Harley Davidson FLH Electra Glide 1970 Owner's manual

1970

Owner’s Manual

Harley-Davidson Motor

~~

Co.,

HARLEY-DAVIDSON

Harley-Davidson products are

manufactured under one or more

of

the following patents:

Patents

2574739, 2770869, 2783927,
2788676, 2872660, 2986162,

2987934, 2998809, 3116089,

3144631, 3144860, 3226994,

3229792.
487981, 490652.

-

D-199,479,2510222,

Canadian Patents

U.

1

S.

-

YO

Welcome to the Harley-Davidson Motorcycling Family! Your new Harley-Davidson Electra-Glide motorcycle is designed
and manufactured to

understandable guide for your motorcycle's operation and care. Follow the instructions carefully for its maximum per-

formance and your personal motorcycling pleasure.
Your owner's manual contains instructions for owner care and maintenance of

of major units such
quires the attention of
facilities, experience and genuine Harley-Davidson parts necessary

'S

AL

be

the finest in its field. The instructions in this book have been prepared to provide a simple and

as

engine, transmission, etc.

a

skilled mechanic and the

a

is

provided in the Harley-Davidson Service Manual. Work of this kind re-

use

of special tools and equipment. Your Harley-Davidson dealer has the

to

properly render this valuable service.

1970

Owner's Manual

minor nature. Information covering repair

OF

TABLE

MOTORCYCLE SAFETY
SAFEGUARD MAINTENANCE
SPECIFICATIONS
CONTROLS

RIDING

CONTENTS

Section Page

.............

...................

.........................

...........................

.........

15

Harley-Davidson Motor

Subsidiary

2

SERVICE AND MAINTENANCE

3

4

9

of

American Machine & Foundry

ENGINE
TRANSMISSION
CHASSIS
ELECTRICAL

.......................

........................

Co.,

lnc.

Co.

Section Page

.......

.................

...................

21
24

27

29

52

Harley-Davidson motorcycles are designed
and built according to our

all

standards and
Vehicle Safety Standards.

applicable Federal Motor

own

rigid safety

2

Because of
inherently one of the safest vehicles designed for use on the highway. However, any
vehicle can only be

skill

and judgement.

It must be remembered
that being a two-wheeled vehicle, it requires different
from those needed to safely operate a four-wheeled vehicle.

We urge that you consult your Harley Davidson dealer who can

cycle traffic
to your riding requirements, and who can provide literature or training in the safe opera­tion of your motorcycle.

its

acceleration, maneuverability and ease of handling, the motorcycle

as

safe

as

the person who operates

-

especially by those not familiar

laws

in your area, who has the necessary clothing, helmet, etc. best suited

it

and depends primarily upon

with

motorcycle operation

skills

and operating procedures

advise

you about the motor-

is

-

In

addition to this owner's manual, a Safeguard Main-

is

tenance booklet
owner. The booklet contains your new motorcycle
Warranty, a Warranty Registration card, and
ber of tear-out service coupons.

The approved service and maintenance procedures on each
coupon and the mileage intervals have been worked out by
Harley-Davidson service personnel,
are the owner's responsibility to have taken care

provided each new Harley-Davidson

a

num-

and

cover items which

of.

Bring the coupon booklet along when you vi
mileages to have your motorcycle ins

Dealer charges for "Safeguard Maintenance" are nominal

with long, trouble-free service and

Harley -Davidson product.

Tools for owner use,
service and minor repairs,
can be purchased from your Harley-Davidson dealer.

will

protect your investment

as

recommended in this handbook for

are

supplied in a tool kit which

it

your dealer at the specified

1

ected and serviced properly.

-

you

will

in

be repaid

a

quality

3

Torque

Compression Ratio FLH

...

FLH
FL

......

.....

FL

65

lb-ft

at 3,200 RPM

62 lb-ft at 3,200 RPM

...........

..........

7.25

8 to

to

1

1

Wheel Base

Overall Length.
Overall Width

Fuel Tank
Oil Tank

Transmission

Model Designation Letters.
Number of Cylinders

Type
Horsepower.

Taxable Horsepower

................

Bore
Stroke
Piston Displacement

4

...................

................

.................

..

Total
Reserve.

...

..

................

...........

...............

................

.

FLH.
FL

.....

.....

...............

.............

...

61.5 in.

89.0 in.

38.5 in.

5 or 3.5 Gallons

1.2

or 1 Gallons

4 Quarts

1-1/2 Pints

E

.....

66.0

57.0
3-7/16 in.

3-31/32 in.

73.66 cu. in. (1207 cc)

FLP

45 Degree V Type

HP

at

HP

at

(US)

(U.S.)

(U.S.)

(U.S.)

-

FLH

5600 RPM
5200 RPM

9.44

(87.3mm)

(100.8mm)

SERIAL

The serial
son are stamped
crankcase and frame steering head. Always give
these numbers when ordering parts or making any
inquiry about your motorcycle.

Circuit Breaker Point

Dwell
Spark Plugs..

Spark Timing

2

Type
Speeds

(V.I.N.)

................

...

Heat range for average use

...........

T

...................

....

Foot Shift.
Hand Shift
(Optional) 3 Forward

NU

numbers of your Harley-David-

on

the right side

ION

SYS

....

Size..

Gap.

.....

(Automatic Advance) 35" B.T.C.

S

of

Gap

....

90"

at

..........

,025 to .030 in.

Retard 5" B.T.C.

Constant Mesh

........

........

and

the engine

,018 in.

1500 RPM

14 mm

. .

No.

3-4

4 Forward

4

Forward

1

Reverse

s

Tail

1.

2.

3.

4.

5.

6.

7.

Lamp

Oil

Filter

Carburetor Air Cleaner
Hydrau

I

ic

Fork
Safety Guard
Brake

Master Cylinder

8.

Ignition Circuit Breaker Cover

9.

Oil

Pump and Pressure Switch

10.

Starter Motor and Relay

11.

Transmission

12.

Battery

13.

Hydraulic Shock Absorber

Oil

Filler

Plug

FIGURE

1.

RIGHT

SIDE

VIEW

3.

Carburetor

4.

Gas

C

TankVa

7

1,

2

3

1.

Clutch Hand Lever

2.

Horn Button

3.

Grip

4.

Instrument Panel Signal
Lights

5.

Foot Gear Shift Lever

6.

Left Foot Board

7.

Gas Tank Cap

8.

Starter Button

9.

Front Brake Hand Lever

10.

Throttle Control Grip

11.

Speedometer

12.

Ignition-Light Switch

13.

