Engine Lubrication

A too low oil tank level or a plugged or damaged lubricating system will quickly lead to engine damage. The engine oil tank should be checked weekly and the tank refilled, as described in Chapter Three. Oil pump service is covered in Chapter Four. The oil light should come on when the ignition switch is turned to ON before starting the engine. After the engine is started, the oil light should go off when the engine is above idle. If the oil light does not come on when the ignition is turned to...

Piston And Cylinder

Piston rings (2 compression) 5. Oil control piston ring and expander spring pound left on the valves or the cylinder head will end up in the engine and will cause damage. 7. After the lapping has been completed and the valve assemblies have been reinstalled into the head the valve seal should be tested. Check the seal of each valve by pouring solvent into each of the intake and exhaust ports. There should be no leakage past the seat. If leakage occurs,...

Spiral Throttle Grip

Remove worn or broken control wire by sliding it through the control adjuster locknut. To replace the control wire on early 1978 and earlier models, unsolder or cut off the control wire ferrule (16, Figure 41) before removing the wire. 4. Lubricate replacement wire with graphite grease and slide it into the control wire casing. 5. If necessary, solder ferrule onto new wire flush with wire end. 6. Attach the control wire onto the throttle grip and assemble the throttle assembly. 7. Adjust the...

Battery

CAUTION If it becomes necessary to remove the battery breather tube when performing any of the following procedures, make sure to route the tube correctly during installation to prevent acid from spilling on parts. The battery is the heart of the electrical system. It should be checked and serviced as indicated. Most electrical system troubles can be attributed to neglect of this vital component. In order to service the electrolyte level correctly, it is necessary to remove the battery from the...

Electrical System

This chapter covers the following systems Refer to Chapter Three for routine ignition system maintenance. Electrical system specifications are found in Table 1 (1966-early 1978) or Table 2 (late 1978-1984). Tables 1-6 are at the end of the chapter. The charging system consists of the battery, generator and a voltage regulator. Two styles of generators were used on 1966-1969 models. These were the standard (Figure 1) and fan-cooled (Figure 2) generators. The standard generator is a two-pole...

Note

On 1972 and earlier models with drum brake, make sure to order parts 41773-58 (valve and seat) and install them in the order shown in 19(G, H), Figure 32 or 12(G, H), Figure 33. 12. Install the stop wire in the end of the master cylinder housing. Make sure the wire seats in the groove. 13. Install the rubber boot and plunger. 15. Bleed the rear brake as described in this chapter. 16. Adjust the rear brake as described in Chapter Three. Overhaul (Late 1979-on FLand Late 1979-on FX Except...

How Much Oil Should Come Out Of A Harley Primary Automatic Oiler

Oiler Light Diagram

Place a shop cloth at the end of the cable(s) to catch all excess lubricant that will flow out. 4. Remove the lubricator, reconnect and adjust the cable(s) as described in this chapter. 1. Disconnect the cables as previously described. 2. Make a cone of stiff paper and tape it to the end of the cable sheath (Figure 24). 3. Hold the cable upright and pour a small amount of light machine oil into the cone. Work the cable in and out of the sheath for several minutes to help the oil work its way...

Fuel Valve

Check for obvious problems even before getting out your tools. Go down the following list step by step. Do each one you may be embarrassed to find the kill switch off, but that is better than wearing down the battery. If the bike still will not start, refer to the appropriate troubleshooting procedures which follow in this chapter. 1. Is there fuel in the tank Open the filler cap and rock the bike. Listen for fuel sloshing around. WARNING Do not use an open flame to check in the tank. A serious...

Engine Performance

In the following checklist, it is assumed that the engine runs, but is not operating at peak performance. This will serve as a starting point from which to isolate a performance malfunction. The possible causes for each malfunction are listed in a logical sequence and in order of probability. a. Carburetor incorrectly adjusted. b. Fouled or improperly gapped spark plug(s). d. Obstructed fuel line or fuel shutoff valve. f. Ignition timing incorrect due to defective igni g. Pushrod clearance...

Late Style

With a screwdriver, carefully remove the switch terminal from the housing, 3. Remove the spring, contact plate and button from the housing. 4. To replace the switch terminal, perform the following a. Cut the terminal wires at the terminal. b. Using wire strippers, strip the 2 switch wires as required for resoldering. c. Solder the 2 switch wires to the new switch terminal with rosin core solder. 5. Installation is the reverse of these steps. 1. Remove the switch housing screws and separate the...

