lower cover telescoped into upper cover.

15. Remove cylinders: Turn engine until both valves are closed in front cylinder. Remove all cylinder base stud nuts, except one on rear cylinder, using Harley-Davidson special wrench. Part No. 12050-30. Raise front cylinder and piston just high enough to place rag over crankcase opening; this is to prevent dirt and possibly pieces of broken rings from falling into crankcase. With piston at bottom of stroke, lift front cylinder free.

After making sure valves are closed, remove remaining stud nut and washer from rear cylinder and remove rear cylinder in same manner as front. See "Checking Connecting Rod Lower Bearing for Excessive Wear and Looseness;" "Piston and Pin," Page 88; "Emergency Piston and Ring Service," Page 87; "Installing and Fitting Connecting Rod Upper Bushing," Page 90.

16. Strip cylinders: Compress valve springs, using Harley-Davidson special valve spring compressor, Part No. 12053-30, and remove valve keys from ends of valve stems. Valve collars, springs, spacers, valve covers and valves can then be removed (see Illus. 29). It is customary to reassemble valves in same cylinder from which they were removed; therefore, before removing, mark them in some manner to identify them with front and rear cylinder.

Check valve guides and valve stems for wear. See "Valve Guides (Side Valve Engine)," Page 46, and "Valves," Page 46.

DIY Battery Repair

DIY Battery Repair

You can now recondition your old batteries at home and bring them back to 100 percent of their working condition. This guide will enable you to revive All NiCd batteries regardless of brand and battery volt. It will give you the required information on how to re-energize and revive your NiCd batteries through the RVD process, charging method and charging guidelines.

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