Rear Hydraulic Brake
Foot Lever

14.

Right Foot Board

15.

Right Footrest

(2)

8

E

3.

TOP

VIEW

position. Turning the unmarked handle to vertical
position turns on main gasoline supply; turning
"RESERVE" handle to vertical position turns on
reserve supply. Valve should always be closed when

is

engine

or

other anti-knock gasoline.

not running.

Use

"Premium Grade" (Ethyl)

The gasoline supply valve

left

on the
ure

4)

and the other

is

shut off when both handles are in horizontal

FIGURE

side under the gas tank. The valve (fig-

has

two

handles; one

is

unmarked. Gasoline to carburetor

4.

GASOLINE SUPPLY VALVE

(4,

figure

is

marked "RESERVE"

2)

is

located

..

~~~~

itc

The ignition-light switch (figure
instrument panel.

key to lock

or

the key inserted

FIGURE

5.

Lift lock cover and use switch

unlock.

INSTRUMENT PANEL

It

is

not necessary to keep

in

the lock to operate this switch

5)

is

locatedon the

9

after

it

has been unlocked. The center position of

the switch

is

the off position for both lights and
ignition. The right (counter-clockwise) of center
position
(clockwise) position
second
The switch can be locked only in the

is

for parking lights only; the

is

for ignition only and the

left

position, for ignition and running lights.

off

and the park

first

left

positions. Remember that lighting the headlamp

is

when the engine
on. The headlamp upper and lower beams
trolled by

a

handlebar. High beam indicator lamp (figure
cates upper beam. Make
that

it

can easily be replaced in case of loss.

Throttle Control Grip

Turn throttle control grip
close throttle; turn

not running also turns the ignition

toggle switch

(2,

figure

a

record of key number

(10,

figure

it

inward to open throttle.

2)

3)

are

con-

on the left

5)

indi-

so

outward to

Clutch

The clutch foot pedal
where
foot. The clutch

Foot

Pedal

is

located on the

it

may be conveniently operated by the

is

engaged when the toe

and released when the heel

Hand

Gear Shift lever

The hand gear shift lever

on the
plainly marked

10

left

side and the various positions are

on

shifter gate. This lever must

is

down.

(figure

6)

left

is

is

side

left

down

located

FIGURE

6.

HAND

SHIFT

be

at

neutral

(N)

and the clutch engaged when start­ing the engine. FULLY RELEASE THE CLUTCH
BEFORE SHIFTING. To shift gears, move upper

or

end of lever forward

rearward. This moves

lower portion of lever in opposite direction against

are

stops in gate where gear positions

VBfC

The clutch hand lever
the left handle bar where

(1,

figure

it

3)

can be conveniently

operated with the left hand. The clutch

marked.

is

located on

is

released
by squeezing the control lever toward the handle
bar. The clutch

control lever to

The foot gear

the

on

left

operated by

the

way down (full stroke)

into the next lower gear;

is

engaged by slowly releasing the

its

extended position.

shift

lever

side where

the

left foot. Pushing foot lever

(5,

figure

it

may be conveniently

shifts

transmission

lifting foot lever

3)

is

located

all

all

the

way up [full stroke) shifts transmission into the
next higher gear. The operator must release foot

it

lever after each gear change to allow
to

its

central position before another gear change

or

can be attempted
Neutral position
gears, and

is

indicated by center light (figure

made.

is

between

first

(low) and second

the instrument panel when ignition-light switch
turned on. First gear

is

the

last

to return

5)

on

is

gear position

obtained by pushing foot lever full strokes down-

ward.

foot lever one

To shift from

half

first

gear to neutral,

of its full stroke. The

lift

shift

to neutral can also be made from second gear

half

its

by pushing foot lever downward one

full

stroke.

With

the motorcycle standing

not running,

it usually

will

the motorcycle backward

clutch fully disengaged while maintaining

the

foot

pressure on

shift

still

and the engine

be necessary to move

or

forward with the

a

slight

lever before

a

shift

from one gear to +other can be made. Even

with

the engine running, clutch disengaged and

it

the motorcycle standing still,

shift

to

gears because transmission gears are

may be difficult

not turning and shifting parts are not lined up

to permit engagement. When this happens, do not

11

under any circumstances force the shift by t'rough­ing" the foot lever; the results of such abuse
will

be

a

damaged or broken shift mechanism.

as

Either roll the motorcycle

if

or,

the engine

is

running, engage the clutch

indicated above

very slightly and at the same time apply light

pressure to the foot lever to make the shift.

Both these procedures

set

the transmission gears

in motion and permit the shift to be made easily.

r

The starter button

right handlebar. With ignition

(8,

figure

3)

is

located on the

ON

and transmission

in neutral, push button to operate starting motor.

ci

S

The brake foot pedal
hand side operates the
while a convenient hand lever

the front wheel mechanical

The steering lock

left

side of the lower front fork bracket. Turning

left

fork to the

steering head.

aligns hole in bracket with hole in

A

(13,

(14,

figure

rear

wheel hydraulic brake

brake.

figure

(9,

2)

3)

on the right

figure

is

located

3)

padlock can be used to lock the

fork in this position.

12

operates

on

the

Steering damper
head. Turn steering damper adjusting

is

located directly over steering

knob

clock­wise to apply dampening action and counterclock­wise to reduce dampening action.

For

solo riding,
apply steering damper only when operating under
conditions where some degree of dampening stabi-

lizes

tageous to keep the damper set

steering. Sidecar users will find

a

little

it

advan-

snug at

all times.

The horn

3)

on the

is

operated by the horn button

left

handlebar. Tone can be set

(2,

as

desired

figure

by turning the adjusting screw back of horn.

655

The oil pressure signal light
strument panel (figure
Light

will

go on when the ignition-light switch

5)

is

located on the in-

and

is

marked

OIL.

is

turned on before starting the engine. After the en­gine has started, light should go off except

it

may

flicker on and off at very slow idling speeds.

turns to the

tank,

stop the engine at once and do
not drive farther until the trouble
and the necessary repairs

are

QP

made.

is

located

A

the oil.

y

signal switch,

ck the oil supply

if

oil supply

is

normal and the light
not go out, lo oil tank and see
the oil return from the outlet
the oil return e engine

If

it

is

returnin there

grounded

first,

still

is

running.

is

some circu-

or

Then,

does

if

of

lation, and you may drive slowly to the nearest
