Figure 68Removing Generator Field Coils

If commutator is brush worn until it will require removal of inch of metal to true it, replace the armature assembly. Before testing the armature on a growler, make sure that the commutator is free from carbon and copper dust deposits. Clean thoroughly between segments and at ends of commutator, blow off with compressed air and proceed to test as follows (a) Test Armature and Commutator for Ground (fig. 69). The commutator and the armature coil windings must be insulated from the...

Chains And Sprockets

Fitting New Sprocket to Used Brake Drum. (1) When necessary to replace rear sprocket with a new sprocket due to worn teeth or badly elongated rivet holes, or both, chisel off heads of all rivets and punch out rivets. If the assembly is one with dowel pins, mark the dowel pin holes in drum before punching out dowel pins and rivets. Sprocket can then be removed and discarded. (2) Carefully inspect brake drum. If original holes are badly worn and elongated and outside diameter of drum...

Description Of System

The generating system consists of the 6-volt, shunt-wound, third-brush and lamp-load regulated generator, the storage battery and the relay. One of the two field coils (shunt coil) is controlled by the lighting circuit to increase the current output when either the running service light or the blackout light are turned on. The ignition-light switch cuts in the field shunt coil for the service light, and a magnetic field switch cuts in the field shunt coil for the blackout light. Maximum...

Fits And Tolerances

(1) Clutch gear standard, 0.125 inch x 0.615 inch. Available in 0.0004-inch and 0.0008-inch oversizes. (2) Mainshaft (sprocket end) Standard, 0.152 inch x g inch. Available to 0.001-inch oversize in steps of 0.0002 inch. (3) Countershaft gear (left end) Same as (2) above. (4) Countershaft gear (right end) Standard 0.114 inch x inch. Available in 0.0004 and 0.0008-inch oversizes. b. Bearing Clearances. All roller bearing clearances to be 0.0006 to 0.001 inch (0.0008 in. preferred). (1) Clutch...

Aline Connecting Rods

Alining Pistons and Connecting Rods. When refitting and reassembling connecting rods and finally fitting pistons, rods may possibly be bent or twisted, throwing upper bearing and lower bearing out of alinement with each other to some extent. Therefore, after pistons have been fitted, rods must be checked and realined if necessary. If a rod is bent or twisted, piston has a cocked relation to cylinder bore and the result is excessive noise and rapid wear. Connecting rod alincment is determined...

Paper Test Strips

Figure 20 Checking Connecting Rod Alinement with Squaring Plate (4I-P-I550-25) Figure 20 Checking Connecting Rod Alinement with Squaring Plate (4I-P-I550-25) (2) To facilitate installing piston pin, heat piston (but not pin) about as hot as it can be handled. (3) With piston pin in place and one lock ring 'already in its groove, install the remaining lock ring. CAUTION Always use a new piston pin lock ring. Use special tool (41-T-3260) to install ring, thus prevent overexpanding with consequent...

Wheel Hubs

(I) Install one of the thick thrust washers then the thrust hearing sleeve then the remaining thick thrust washer. (5) Install the thin adjusting shims. (6) Install paper gasket, thrust bearing housing, cork grease retainer, and bearing outer cover. Draw up the five cover screws tight. (7) Hub is now ready to chcck end play adjustment. b. Knd Play Adjustment (fig. 122). End play adjustment is made by adding or removing thin steel shim washers (0.002 in. thick) in the left end of the- hub. The...

Ra Pd 310368

Figure 48 Line-reaming Oil Pump Drive Shaft Bushing and Crankcase Rear Exhaust Cam Bushing with Reamer (4I-R-2303) c. Line-reani Bushings. Assemble gear case cover to crankcase to correctly line-ream all timing gear and gear shaft end bushings. NOTE Reamer (41 -R-2265) for cam gear shaft and timer drive shaft bushing is of two-piece construction and large reamer end must be installed before case cover is assembled to crankcase as follows (1) Reaming Rear Cylinder Inlet Cam Gear Shaft and Timer...