Clutch Troubleshooting

The starter connections at the battery, solenoid and at the starter switch. 3. Headlight comes on, but goes out when the starter button is pushed There may be a bad connection at the battery. Wiggle the battery terminals and re-check. If the starter starts cranking, you've found the problem. Remove and clean the battery terminal clamps. Clean the battery posts also. Reinstall the terminal clamps and tighten securely. 4. Headlight comes on, but dims slightly when the starter button is pushed The...

Engine Noises

Often the first evidence of an internal engine problem is a strange noise. That knocking, clicking or tapping sound which you never heard before may be warning you of impending trouble. While engine noises can indicate problems, they are difficult to interpret correctly inexperienced mechanics can be seriously misled by them. Professional mechanics often use a special stethoscope (which looks like a doctor's stethoscope) for isolating engine noises. You can do nearly as well with a sounding...

Hand Clutch Booster Adjustment

Control coil adjusting sleeve locknut 4. Bellcrank adjusting screw locknut 6. Clutch control booster spring 8. Clutch control booster bellcrank 12. Clutch booster spring tension adjuster 13. Clutch booster spring tension upper adjuster nut 14. Clutch booster spring tension lower adjuster nut 16. Gear shifter foot lever and rubber pedal 19. Foot lever positioning mark 18. Tighten the control coil adjusting sleeve locknut (2, Figure 57). 19. Pull the clutch hand...

Bleeding The System

WARNING Harley-Davidson specifies DOT 3 brake fluid for models produced prior to September, 1976 and DOT 5 for later models. Mixing the two types of brake fluids can cause brake failure. If you own a 1976 or 1977 model take your frame number to a Harley-Davidson dealer to find out your bike's production date. This procedure is necessary only when the brakes feel spongy, there is a leak in the hydraulic system, a component has been replaced or the brake fluid is being replaced. 1. Flip off the...

Engine Starting

An engine that refuses to start or is difficult to start is very frustrating. More often than not, the problem is very minor and can be found with a simple and logical troubleshooting approach. The following items will help isolate engine starting problems. Perform the following spark test to determine if the ignition system is operating properly. 1. Remove one of the spark plugs. 2. Connect the spark plug wire and connector to the spark plug and touch the spark plug base to a good ground like...

Front Brake Adjustment

Support bike so that front wheel clears ground. 2. Loosen the adjusting sleeve locknut (3, Figure 43). 3. Turn the adjusting sleeve nut (4) clockwise toward the cable support to tighten brake or turn sleeve nut (4) counterclockwise to loosen brake. Hand lever should move approximately 1 4 of its total travel before brake starts to operate. 4. Tighten the adjusting sleeve locknut (3). Recheck the adjustment. 5. Spin the wheel to make sure the brake does not drag....

Throttle Cable Replacement

Disconnect the throttle cable at the handlebar as described in Chapter Eight under Handlebar Removal Installation. 3. Remove any throttle cable holding bolt or bracket. 4. At the carburetor, hold the lever up with one hand and disengage the cable end (Figure 17). Slip the cable out through the carburetor bracket. Figure 17 shows the throttle cables for 1981 and later models. 1980 and earlier models are equipped with one throttle cable.

Servicing Engine In Frame

Many components can be serviced while the engine is mounted in the frame a. Rocker arm cover. j. Generator or alternator and electrical systems. 1. Thoroughly clean the engine exterior of dirt, oil and foreign material, using one of the cleaners designed for the purpose.

Breakerless Ignition Troubleshooting

The following basic tests are designed to pinpoint and isolate problems quickly in the primary circuit of the breakerless inductive discharge ignition system. The procedure requires a voltmeter, non-magnetic feeler gauge (late 1978-1979) and an ignition test adapter (1980-on). Perform the following test to determine if the ignition system is operating properly. 1. Remove one of the spark plugs. 2. Connect the spark plug wire and connector to the spark plug and touch the spark plug base to a...