Harley-Davidson dealer to have the oiling system

as

checked and serviced,

needed.

If

no oil re-

This type fork
for sidecar service. The forks are pivoted

is

used on motorcycles intended

so

that

the wheel can be adjusted forward for less trail

or

(in sidecar service),

justed rearward for more

this

Normally,

as

shipped from the factory, and must be read-

fork

justed for sidecar service

1.

Raise

is

is

with

front end of motorcycle

free. Underneath fork head lower bracket

a

large bolt with castellated nut locked
a

cotter pin. This bolt fastens lower

the wheel can be ad-

trail

(in solo service).

is

adjusted for solo service

as

follows:

so

front wheel

fork bracket to fork stem bracket which has
a slotted hole for the bolt. Remove cotter

far

pin from nut and back off nut

so

that

lock plates underneath bolt head and

enough

bolt nut can be disengaged from slots in

each side of fork bracket. Now grasp front

13

wheel and pull fork sides forward

as

far

as

elongated holes in bracket will permit. Re­engage lock plates in elongated holes with
plate engaging to the front. Securely tighten
nut and insert cotter pin.

2.

Re-aim headlamp after fork

(See page

3.

For solo service, when sidecar

52.)

is

readjusted.

is

removed,

move fork back by reversing above procedure.

t

The rear shock absorber springs can be adjusted

ta

three positions for the weight the motorcycle

is

to carry. The average weight solo

use the extended spring position

(off

rider

cam).

would

A

heavy solo rider might require the position with

springs slightly compressed (first cam step);

seat

buddy

riders require the fully compressed

spring position (second cam step).

To

adjust the rear shock absorber springs, turn

cam

cushion spring adjusting

(figure

7)

to desired
position with spanner wrench. Both cushion spring
adjusting cams must be adjusted to the same

position. When returning to off cam position, cams

A

should be backed off in opposite direction.

is

ner wrench for this purpose

available from

span-

your Harley-DaTidson dealer.

EAR

SHOCK

SPRING ADJUSTMENT

ABSORBER

14

IMPORTANT

If

you are not familiar with operating the
motorcycle, read paragraphs on "SAFETY"
(page

2)

and

"CONTROLS"

(page

9)

before

riding this motorcycle.

irst

5

es

The sound design, quality materials, and workman-

that

is

ship

will

give you high performance rightfromthe

However, for the

built into your new Harley-Davidson

start.

first

few hundered miles, to wear-

in critical parts, observe the few simple driving

will

rules below. This

guarantee future performance

and durability.

1.

During the

45

miles per hour.

2.

Up to

first

50

miles, keep the speedbelow

500

miles, vary the speed, avoiding any
steady speed for long distances. Any speed up
to the maximum legal limit

is

permissible

for short distances.

3.

Avoid

fast

starts

at

wide open throttle and
over-speeding engine in lower gears. Drive
slowly until engine warms up.

ing

lns~ruct~~ns

IMPORTANT

Use recommen ation to pre­dominating temperatures. See engine lubri­cation, page

24.

When starting the engine determine thatthe motor-

cycle

is

in neutral and

that

the clutch

is

fully

engaged.

is

The carburetor choke control knob

the

left

side

under the gas tankon

To

start a cold engine, move the knob outward to

of the motorcycle.

located just

15

the fully closed (choke) position; with throttle
to

1/4

open, turn ignition switch on and operate

the

starter.

To

start

a

warm

or

hot engine move choke knob out-

1/2

ward to
turn on ignition switch and operate the

soon

as

enough to keep

ready to

warms up and misfires, because of the over-rich

mixture, gradually open choke by moving choke knob
inward.
choke knob should be all the way in.

When the engine does not
revolutions
but engine does not
cause ,of an over-rich (flooded) condition.
This
the engine
turn ignition on and operate
choke and throttle wide open.

closed position,

the engine

set

the motorcycle in motion.

After

the engine has thoroughly warmedup,

is

especially true of a hot engine.

is

starts,

it

running while warming up

or

if

one cylinder

flooded, open choke

set

throttle

open throttle just

As

start

after afew

fires

start,

it

is

usually be-

all

starter

starter.

the engine

weakly

the way,

1/4

or

1/8

open,

As

far

until

If

with

Start the engine, fully release the clutch, shift
into

first

desired speed
the clutch,

shift into second and again engage clutch. Shift
in like manner for third and fourth gears.

DO

NOT SHIFT GEARS WITHOUT FULLY DIS-

ENGAGING THE CLUTCH.

When the motorcycle
is
shift from "third" to "second" until speed

is

from "second" to

duced to below
gears when speeds

in

Stopping the Engine

and slowly engage the clutch.

is

attained in

lift

the foot lever

desired to shift to lower gears, do not

reduced to

20

mph

"first"

10

damage to the transmission.

first,

fully disengage

all

the way up to

is

in motion and it

or

less;

do

not shift

until speed

mph. Shifting to lower

are

too high may result

is

re-

After

Operation

With motorcycle standing (engine stopped) proceed

as

follows to get under way. Determine that trans-

is

mission

16

in neutral and clutch

is

fully engaged.

Stop the engine by turning off the ignition switch.

If

the engine should be stalled

other way than with the switch, turn off the switch

at

once to prevent battery discharge through the

circuit breaker points.

or

stopped in any

5

To prevent possible vapor lock with a hot engine

start

in very warm weather,
and leave
richer mixture and cool carburetor. Develop the

habit

instant when running
additional lubrication to pistons and cylinders and

helps cooling.

Do not idle engine unnecessarily with motorcycle
standing.
is

thoroughly warmed up to avoid possible damage

to pistons, rings, and other parts before oil

enough to circulate freely.

An

speed, particularly in sidecar service, must be
given closer than ordinary attention to avoid over-

heating and possible consequent damage. Have the

engine checked regularly and keep

Valve seating and good compression

larly important. The carburetor intermediate speed

needle should be adjusted moderately rich rather

than lean.
suit type of service. This applies particularly to
motorcycle equipped with windshield and splash
shields-or lap apron.

at

half choke for a few blocks to provide

of

frequently snapping the throttle shut for

at

In

cold weather

engine which has run long distances

Use

correct heat range spark plugs to

engine

high speed. This draws

run

engine slowly until

at

half choke

is

at

it

well tuned.

are

particu-

an

it

warm

high

The spark plugs originally installed in the engine