Removal And Disassembly

Remove Wheel and Disconnect Linkage. If brake is in vehicle, remove front wheel, following instructions in TM 9-879. Disconnect control wire clevis from brake operating lever to free side cover and shoe assembly from control linkage. b. Disassemble Side Cover. Remove shoes. Use a large screwdriver and spread pivot ends of shoes so that both shoes and springs can be pried off of stud and operating cam (fig. 111). Remove pivot stud and operating cam from side cover. Remove shackle arm. Re

Description And Engine Data

The vehicle is powered by a two-cylinder, V-type, L-head gasoline engine, operating on four-stroke, four-cycle principle. The bearings, pistons and rings, cylinder walls, bushings and gears are lubricated by a force-feed circulating oil system. Engine oil supply is maintained in a separate tank. Tolerances and fits are held to close standards, calling for precise and fine workmanship on the part of the mechanic. Engine type V-type. L-head Number of cylinders 2 Engine cooling Air...

General Performance

Test engine for all-around general performance, starting, acceleration, smoothness of operation, and excessive overheating. Observe for abnormal vibration which might indicate looseness of bolts and nuts or flywheels out of true. Go& erve for sluggishness which might be caused by lack of correct bearing tolerances. b. Vehicle Service. Engine unit must be in such mechanical condition after road test as to render dependable field service, the same as a new engin . ROAD TEST OF ENGINE,...

Inspection And Repair Of Valve Tappets And Valve Tappet Guides

Inspect valve tappets for excessive clearance in guides. Also inspect tappet rollers for excessive bearing looseness and damaged roller faces. Tappets have 0.0005 to 0.001-inch normal clearance in guides, and it is recommended practice to install new tappet and roller and or guide assembly when clearance exceeds 0.0025 inch. (1) Replacement of Tappet Roller. When tappet roller only is excessively loose on pin, or otherwise in bad condition, it is recommended that...

Relay Adjustment And Repair

The relay is provided with an additional contact for the normally open position to control the signal light in the instrument panel. When the generator voltage exceeds the battery voltage (between 6.3 and 6.8 volts) the relay closes the battery-generator circuit. At this time, the upper contact points break and the panel green indicator light goes off, indicating that the generator is charging the battery. This occurs at approximately 20 miles per hour in high gear. 1 ....

Output of Generator

Mount the generator on a conventional test stand so as to drive generator counterclockwise (looking at generator drive gear end). Connect positive lead from ammeter to the relay terminal. The other ammeter lead must be connected to a 6-volt storage battery positive post and the battery negative post grounded to the test stand (generator frame). This connects the generator to use the regulating field coil only, the same as operating the vehicle with the lights...

Gage Tool

(2) Install flywheel assembly in right side crankcase and install roller bearing and bearing washer on sprocket shaft and install left side crankcase. NOTE No gasket is used between crankcase center joint, nor should joint be shellacked as yet. Insert the two cap screws at top of crankcases and two studs at bottom of crankcases and tighten to clamp cases securely together. (3) With crankcase and flywheel assembly supported in vertical position, push back and forth on ends of sprocket and pinion...

Preliminary Instructions

When an engine needs repair, it is not always possible to definitely determine beforehand whether repair can be made with only upper end disassembled, 01 whether engine must be completely disassembled for lower end repair. Most commonly only upper end repair is needed (valves, rings, pistons, etc.) and it is recommended procedure to first disassemble upper end only, allowing engine base to remain in frame. After disassembling upper end only, be sure to inspect connecting rod...

Ra Pd 310336b

Legend for Figure 95 Transmission, Disassembled (10) Remove Mainshaft, Gears, Etc. Withdraw the mainshaft, with gears, spacers, shifter cams, etc., from the transmission case. The clutch gear will probably stay in position due to friction of the oil seal. Remove the clutch gear, thrust race, thrust ball bearing and the needle rollers. Keep needle rollers in a container and identify location. Remove the lock ring, push rod guide, seal, washer, spring, b removing sprocket from mainshaft taper...

Info

Bushing hole, 0.375 inch. (1) Clearance on fork shifter shaft, 0.0005 to 0.001 inch. n. Gear End Play. Low and second gear end play between the second gear retaining bracket and case side cover 0.005 to 0.007 inch. (1) Diameter End that runs in clutch gear, 0.748 inch. Diameter at low and second gear positions, 0.9365 inch. Diameter at roller bearing end, 0.874 inch. (2) End Play 0.003 to 0.005 inch. (3) Clearance in clutch gear bushing 0.002 inch. (1) Shifter cam...