Clutch Push Rod For A 1977 Shovelhead

How Set Motorcycle Clutch Cable

Spring tension adjusting nuts 1. Disengage the clutch by pushing the foot pedal (1, Figure 50) all the way down (heel down). Check that the clutch lever (8) just touches the transmission cover. 2. Loosen the clutch lever rod (3) locknuts and turn the lever rod adjuster so that the rod just clears the foot pedal bearing cover (2). The rod should not be bent down by the bearing cover. Tighten the locknut and recheck the clutch lever rod position. 3. Remove the...

Worn Chain Shovelhead

Motorcycle Chain Drive Figure

As drive chains stretch and wear in use, the chain will become tighter at one point. The chain must be checked and adjusted at this point. 1. Turn the rear wheel by pushing the bike and check the chain for its tightest point. Mark this spot and turn the wheel so that the mark is located on the chain's lower run, midway between the drive sprockets. Check and adjust the drive chain as follows. 2. Have a rider mounted on the seat. 3. Push the chain up midway between the sprockets on the lower...

Front Suspension And Steering

Poor handling may be caused by improper tire pressure, a damaged or bent frame or front steering components, worn wheel bearings or dragging brakes. Possible causes of suspension and steering malfunctions are listed below. b. Loose or worn steering head bearings. c. Excessive wheel hub bearing play. e. Spoke wheel out of alignment. i. Bent or damaged steering stem or frame (at steering neck). j. Tire incorrectly seated on rim. k. Excessive front end loading from non-standard equipment. a. Low...

How To Install The Seal On Oil Pump Drive Shaft 1977 Shovelhead

Bbc Oil Pump Drive Shaft Installation

CAUTION When performing the following steps, make sure the drive gear shaft is not pushed into the gearcase, as the Woodruff key on the end of the shaft could fall into the gearcase. 5. Remove the oil pump body mounting nuts (9) or bolts. Then slide the oil pump body off the drive gear shaft. 6. Remove the drive gear (12), Woodruff key (13) and the idler gear (14). 7. Remove the check valve spring cover screw (18), check valve spring (19) and the check valve ball (20). 8. Remove the bypass...

Shovelhead Removing Camshaft Oil Seal

The pinion gear shaft nut has left-hand threads. 9. Remove the pinion gear shaft nut (Figure 131) using the socket (HD-94555-55A), if necessary. Then remove the pinion gear (Figure 132) using the pinion gear puller (HD-96830-51A). 10. Remove the following parts in order b. Gear shaft pinion spacer (Figure 134). c. Oil pump pinion shaft gear (Figure 135). 11. If required, remove the oil pump drive gear and the oil pump as described in this chapter. 1. Thoroughly clean gearcase compartment, cover...

Shovelhead Primary Safety Wire

Label all hoses before removal so that they can be reinstalled in their original positions. 5. On primary chain models, disconnect the chain oiler hose at the oil pump. 6. Remove the primary case-to-engine case bolts (Figure 33). 7. Remove the primary case-to-transmission case mounting bolts (Figure 34). 8. Remove the bolt at the rear of the primary case. 9. Label any oil or vent hoses at the primary case. Then disconnect the hoses. 10. Lightly tap the primary case with a plastic mallet and...

Motorcycle Cam Sprocket Adapter Position

The shifter shaft and shifter gear must be timed correctly as described in Steps 1-4 or the transmission will not shift into all gears. 1. There is a timing cut (2 cuts on 1970 and later models) between the 2 center teeth on one side of the shifter gear. This mark must be aligned with the corner of the squared end of the shifter shaft which is just to the left of its last ratchet tooth. See Figure 100. 2. Position the shifter gear (28) and spring (29) into the shifter cover. Install the shifter...

Front Master Cylinder

Refer to Figure 29 for this procedure. 1. Attach a hose to the front caliper bleed valve (Figure 30). Then open the bleed valve with a wrench and drain the brake fluid by operating the hand lever. Discard the brake fluid. CAUTION Brake fluid will damage paint and chrome part. Wipe up any spilled fluid immediately, then wash the area with soap and water. 2. Loosen the front brake hose (5, Figure 29) at the front of the caliper. 3. Disconnect the brake light switch wires at the master cylinder....

Primary Belt Inspection

Belt wear or damage on one side only 5. The rubber dampers 22 and 23, Figure 29 should be lubricated every 10,000 miles with Harley-Davidson Poly-Oil. 6. Assemble the compensating sprocket in the order shown in Figure 29. Install the rubber dampers as shown in Figure 31. 7. Align the hole in the outer plate with the hole in the hub and install the set screw. 8. If any component was replaced, check the primary belt alignment as described in this chapter. PRIMARY CHAIN BELT CASE Removal...

