Info

Engine - Right Side View (1967 Model XLH Shown) gasoline lines (1, 2 and 2A) and remove bolts securing gasoline tank. Tank can then be removed from motorcycle. Remove the following parts from right side of motorcycle. 2. Remove air cleaner assembly (3) including back plate. 3. Disconnect throttle and choke control at carburetor (4 and 22). 4. Remove top engine support bolt located at point (5). Be sure to note the number of shim washers between cylinder head bracket and frame lug...

H

Conduit Conduit Conduit Conduit Conduit Conduit two wires) - Red and green one wire) - Black one wire) - Green 3 wires) - Red and 2 green two wires) - Black and red 6. Oil signal light switch - Green wire 8. Terminal - Black, red, and rectifier positive terminal. 10. Speedometer light - Green wire 11. Terminal - Not used with standard wiring 12. Terminal - Not used with standard wiring 13. Generator signal light - Green and black wires 14. Oil signal light - Green and black wires 15. Ignition -...

Assembling Transmission

Install retainer ring (15) and retainer (14) in access cover. Insert springs (8) into slots of support (7). Position carrier (6) in support (7). Insert right and left shifter pawls and springs (9) into their respective sockets, top ratchet engaging grooves facing each other. Hold spring loaded pawls in place with a thin spoke or knife blade and assemble cam (5), carrier (6) and support (7) with shims (7A) (if used). With TruArc pliers install washer (4) and new retaining ring...

Note

Before making adjustments or servicing regulator, identify regulator by number stamped on regulator base, or mounting bracket, then refer to table Fig. 51-1 which contains service information for desired regulator. Delco Remy Bulletins listed in table may be obtained from a Delco Remy service station or the Harley-Davidson Motor Co. B. TESTING CUTOUT RELAY UNIT CLOSING VOLTAGE (THE SAME CONNECTIONS ARE USED AS IN TEST A (FIG. 51-2.) 1. Turn field control variable resistor to open position. 2....

Wiring Diagram Key

Conduit (two wires) - Red and green F. Conduit (two wires) - Red and green G. Conduit (three wires) - Red wire with black tracer, red wire with yellow tracer, black wire with red tracer H. Conduit (two wires) - Green and red I. Horn switch - Two black wires 2. Headlamp - Black wire with red tracer and red wire with yellow tracer 3. Headlamp dimmer switch - Red wire with black tracer, red wire with yellow tracer, black wire with red tracer 4. Ignition cut-out switch - Black wire F terminal -...

Testing Cutout Relay Unit Closing Voltage

Cutout Relay Figure

Use same tester connections as previous Test C. (Fig. 51-9) 1. Turn field control variable resistor to Open position. 2. Turn load control knob to Direct position. 3. Operate engine at 1500 RPM (approximately 30 MPH). 4. Slowly turn field control resistor knob toward Direct position observing voltmeter. As resistance is decreased in field circuit, voltage will rise. Note highest reading before meter pointer kicks to read battery voltage. Repeat operation several times, each time turning field...

Straightening Fork Tubes

Straightening fork tubes requires several special tools including a hydraulic or arbor press, dial indicator and straightening blocks. If facilities are not available locally for straightening fork tubes, they may be returned to the factory through any authorized Harley-Davidson dealer. Figure 2F-28. Straightening Fork Stem and Bracket Assembly Figure 2F-27. Pressing Fork Tube Round to the factory through any authorized Barley-Davidson dealer. Do not attempt to repair fork stem and bracket...