are of the proper heat range for most normal opera­ting conditions. However, more severe than average

or

service
plug

of

in the case of very severe

case

When plugs need to be replaced, get them from
your Harley-Davidson dealer. He can supply you
with the type of plug
ments. Experimenting with plugs of unproven quality
and suitability

loc~ting Operating Troubles

The following check
their probable causes will be helpful in keeping
your motorcycle in good operating condition. Re­member that more than one of these conditions
may be causing the trouble and
carefully checked.

df

engine

1.

Spark plugs in bad condition

a

gap

2.

Circuit breaker points out of adiustment
need

very light service may call for a spark

adifferent heat range to prevent overheating,

of very light service.

best

is

inviting trouble.

list

starts

hard

or

runs unevenly

service

suited to your require-

of

operating troubles and

orfouling in the

all

or

have improper

-

of

cleaning.

should

or

misses:

or

be

in

17

Condenser connection loose.

3.

Battery nearly discharged.

4.

Loose wire connection

5.

at

minals or
Water or dirt

6.

Gasline tank cap vent plugged

7,

vent line closed
Carburetor not adjusted correctly.

a.

Engine and transmission oil too heavy (winter

9.

operation).

df

cranking motor does not operate:

1.

Ignition switch

2.

Starter button or relay defective.

3.

Discharged battery, or loose or corroded cable

connections (solenoid chatters).

4.

Starter control circuit wiring defective.

/

dIf

engine turns over but does not

Gasoline tank empty, valve shut off or gaso-

1.

line line clogged.

Fouled spark plugs or shorted spark plug

2.

wires.

Circuit breaker points

3.

Loose wire connection at coil or circuit

4.

breaker

coil or circuit breaker.

in

fuel system and carburetor.

off

is

not on.

.

at

one of battery ter-

or

carburetor

restricting fuel flow.

start:

badly

out

of

adjustment.

5.

Sticking valves or tappets set too tight.

.

Engine flooded

a

spark plug fouls repeatedly:

1.

Too

cold a plug for the kind of service.

2.

Piston rings badly worn or

engine pre-ignites:

1.

Excessive carbon on piston head or in com-

bustion chamber.

2.

Too

hot a spark plug for the kind of service.

3.

Defective spark piugs.

/

If engine overheats:

1.

Insufficient oil supply or oil not circulating.

2.

Carburetor high speed adjustment too lean.

3.

Ignition timing too late,

df

engine detonates:

1.

Unsuitable fuel (octane rating too low).

2.

Heavy deposit of carbon on piston and in com-

bustion chamber.

3.

Defective spark plug or of wrong heat range.

4.

Ignition timing too early.

f

oil does not return to oil tank:

1.

Oil tank empty.

2.

Oil pump not functioning.

as

a

result of overchoking.

in

bad condition.

18

engine uses too much oil:

1.

Piston rings badly worn

2.

One

or

more push rod cover cork washers in
bad condition
properly against

3.

Rear chain oiler setfor excessive amount of oil.

vibration

.

Cylinder bracket loose

2.

Engine mounting bolts loose.

3.

Transmission and/or transmission submount-

ing plate loose.

4.

Tires

is

or

or

a

its

excessive:

wheels defective.

or

in bad condition.

push rod cover not seating

washer.

or

broken.

transmission shifts hard

1.

Bent shifter rod.

2.

Clutch dragging slightly.

.

Transmission oil too heavy (winter operation).

transmission jumps out of gear:

1.

Shifter rod improperly adjusted.

2.

Shifter clutch dogs and/or dogs on
gear badly worn.

clutch slips:

.

Clutch controls improperly adjusted.

2.

Insufficient clutch spring tension.

3.

Friction discs oily.

its

mating

If

alternator does not charge

below normal:

1.

Defective regulator-rectifier module.

2.

Loose, broken,

to module circuit;

3.

Defective alternator stator

carburetor floods:

1.

Inlet valve and/or valve

2.

Dirt between float valve and

3.

Excessive "pumping"

or

shorted

or

or

module to battery circuit.

seat

of

hand throttle grip.

charging rate

wires

in alternator

or

rotor.

worn

or

its

seat.

is

damaged.

clutch drags

.

Clutch controls improperly adjusted.

2.

Clutch spring tension too tight.

3.

Friction discs gummy

brakes do not hold normally:

1.

Brake improperly adjusted.

2.

Brake controls binding

lubrication

3.

Brake linings badly worn

4.

Hydraulic system contains

inder reservoir low on hydraulic brake fluid.

5.

Leak in hydraulic system.

or

does not

or

damage.

release:

or

oily.

as

result of improper

or

glazed.

air

or

master cyl-

1

Keep on the right side of the road when meet-

1.

ing other vehicles coming in the opposite
direction.

Always sound your horn and pass on the left

2.

side when passing other vehicles going in

the same direction. Never try to pass an-

other vehicle going in the same direction
at

street

going up

3.

At

street intersections give the right-of-way

to the vehicle on your right.

intersections, on curves,

or

down

a

hill.

Do

or

not presume
too much when you have the right-of-way; the
other driver may not know you have it.

Always signal when preparing to stop, start,

4.

or

turn.

All

5.

traffic signs, including those used for the

control of traffic

at

intersections, should be

obeyed promptly and to the letter. "Slow Down''

signs near schools and caution signs

at

road crossings should always be observed and

your actions governed accordingly.

when

rail-

6.

Never "crash" a light. When a c
cated from
the traffic control systems

await

the change.

7.

When intending to turn to the left, give signal

at

least

q'Go" to "Stop"

100

feet before reaching the turning

(or

vice versa) in

at

intersections,

point. Move over to the center line of the

street (unless local rules require otherwise),
slow down passing the intersection
street and then turn carefully to the

8.

In turning either right

destrians

9.

Do not leave the curb

as

well

as

signaling and seeing that your way
drive into moving

or

left, watch for pe-

vehicles.

or

parking area without

traffic.

A

moving line of

is

traffic has the right-of-way.

10.

See that your license tags are installed in

the position specified by law and that they

are

clearly visible under

all

conditions. Keep

them clean.

11.

Ride

at a

safe speed
the type of highway you
whether the road

condition on

the

-

a

speed consistent with

are

on, and always note

is

dry

or

wet. Each varying

highway means adjusting your

speed accordingly.

of

the

left.

clear to

20

re:

After

a

new motorcycle has been driven

500 miles and again

its

at

approximately 1000 miles,

first

the motorcycle should be taken to the dealer from
whom

operations with which the dealer

If

dealer
owner should
attention,

it

was purchased for certain initial service