Circuit Breaker Timer Disassembly

Circuit breaker can be disassembled for replacement of timer base, timer shaft, and spiral gear (fig. 63). The circuit breaker timer head mounts the circuit breaker lever, adjustable contact point, and condenser which are readily accessible (on or off the vehicle) for adjustment and or replacement when timer cover is removed. Timer base bushings are not replacable. (1) Remove Timer Shaft. Remove the pin from spiral gear hub and drift or press the timer shaft out of gear. Withdraw timer shaft...

Standard Nomenclature Lists

Motorcycle, chain drive (Harley-Davidson) SNL G-523 Cleaning, preserving and lubricating materials, recoil fluids, special oils, and miscellaneous related items SNL K-l Soldering, brazing, and welding materials, gases, and related items SNL K-2 Tools, maintenance, for the repair of automotive vehicles SNL G-27 Tool sets motor transport SNL N-19 Tool sets for ordnance service command, automotive shops SNL N 30 Current Standard Nomenclature Lists are listed above.

And Assembly

Use spring lifter (41-L-1409) to compress valve springs and remove split keys from ends of the valve stems (fig. 7). Valve spring collars, valve springs, valve covers and valves can then be removed. Mark valves so they can be installed in the same cylinders from which they were removed. 8. CLEANING AND INSPECTION OE CYLINDERS AND RELATED PARTS. (1) Clean outside of cylinder and head writh wire brush to remove dirt and rust, getting in between cooling fins as much as possible. Use...

Pushing Lock Into Piston Pin Groove With Sleeve

B FORCING SPLIT LOCK RING INTO PISTON PIN GROOVE WITH TOOL SLEEVE Figure 19 Installing Piston Pin Lock Ring with Tool (4I-T-3260) (41-T-3091). Raise rod just enough to give clearance for bushing tool when rod is held in holding fixture (fig. 18). Be careful to start new bushings with bushing oil slot in alincment with oil slot in rod. (2) Ream new bushing nearly to size and finish to exact size with special hone (41-H-2382). A properly fitted pin should have 0.001 inch clearance with this...

Disassembly Cleaning Inspection Repair And Assembly Of Scavenger Pump And Crankcase Breather Valve

The crankcase rotary breather valve is an integral part of the scavenger (oil return) pump. The rotary valve (which drives gears in scavenger pump) is driven by a spiral gear located on engine pinion shaft. Rotary breather valve must be accurately timed to control the scavenging of oil from the engine crankcase. The scavenger pump also provides oil for rear chain lubrication, allowing a small amount of oil to flow past an adjustable needle valve through a small pipe to rear chain. It is...

Figure 50 Oil Feed Pump Disassembled

Remove rotor, with vanes and spring, from pump body, holding vanes to prevent expansion of spring and possible loss of parts. (2) Remove Regulating Ball-spring Valve. Remove valve cover screw exposing adjusting screw. Remove adjusting screw, spring, and steel ball. (3) Remove Check and Regulating Valves. Remove the screws, springs, and balls of the check and regulating valves. NOTE Both check valve springs are the same and are interchangeable. Special steel...

Assembly And Installation

The clutch cannot be completely assembled until the clutch hub and sprocket assembly is installed on the splined end of the transmission clutch gear. Refer to figure 89 for correct order of assembly. b. Install Clutch Hub on Transmission Clutch Gear. Engage the hub and gear shaft splines and drift the hub onto the splines with a block of wood and a hammer. Install the lock washer and nut and tighten nut (fig. 90) securely with wrench (41-W-866-10). Lock the nut by setting the washer in one of...

Figure 49tinereaming Front Cylinder Inlet and Exhaust Cam Bushings in Crankcase and Gear Case Cover with Reamer

(3) Line-ream Rear Cylinder Exhaust Cam Gear Shaft and Oil Pump Drive Shaft Bushings. Use reamer (41-R-2303) and with crankcase and gear case cover assembled, pass reamer through bushings from gear case cover side (fig. 48). Turn reamer just sufficient to clean up and aline bushing holes. (4) Front Cylinder Exhaust and Inlet Camshaft Bushings. Line-ream with reamer (41-R-2265) using only smaller size of reamer combination (fig. 49). Pass reamer through bushings from inside of crankcase and turn...