Shovelhead Drive Key Rivets

The clutch hub nut to be removed in Step 18 uses left-hand threads. 18. Pry back the clutch hub lockwasher tab. Then remove the clutch hub nut A, Figure 16 and lock-washer. 19. Attach the clutch hub puller HD-95960-41A to the clutch hub Figure 17 . Then turn the puller's center bolt clockwise and remove the clutch hub B, Figure 16 . 20. Remove the clutch hub Woodruff key Figure 18 from groove in main shaft. 1 A. Primary chain models Clean all clutch parts in a non-oil based solvent and...

Front Fork 1966early 1977 Fl

Fork upper bracket bolt and valve 25. Slider upper and lower bushing c. Oil seal 23 . Remove the oil seal by carefully prying it out of the slider with a screwdriver or small pry bars. Make sure to work around the seal to prevent damaging the fork slider. 10. The slider is equipped with an upper and lower bushing. If the bushings require replacement, refer service to a Harley-Davidson dealer, as special tools are required. 11. Inspect the fork assembly as described in this chapter. 12....

Starter Crank Gear

Install the kickstarter gear lockwasher and nut. Tighten the nut to 50-60 ft.-lb. 69-82.8 N.m 1966-early 1978 or 30-40 ft.-lb. 41.4-55.2 N.m late 1978-on . Bend the lockwasher tab over the nut to lock it. Starter Clutch Removal Inspection Installation Refer to Figure 120 or Figure 121 for this procedure. 1. Remove the kickstarter side cover as described under Removal Installation in this chapter. 2. Remove the pushrod Figure 125 . 3. Lock the transmission into 2 gears at once. 4. Bend the...

Shock Absorbers

The rear shocks are spring controlled and hydrau-lically damped. Spring preload can be adjusted on all models. Refer to Chapter Three. Removal and installation of the rear shocks is easier if they are done separately. The remaining unit will support the rear of the bike and maintain the correct relationship between the top and bottom mounts. If both shock absorbers must be removed at the same time, cut a piece of flat metal a few inches longer than the shock absorber and drill two holes in the...

Disc Brakes

Disc brakes are actuated by hydraulic fluid from the master cylinder. The master cylinder is controlled by the hand or foot lever. As the brake pads wear, the brake fluid level drops in the master cylinder reservoir and automatically adjusts for pad wear. When working on a hydraulic brake system, it is necessary that the work area and all tools be absolutely clean. Any tiny particles of foreign matter or grit on the caliper assembly or the master cylinder can damage the components. Also, sharp...

Valves And Valve Components

General practice among those who do their own service is to remove the cylinder heads and take them to a Harley-Davidson dealer or machine shop for inspection and service. Since the cost is low relative to the required effort and equipment, this is the best approach, even for experienced mechanics. Refer to Figure 64 for this procedure. CAUTION All component parts of each valve assembly must be kept together. Do not mix with like components from other valves or excessive wear may result. 1....

Gearcase Cover And Timing Gears

Refer to Figure 122 for this procedure. 1. Remove the pushrods, tappet guide and tappets as described in this chapter. 2. Remove the oil screen cap 1, Figure 122 and gasket from the top of the gearcase. Then remove the spring. 3. Rotate the oil screen 4 until the notch in screen aligns with the housing key. Then remove the screen 4 and seals 1966 . 4. Remove the cover screws 6 . 5. Remove the generator as described in Chapter Seven. 6. Remove the circuit breaker as described in Chapter Seven....

Stroke Operating Principles

As the piston travels downward, the exhaust valve is closed and the intake valve opens, allowing the new air-fuel mixture from the carburetor to be drawn into the cylinder. When the piston reaches the bottom of its travel BDC , the intake valve closes and remains closed for the next 11 2 revolutions of the crankshaft. While the crankshaft continues to rotate, the piston moves upward, compressing the air-fuel mixture. As the piston almost reaches the top of its travel, the spark plug fires,...