is

familiar.

it

is

impossible to take the motorcycle to

at

the mileage intervals mentioned, the

at

least give the following outlined

or

arrange to have

it

given, and take

a

the motorcycle to the dealer for more complete

servicing

1.

Drain oil tank through drain plug

later

on

when convenient to do

(7,

figure

so.

2)

flush tank and refill with fresh oil.

2.

Clean oil filter, crankcase screen for overhead
and tappet oil supply and magnetic plug in
chain housing.

3.

Drain transmission through drain plug and

refill

to level

of

filler

opening with fresh oil.

Use same grade oil used in engine.

4. Lubricate
attention in the SERVICE

all

points indicated for

AND

2000

mile

MAINTENANCE

CHART.

5. Aim headlight.

6.

Check front fork bearing adjustment.

7.

Clean carburetor gas strainer.

8.

Clean chain housing magnetic drain plug.

9.

Inspect and clean spark plugs.

10, Check ignition timing and circuit breaker

point gap.

11.

Oil

all

control joints and parts indicated for

2000

mile attention.

12.

Inspect and service

13.

Check adjustment of chains and readjust

air

cleaner

if

needed.

if

necessary.

14. Check lubrication of chains.

15. Check

all

nuts, bolts and screws, and tighten

any found loose.

16. Check wheel mounting socket bolts and tighten

if

needed. These bolts must be kept very tight.

17. Check and tighten wheel spokes.

21

18. Check level of solution in battery and add

if

distilled water

needed. See that terminals

are clean and connections tight.

19. Check tightness of
and

all

cylinder base nuts, and tighten where

all

cylinder head bolts

necessary.

20. Check brake adjustment and hydraulic fluid
level.

21.

Check clutch adjustment.

22. Check tire pressure and inspect tread.

23. Road test.

FI

1.

Drain oil tank and refill with fresh oil.

2. Clean oil filter.

3. Check level of oil in transmission and add

if

oil
engine.

4.

5.

6.

7.

needed. Use same grade of oil used in

Service

air

cleaner.
Check circuit breaker point gap.
Check adjustment of chains and adjust ifneces-

sary.
Check lubrication of chains.

8. Check level of solution in battery, and add
distilled water

are

clean and connections tight.

if

needed. See that terminals

..

9. Check brake adjustment and hydraulic fluid
level.

10. Check clutch adjustment.

11.

Check tire pressure and inspect tread.

12. Road

test.

s

Regular motorcycle lubrication and maintenance
will help you keep your new Harley-Davidson
operating

lower operating costs, longer motorcycle

at

peak performance, and will give you

life,

and greater riding pleasure. Your Harley-Davidson
dealer knows best how to service your motorcycle
with factory approved methods and equipment

as-

suring you of thorough and competent workman-

ship for every job.
The chart on the next page shows the regular

at

intervals

should be performed.

which specified service operations

For

more detailed description

of the service and maintenance procedures speci­fied,

refer

to information following after chart.

22

S

CE

23

Run engine until

1.

ture.
Remove fuel supply hose at tank and drain gas

2.

tank, including reserve supply
Mix about

3.

of gasoline and put in gas
Run engine with gas-oil mix for several minutes

4.

until exhaust smokes.

Remove spark plugs, inject

5.
cycle oil into each cylinder and crank engine

or

6

5

Drain oil tank.

6.

See that rear chain

7.

Wax chrome plated surfaces and apply some oil

8.

to exposed unpainted surfaces.
Store battery above freezing temperature,

9.

trickle charge at least once
water level above plates.
from motorcycle
on ground or concrete.

When riding time comes again, your motorcycle

be

will

24

revolutions.

ready. Just

it

reaches operating tempera-

-

replace hose.

4

ounces of 2-cycle oil in one quart

tank.

a

few squirts of

Clean and replace plugs.

is

clean and well lubricated.

a

month, and keep

If

battery

it

must not be placed directly

fill

the oil tank,

start

is

removed

up and go

2-

Your Harley-Davidson dealer has the proper grade
oil to suit your requirements.

indiscriminately
chemically when mixed.

The oil tank capacity
full when the oil level
stick. Tighten the cap securely to prevent leakage.
The oil signal light
cates oil circulation. Oil mileage normally varies
from 250 to
nature
driving, and
mileage

!

of

service, solo

is

not within this range, see your dealer.

-

some oils tend

is

4

is

on

500

miles per quart depending on the

or

how^

well the engine

Do

not switchbrands

to

quarts and

at

upper mark on the dip-

the instrument panel indi-

sidecar,

is

considered

fast

or

is

kept tuned.

interact

moderate

If

Remove tank cap
MORE THAN
REFILL.

If

and

CHECK OIL SUPPLY NOT Oil will run cooler and mileage

300

MILES AFTER EA COMPLETE

oil level

is

at

lower m on dipstick,

higher with oil level well up
unless oil tank

two quarts can be added. ing of oil level

chance of running dry.

will

be somewhat

in

tank. Furthermore,

is

kept well filled, frequent check-

will

be necessary to avoid any

Do not allow oil level to go below the lower

Oil should be changed after the

1000

and

at

at

about

warm

miles for a new engine, and thereafter

2000

mile intervals in normal service

or

moderate temperatures. Oil change

first

500

miles

mark on gauge rod. intervals should be shorter in cold weather

See 'Winter Lubrication." Completely drain oil

tank of used oil and refill with fresh oil.

vice

is

extremely hard
competition, drain and
Draining should be done after

It

is

not necessary to drain the crankcase

or

on dusty roads

refill

at

shorter intervals.

a

run while oil

not accumulate used oil. At the time of the

mile oil change, and along with

at

least every second

as

first

If

is

it

ser-

or

does

oil change thereafter, thoroughly flush and clean
tank with kerosene to remove any sediment and
sludge that may have accumulated. Your dealer has
facilities for quick flushing and cleaningof oil tank.

UPPER

MARK

(FULL)

LOWER

MARK (ADD OIL)

-

in

hot.

500

out

25

Oil filter

service the filter, unscrew wing nut and remove
filter cup from oil
from top of filter anddisassemble. Thoroughly wash
the filter element in clean gasoline
least once every

changed. Renew filter element every

Overhead and tappet oil filter screen

is

located in crankcase above oil pump. Unscrew
slotted plug, remove and clean
The chain housing magnetic drain plug

13)

is

screw plug and remove foreign material from end

of plug. This should be done when engine oil
changed initially
thereafter.

Combustion in any engine generates water vapor.

When starting and warmingup in cold weather, much

of the vapor condenses to water on relatively cool
metal surfaces.
crankcase thoroughly warmed up, frequently, most