Bushing41 R2265

I TOOL, REPAIR, DRIVE CHAIN r -REMOVER AND REPLACER, TRANSMISSION OIL SEAL 41-T-2389-47 O GUIDE ASSEMBLY, CLUTCH GREASE, THROUGH OIL SEAL, 1941 H WRENCH, CLUTCH HUB J WRENCH, HEAD K PULLER, CLUTCH HUB, MODEL L WRENCH SPOKE NIPPLE, FRONT WHEEL . 41-W-3339 M WRENCH, CYLINDER BASE NUT, N PILOT, VALVE GUIDE, SMALL, 0.334 IN 41-P-412 0 REAMER, VALVE GUIDE P HOLDER, CUTTER HANDLE AND Q CUTTER, CLEARANCE, FOR 45 CU IN. TWINS 41-C-2822-30 1 PLATE, PISTON SQUARING, FOR ALL SINGLES AND

Crank Pins41 A33710

U GAGE, FLYWHEEL END PLAY, ALSO CHECK END PLAY OF MAINSHAFT ON 45 CU IN. V LIFTER, VALVE SPRING, W TOOL, CONNECTING ROD X WRENCH, WHEEL Y STAND, FLYWHEEL TRUING, UNIVERSAL TYPE 41-S-4970 Z TAP, HANDLEBAR END. AE PULLER, TAPPET, AC PULLER, BEARING AND AO WRENCH, AI REAMER, OILER DRIVE SHAFT AND PIN SHAFT BUSHING, 74 CU IN. PIN SHAFT AND 45 CU IN. OILER

Figure 70Testing for Shorted Armature Coils Using Growler 4UG5940

Armature Coiling Figure

This is a current draw test and results will depend upon condition of battery and accuracy of the ammeter. The regulating field coil is located in the upper side of tb frame and is identified by an orange paint mark. (a) Test for Open or Internal Short (fig. 72). With tester, battery and test prods correctly connected, touch the coil and terminals of the coil. Tester should register 1.4 to 1.9 amperes. If no tester reading is recorded, field coil is open. If tester...

Brush Holder Installation

Are utilized to mount the positive brush holder to the generator frame end. Exercise care when assembling these parts to ensure correct connections, location, and insulation. (a) Relay Terminal Post. The relay terminal post makes contact with the positive brush holder and is insulated from the generator frame end by a fiber bushing and washer. (b) Positive Brush Holder. The positive brush holder is insulated from the generator frame end by a thick fiber paper insulator. (c) Shunt Field Coil...

Shifter Gear Shifter Lever

Inspect for cracks or breakage. See that mounting studs are in good condition and are tight in case. (a) Secqnd Gear Retaining Bracket (fig. 99). The second gear retaining bracket locates the second gear on the mainshaft. Inspect for wear caused by contact with side of the second gear. Replace if badly worn where face contacts side of the second gear. (b) Clutch Gear Outer Roller Race. Inside diameter 1.722 inches. Inner face of race is for thrust ball bearing. Inspect races...

Truing W Heels

Mount wheel in truing stand, and adjust stand gages to determine position of rim as regards side wobble and eccentricity. b. Center and True Rim. Use wrench 41-W-3340 for rear wheel spoke nipples and wrench 41-W-3339 for front wheel spoke nipples fig. 119 . When tightening the spoke nipples, bear in mind that the rim must be centered in relation to the hub. From time to time, check the distance from the rim to the straight edge or a point on the truing stand to determine rim...

Figure 53 Checking End Play of Flywheels in Crankcase with

Selecting and Fitting Thrust Collars. With right crankcase supported on open box, and with gear shaft bearing spring ring engaged in groove in roller race, install bearing washer and gear shaft roller bearing assembly. 1 Select two thrust collars between 0.080 and 0.090 inch and install them on flywheel hubs, making sure that collars register on dowel pins and seat against flywheel faces fig. 52 . Both thrust collars should be approximately the same thickness in order to keep flywheels...

Squaring Plate

Figure 21 Straightening Bent or Twisted Connecting Rod c. Locating Squaring Plate on Crankcase. Make sure crankcase cylinder base face is clean and free from burs so that piston squaring plate 41 -P-1550-25 seats firmly and squarely on crankcase for accurate inspection. Also see that skirt end of piston is not nicked or damaged. Alinement inspection must be made for each connecting rod and piston. d. Checking Alinement with Tissue Paper fig. 20 . Insert narrow strips of thin tissue paper not...