Front Wheel Mounting Late 1978on Fx Models Except 1984 Fxefxwg

Remove the axle nut and lockwasher. 4. Loosen the fork slider cap nuts. 5. Push the axle out with a punch or drift. 6. Pull the wheel away from the fork sliders slightly and remove the speedometer drive gear from the wheel. 7. Remove the axle spacer if so equipped . Remove the wheel. CAUTION Do not set the wheel down on the disc surface, as it may be scratched or warped. Either lean the wheel against a wall or set it on 2 wood blocks Figure 3 . 8. Installation is the reverse of these steps....

Handlebar Switch Assembly 19721981

This may be caused by worn-through insulation or by a wire which has worked loose and shorted to ground. Occasionally, the electrical overload which causes the fuse to blow may occur in a switch or motor. By following the wiring diagrams at the end of the book, the circuits protected by each fuse can be determined. A blown fuse or tripped circuit breaker should be treated as more than a minor annoyance it should serve also as a warning that something is wrong in the electrical system....

Tappets And Tappet Guides

All models are factory equipped with roller tappets and hydraulic lifters. Hydraulic lifters consist of a piston, cylinder and check valve. During operation, hydraulic lifters pump full of engine oil, thus taking up all play in the valve train. When the engine is off, the hydraulic lifters will leak down as oil escapes from the hydraulic unit. When the engine is started, it is normal for the tappets to click until they refill with oil. If the tappets stop clicking after the engine is run for a...

Cylinder Head And Cylinder Assembly

Refer to Figure 6 for this procedure. 1. Remove the rocker arm cover nuts and washers Figure 6 . 2. Tap the rocker arm cover with a plastic mallet and remove it from the cylinder head. 3. Remove the rocker arm shaft screw and O-ring Figure 17 . On 1981 and later models, remove the spacer washer also. Discard the O-ring. 4. Turn the rocker arm cover over so that the rocker arm shaft and rocker arms are exposed. 5. Tap the rocker arm shaft Figure 18 out of the cover. 6. Lift the rocker arm Figure...

Fuses And Circuit Breakers

Each model uses either fuses or circuit breakers to protect the electrical circuit. Refer to the wiring diagram at the back of the book for your model for the type of protection used. Whenever a failure occurs in any part of the electrical system, check the fuse box to see if a fuse has blown. On models equipped with circuit breakers, each circuit breaker is self-resetting and will automatically return power to the circuit when the electrical fault is found and corrected. CAUTION If the...

Model Hd Carburetor

Turn or until the engine runs smoothly at idle speed with ignition fully advanced. 8. Adjust throttle stop screw 4 until engine idles at 900-1,100 rpm. 9. Repeat Step 7 and Step 8 as required. 10. Operate motorcycle at various speeds. Back out the high speed needle 1 and turn it in or out until best overall performance is obtained. This point should occur with needle set from 3 4 to 1 1 4 turns open. Bendix 16P12 Carburetor Adjustment Refer to Figure 91 for this procedure. 1. Attach a...

Ignition 1980 And Later

Start the engine and run it until it reaches normal operating temperature and the choke can be turned off. 6. Slowly turn the intermediate speed needle 2 in the direction in which the highest engine speed is produced without missing or surging. Then turn the intermediate speed needle 2 counterclockwise 1 8 turn from that point. 7. Turn the throttle stop screw until the engine idles at 900-1,100 rpm. 8. Alternately adjust the low speed needle 1 and the throttle...

Solenoid Late 1978on

Shovelhead Solenoid Diagram

Starter relay wire small terminal b. Attach the positive battery cable to the long solenoid stud. c. Attach the starter relay wire small diameter to the small solenoid stud. d. Place a lockwasher under each wire connector nut. 10. Reattach the negative battery cable when the solenoid is bolted tight and all solenoid wires are attached correctly. LIGHTING SYSTEM Headlight Replacement These models are equipped with a sealed beam unit. Refer to Figure 70,...

Headlight Assembly Fxwb

Disconnect the connector from the headlight and remove the headlight. 4. Install by reversing these removal steps. 5. Check and adjust the headlight beam as described in this chapter. These models use a sealed beam or quartz halogen bulb. Special handling of the quartz halogen bulb is required as described in this procedure. Refer to Figure 70 and Figure 73 for this procedure. 1. Remove the headlight door screw and remove the headlight door. 2. Remove the retaining ring screws and remove the...