is

located

located

2,000

at

bottom

at

If

engine

at

the top of the oil

tank,

remove retaining spring

or

miles when the engineoil

5,000

ic

(3,

or

replace screen.

(11,

rear

of chain housing. Un-

500

miles and every

is

driven enough to get the

2,000

tank.

solvent

miles.

figure

figure

miles

To

at

is

9)

is

of

this water

through the breather. owever,

engine, making only short runs now and then and sel­dom being thoroughly warmed up,
mulate an increasing amount of water in the oil tank.
This water will, in freezing weather, become slush

or

ice and
block oil lines
mixed with oil for some time forms sludge that
harrnful to the engine and causes undue
ious working parts. Therefore, in winter the oil
change interval should be shorter than normal for

all

engines, and any engine used only for short runs,
particularly in commercial service, must have oil
changed frequently along with
out to remove any water and sludge, beforenew oil
is

put in tank. The farther below freezing the tem-

perature drops, the shorter the oil change interval

should be.

In

normal service on hard surfaced roads, remove

air

cleaner mesh, wash in gasoline, and saturate
with engine oil
under dusty service conditions.

service, clean and oil filter mesh every

or

at

least

is

again vaporized and blown out

a

moderately driven

is

likely to accu-

if

allowed to accumulate too long,

and

damage the engine. Also, water

a

thorough tankflush-

at

least

every

1000

miles,

In

extremely dusty

once a day.

wear

or

100

will

is

of

var-

oftener

miles

26

The gasoline strainer

is

located on top of the

gasoline supply valve inside the gasoline tank

(see

figure

as

indicated by irregular carburetion, remove the

4).

If

the supply of gasoline

is

impeded,

gasoline supply valve from the tank and thoroughly

clean the gasoline strainer. Be sure to drain the

tank before removing the gasoline supply valve.

1'

2

1.

Chain Inspection Cover

3.

Chain Housing Cover Screws

FIGURE

5.

Clutch Cover Screws

8.

CHAIN INSPECTION COVER

3'

2.

4'

Inspection Cover Screws

(8)

4.

Clutch Cover

(3)

(4)

Use

same grade of oil used in engine.

Remove transmission oil filler plug

(11,

figure

1)
and check oil level every month or every 10
miles, whichever comes

fill

and

to the level of the filler opening. The

motorcycle should be standing

Add oil

STRAIGHT

if

necessary

UP,

not

first.

leaning on jiffy stand, when adding oil to the

transmission. Drain transmission and

refill

to

correct level with fresh, clean oil after the first

500 miles, and thereafter seasonally or every
5,000 miles, whichever comes
should become submerged in water, drain

first.

If

transmission

it

im-

mediately and refill to proper level.

is

A fixed amount of oil

line from

a

metering orifice in the oil pump. Oil

supplied through an oil

drops on front chain from oiler outlet tube (10,

figure 13). Excess oil collects

is

compartment and

drawn back into engine gear

at

rear of chain

case breather.

27

When the front chain adjustment
2000 mile intervals (see page
to

see

that oil comes out of oiler tube when

is

engine
inspection hole
from oiler, supply orifice

running, when viewing through cover

(1,

figure

8).

at

is

checked

43)

,

also check

If

oil does not come

pump

is

probably

at

blocked due to accumulation of dirt, and requires
cleaning.

To

do this, remove orifice screw and
washer from oil pump and blow out passage to
chain compartment with compressed

air.

Motorcycle

At

regular 2,000 mile intervals, make a close

inspection of
appear to be getting sufficient lubrication, or
there

is

is

evidence of

equipped with

rear

chain.

an

a

rear

chain oiler.

If

rear

chain does not

if

over-supply of oil, re-

adjustment should be made with rear chain oiler
adjusting screw. The
the oil pump

is

1/4

turn open which provides 2

minute.

as

shown in

If

oiler should become blocked, remove

chain oiler

figure

is

locatedon

9.

Normal setting

or

3

drops per

rear

screw and clean orifice.

If

chain oiler

chain and lubricate

is

not being used, brush dirt off

at

1000

mile intervals with

Harley-Davidson "Chain Saver," "Chain Spray" or

28

3.

1.

Rear Chain Oiler Adjusting
Screw Tappet and Overhead

2.

Rear Chain
Screw Locknut

Oiler

FIGURE

Adjusting

9.

REAR

Cover Plug

Oil

CHAIN

OILER

for

Supply Screen

"Chain Grease"

engine oil.

If

the motorcycle
dusty
lubrication of the
time to time. Under these conditions, proceed
follows:

Remove chain from motorcycle.
thoroughly in a pan of kerosene. Remove chain
from kerosene and hang
kerosene to drain off. Immerse for
in
engine oil.
not

move chain around to

oil works through
from hot grease
wipe

of

connecting link and spring clip closely

condition. Replace

spring clip
pin ends.

or

dirty conditions, thorough cleaning and

a

pan of grease heated to consistency of light

at

hand, substitute engine oil. While immersed,

all

surplus grease

the chain. Install chain on motorcycle. Inspect

if

available;

is

operated under extremely

rear

chain may be advisable from

If

grease and facilities for heating are

be

all

inside parts. After removing

or

oil, allow chain to drain and

if

not available, use

Soak

and wash

it

up for a time to allow

a

short time

sure that hot grease

or

oil from the surface

for

if

at

all

questionable. Be sure

is

properly and securely locked on

as

it

or

bad

ey-Davidson "Grease All" for greasing

requirements.

All chassis bearings requiring frequent applica­tions of grease are provided with grease gun
fittings. Locations and recommended greasing

intervals
TENANCE CHART (Page

Use

Excess grease produces

Remove and grease handlebar throttle grip spiral
with fresh grease every
operation

Remove and grease speedometer and tachometer
drive cables every

On grease fitting of
apply

of

grease gun) to fitting

with hand grease gun.

are

listed in the SERVICE AND MAIN-

23).

a

hand grease gun to avoid over-greasing.

a

messy condition.

5,000

of

grip indicates lubrication

5,000

miles.

rear

fork

a

very small quantity of grease (one stroke

at

miles, or when

is

necessary.

pivot bearing housing,

2,000

mile intervals

29

CAUTION

an appreciable amount of oil leakage should de-

attention should

e given by an authorized

y-Davidson dealer.

Over-greasing will damage seals.

Pack the steering head bearings with fresh grease

at

50,000

miles.

Incorrect recoil action will result
sufficient oil in either side of the fork.
the amount, completely drain the oil and then

pour back into each side

6-1/2 to

if

there

To

7

ounces of

is

in-

check

Harley-Davidson Hydraulic Fork Oil. Oil drained
from the fork may be used again provided