Repair Of Gear Case Cover

It is not advisable to make a weld repair to gear case cover. A broken or badly damaged cover should be replaced. Before removing old bushings, note location of oil transfer hole rectangular shape in pinion shaft bushing. Gear case cover bushings can be removed as follows 1 Remove Bushings. Use special puller 41-R-2372-20, fig. 45 to pull blind bushings from gear case cover. Puller body provides four special puller-tap sizes to accommodate bushings. The open bushing rear cylinder exhaust cam...

Disassembly Cleaning Inspection Repair And Assembly Of Oil Feed Pump

Main oil feed pump is of the vane-type. A rotating member, driven by rear cylinder exhaust camshaft, retains and drives two vanes within a slightly eccentric housing. Pump incorpo rates an automatic centrifugal by-pass valve, reducing oil feed supply at low engine speeds and increasing oil feed supply at high engine speeds. Pump is provided with ball spring adjustable pressure regulating valve and two ball-spring check valves. Maximum oil pressure is approximately 30 pounds....

Figure 55 Timing Gears Installed

3 In summarizing the above breather timing instructions, refer to figure 54. Spiral gear must be so engaged with breather sleeve gear that when flywheel mark is in center of inspection hole and pinion gear is y rinch from joint face, timing hole in the sleeve registers in slot as shown. 4 After timing breather valve, exercise care that timing gears are not pulled out of mesh, permitting timing to change, while installing the valve timing gears. e. Install Timing Gears. All timing cam gears are...

Inspection Of Timing Gears

Timing gears, cams, and shafts must be considered as integral units and must be replaced as such when necessary. Inspect for worn shafts and gear teeth, damaged gear teeth and worn and or pitted cam lobe face. 1 Timing Gear Camshaft Ends for Crankcase Bushings. Standard size is 0.6875 inch. 2 Rear Cylinder Exhaust Cam-oil Pump Drive Shaft Gear Case Cover Bearing . Standard size is 0.7805 inch. 3 Rear Cylinder Inlet Cam-timer Drive Shaft Gear Case Cover Bushing . Standard size is 1.2425...

Assembling Flywheels

The flywheel assembly is a built-up crankshaft and must be as true as possible as.if in one piece after alinement. When assembling flywheels, make sure that connecting rods are installed on crank pin bearing so that female forked end rod will fit into rear cylinder, and male single end rod will fit into front cylinder fig. 38 . This rod arrangement provides better crank pin bearing lubrication. Do not assemble flywheels until crankcase main bearings have been repaired par. 25 . b. Install...

Cleaning And Inspection

Clean all carburetor parts except cork float carefully in dry-cleaning solvent. The carbon crust formation within the barrel may be scraped off with a suitable tool, taking care not to cut or damage the parts, and the throttle disk may be rubbed on fine emery cloth on plane surface . After cleaning, wash parts in dry-cleaning solvent. b. Inspection. Inspect all parts for excessive wear and or damage. Any excessively worn and or damaged parts should be replaced to place carburetor back in...

Ra Po 310333

After flywheels are thoroughly cleaned, inspect for breaks or cracks, especially at taper holes. A wheel with crack at taper hole cannot be made to stay in alinement after assembly. a Inspect Flywheel Connecting Rod Thrust Washers. If washer in either wheel is worn and or grooved to any extent, it must be replaced. a. The only repair that can be made to flywheels is the replacement of the connecting rod thrust washers which fit into recesses in flywheel faces, around the...

Repair Of Crankcase

Recondition Battery Guide

In cases where welding can effect a satisfactory repair without warping or distorting case or necessitating use of special tools and jigs for accurate machining after repair is made, it is recommended procedure. General practice is to replace broken or damaged case. Figure 43 Lapping and Truing Crankcase Main Bearing Races Figure 43 Lapping and Truing Crankcase Main Bearing Races 1 Replacing Timing Gear Bushings in Crankcase. The four timing gear bushings in crankcase can be replaced with an...

Low Speed Needle Valve Seat Hole

With air from the low speed air bleed into the carburetor bore through small holes and a narrow slot located at the edge of the throttle disk. The adjustable low speed needle valve controls the fuel supply feeding into the low speed channels. As the throttle is opened, the air stream through the venturi becomes more active, thus shifting from the low speed circuit to the high speed circuit. d The Choke Circuit. The choke circuit is used to supply a rich fuel mixture, from which sufficient vapor...