does not appear to be contaminated by water or
other foreign matter. Add only enough fresh oil

All control connections and parts

as

indicated in

to provide the required amount.

the SERVICE AND MAINTENANCE CHART (Page

23)

should

be oiled regularly, particularly after

washing motorcycle

Pa-

or

driving in wet weather.

fork should

water, drain and

In

an

emergency, when Harley-Davidson Hydraulic

Fork Oil

at

any time become submerged in

refill

immediately.

is

not available, use the lightest auto-

If

The Hydra-Glide fork requires very little main- mobile engine oil obtainable. Do not use shock­tenance or attention. It requires no greasing.
fork does not appear to be working properly, or drain and replace with Hydraulic Fork

If

absorber fluid.

If

engine oil

is

used, however,

Oil

as

soon

30

it

consistency of engine oil varies

changes, and

a

rough ride will

and

emper atur e changes

ommended oil.

To

drain and refill fork, remove headlamp and

headlamp housing, then remove the hex headcap

at

screw

drain plug

3/16 inch Allen wrench, and drain the oil into
clean container. Add oil to container,
to make up the required amount. Replace the

drajn plugs and add 6-1/2 to
through the hole in the upper end of eachfork
tube. Then install the cap screw and tighten

securely.
Filling the fork using only

slow job because the

are

air

locked. It
Harley-Davidson dealer when this service
quired,

the job cleanly and quickly.
The adjustable

equipment for sidecar service) does not have

hex head cap screw
but has oil

the top

at

small and the

as

he

of

each fork side. Remove the

the lower end of each slider with

filler

filler

is

recommended that you see your

has

the necessary equipment to do

trail

filler

plugs

channel tends to become

Hydra-Glide Fork (special

at

the top of each fork side,

at

stiff

recoil action

at

lower temperatures.

little

effect on the rec-

if

necessary,

7

ounces of oil

a

funnel

openings in the fork

the rear of each fork

is

a

rather

is

a

a

re-

a

e

removed with a large screw-

Every
cylinder
brake foot pedal. When removing
sure that
plug to prevent entrance into reservoir. Level
should be 1/4 inch from top of cover.
HYDRAULIC
for use in hydraulic brake systems.

It
and miles of service, which
in determining

so

Inspect level of battery solution

week during motorcycle operation, adding distilled

or

keep the solution above the plates.

cycle
check solution level before placing in service.

Remove battery cover and take out 6 screw end

filler

1000

miles, check fluid level in master

(6,

figure

all

dirt

BRAKE

is

the

care

lilt

ion

other approved water

is

not used for an extended period of time,

plugs. With a hydrometer

1)

located just ahead of re

is

removed from around

FLUID, which

given a battery, rather than time

its

life.

as

filler

is

is

most important

at

least

often

as

necessary to

If

or

syringe, add

plug,

filler

Use

only

approved

once

the motor-

a

31

water to each cell to
triangle or circle

at

base of filler hole.

raise

level of solution up to

is

especially important that the battery be kept
well charged in below freezing weather. A low or
discharged battery

very likely to

be

frozen

is

and ruined.

If

battery
of the solution
the vent holes when battery
This

is

filled

will

not only weaken the solution,

to a higher lever, some

will

be

forced out through

is

charging.

but also may damage parts near the battery.

Avoid getting battery acid on clothing

other

fabrics.

Keep battery clean and ter-

or

minal connections tight.

hwgin

Check solution in each cell

drometer.

If

hydrometer reading

remove battery and charge

source. The charging current should be

with

a

battery hy-

is

below

it

from an outside

1.200,

12

volt
direct current and charging rate should not be
allowed to go over

4

amperes.
A higher battery charge rate may heat and damage
the battery.

E'or

this

reason, do not allow the
motorcycle battery to be charged in the same
line with auto batteries. Hydrometer reading of

fully charged battery in good condition will be
from

1.265

to

1.300.

Allowing battery to remain in a discharged con-

its

dition for any length of time shortens

life. It

32

CIS

Keeping the motorcycle clean on the outside
well

as

on the inside not only

maintenance, it

$

good maintenance. To

keeping your motorcycle clean

Davidson

dealer

for the following:

is

a

sign

aid

see

your Harley-

as

of good

you in

leam?.r

Harley-Davidson trGunk" will quickly and efficiently
remove grease and oil from the metal parts of

your motorcycle leaving

a

clean, bright finish. For

unpainted metal surfaces, use full strength. For

enameled surfaces, dilute according to instructions
on can.

Do

not allow "Gunk" cleaner to come in

contact with any plastic parts such

as

wind­shield, trim strips, seat or saddlebags,
since

deterioration.

it

will discolor

Use

the

surface or cause

Harley-Davidson "Plastic
Cleaner" or mild soap and water to clean
these materials.

ley-Davidson "Chrome Cleaner" to make
the chrome parts of your motorcycle glitter and
sparkle.

-

...-

.

. . . . . - .- .

L

.

..

'

-.

__

-

...

*,

,

.:.

.

.

~

. .

.

,

:

,,

.. . ..

A..L

.,

.l-,l

.

.

.?-

\'-

,I

..

.(

is

arley-Davidson "Polish and Cleaner"

made to
clean and polish the enamel parts to maintain or
restore these parts

close

as

possible to their

as

original luster.

Harley-Davidson Plastic Cleaner,

64

is

recommended for cleaning of vinyl plastic
seats. Cleaner comes in
spray on and allow to
wipe clean with

a

15

02.

set

for a few seconds. Then

damp cloth

Part

No.

98680-

spray can. To use,

or

sponge. Full in-

structions appear on the can.

oe

Use mild soap

plastic windshield. Flush with water

-

dirt

then wipe clean with sponge

or

detergent with water to clean

first

to soften

or

soft cloth

using plenty of water. Do not wipe windshield when

or

dry

with dry towel because dirt particles may

scratch surface.

To

obtain

the longest possible

possible performance from your motorcycle

necessary not only to keep
but also correctly adjusted to the tolerances
which

it

was manufactured. The following

life

and

the best

it

adequately service

are

it

the

is

to

adjustments and general maintenance facts per­taining to your motorcycle.

s

Keep plugs clean and the gap between the
trodes adjusted to

a

with

Be

sand blast cleaner.

sure

your motorcycle

.025

inch to

is

.030

inch. Clean

operating with the

elec-

correct heat range plug best suited to your type

If

of riding.
dealer.
installed every

in doubt see your Harley-Davidson

It

is

recommended that new plugs

5000

miles.

are

33

The carburetor, once properly adjusted, requires

little

if

any readjustment. It should not be neces-

the

sary to adjust

1/8

turn and the intermediate speed needle

1/4

than
ture

turn, richer or leaner, to correct the mix-

f9r

a

change

low speed needle

in

weather conditions.
tinually tamper with carburetor adjustments.
gine does not

start

and run right,

(1)

more than

Do

first

(2)

more

not con-

If

en-

look

for

trouble elsewhere, before checking carburetor.

Inlet fitting

and vent fitting

(8)

have strainer

(7)

screens located in threaded holes in carburetor

body.

passages with an

If

faulty carburetion indicates fuelflow

stricted, remove elbow fittings

a

extract both screens with

air

bent wire, andblow

hose. Replace screens and

(7

and

8)

is

frombody,

elbows, being sure that screens are not bent
damaged

so

as

to allow dirt to pass through.

re-

out

or

34

FIGURE

10.

CARBURETOR

Carburetor

We

suggest having carburetor adjustments made by

Adjustments (see

fi

your Harley-Davidson dealer.
The fuel supply for

low

engine speed

is

completely
regulated by the low speed needle. The fuel
for intermediate engine speed
an adjustable needle,

A

fixed

is

also regulated by

jet

supplies the high

speed fuel requirements.

supply

Both the intermediate speed needle and low
needle turn inward (to right) to make mixture leaner

at

the respective speeds for which they adjust. Back-

ing them out (to left) makes mixture richer. Closed

throttle idling speed of engine

speed stop screw
A carburetor that

be readjusted

Make sure carburetor control

1.

throttle lever

handlebar grip movement.

Turn both the low speedneedle

2.

mediate speedneedle

Do

not close

damage to needle and seat may result.
Back up (left) both needles about

3.

needles in this position, engine

speed mixture
Start engine and

4.

temperature and choke has been moved toopen
position, adjust throttle control to idle speed
(700

to

900

5.

Turn low speed needle

until mixture becomes

misses and

back needle out

(3).

as

follows:

RPM).

is

is

badly out of adjustment may

(4)

fully closes and opens with

off

either needle too tightly or

will

after

inclined to stop; then, slowly

(to

left)

is

adjusted with idle

is

(1)

andthe inter-

(2)

all

the way in (to right).

7/8

will

start

probably

it

has

(1)

so

until engine hits regu-

be

reached operating

in (to right) slowly

lean that engine

s

adjusted

turn. With

but low

too rich.

so

le

speed. Startin

ill

be better wit

low speed adjustment slightly rich, rather th

lean

as

Adjust throttle lever stop screw

6.

sary, to make engine idle at proper speed with
throttle
Turn screw to right to make engine idle faster
and to left to make engine idle slower.
idle an engine
cause
causes hard starting. Changing the idle speed
with throttle stop screw

low speed mixture slightly. It will, therefore,
be necessary to again check and correct low

speed needle adjustment by the same procedure
followed in making the initial adjustment.

7.

Check intermediate speed adjustment,

speed adjustments have been completed.
motorcycle on the road

Best
be found with the intermediate speed needle

(2)

Changing either mixture setting also

8.

other setting to some degree. Therefore,
be necessary to recheck low speed mixture after

intermediate mixture final setting

as it can be made.

(3)

in

closed position (screw against stop).

at

the slowest possible speed be-

an

extremely slow idling adjustment

is

likely to change the

at

35

miles per hour.

all

around engine performance can usually

set from

3/4

to

7/8

turns open.

as

after

affects

is

obtained.

neces-

Do

not

low

Run

the

it

will

35

.

... . .

....

-

ADVANCE MARK POSITION

1.

Contact Point Adjusting

Notch

2.

Moving Contact Point

3.

Stationary Contact Point
Lock Screw

4.

Cam Follower

5.

Breaker Cam

6.

Circuit Breaker Plate
Screw (2)

7.

Condenser

-

RETARD MARK POSITION

8.

Circuit Breaker Plate

9.

Circuit Breaker Plate

Adjusting Notch

10.

Contacts

11.

Timing inspection Hole

(354

(5'

B.

of

Piston Top

Timing

12. Advance
Mark on Flywheel

13.

Retarded

Position
Center Mark on Flywheel

T.

C.

)

36

FIGURE

11.

CIRCUIT

BREAKER

AND TIMING

MARKS

Circuit breaker points should be checked for gap

at

500

and contact surface condition initially

1000

miles, and thereafter every 2000 miles. Re-

move spark plugs to permit engine to turn easily

and rotate flywheels
either of the highest points of cam
gap between the contacts (10) with a .018 inch gage
(wire preferred).

the cam follower

(5),

of cam
gap spacing affects ignition timing. To adjust the

points, loosen the lock screw

ary contact plate, using screwdriver in adjusting

notch

tighten the lock screw
to make sure
or worn condition should

Ignition timing

Correct ignition timing and correct setting
circuit breaker contact point gap
necessary for proper engine operation and per­formance.

adjustment

(1)

to provide correct contact point gap. Re-

it

so

that cam follower

(5).

If

it

is

not exactly .018 inch when

(4)

is

on either of the highest points

is

necessary. Incorrect point

(3)

and move station-

(3)

and again check the gap

remains correct. Points in pitted

be

replaced.

is

controlled by the circuit breaker.

is

and

(4)

is

on

Check the

of

the

absolutely

The spark timing cam
as engine speed increases through action of the

flyweights

sures

speed and high speed requirements.

To

check or reset ignition timing proceed

Remove circuit breaker cover and set circuit
breaker contact gap at exactly .018 inch
under CIRCUIT BREAKER.

Use a strobe flash timing light (timing gun) to view
advanced timing mark (12) on flywheel through ac­cessory plastic view plug screwed into timing in-

spection hole
RPM.
front spark plug, ground and positive red wire to

battery terminal. Light will flash each time front

cylinder spark occurs. Loosen circuit breaker
plate screws

plate (8) can be shiftedusing

(9)

as

timing mark (12) in center of hole. Timingwill
tard

in the circuit breaker base. This in-

correct spark timing to suit starting, low

(11)

Timing light leads should

(6)

light aimed into inspection hole

30"

automatically when engine

is

advanced automatically

while engine

just enough

a

as

follows:

as

outlined

tP

is

running

be

so

circuit breaker

screwdriver in notch

at

2000

connected to

(11)

stops

re-

is

stopped.

37

If a strobe timing light
timing can be obtained in an emergency, by using the
following procedure:

Remove screw plug from timing inspection hole
in left side of crankcase. Then remove front push

so

rod cover

observed.

Turn engine in direction in which it runs until front
piston
intake valve closes), and continue turning engine
very slowly (less than

top center timing mark (13) on flywheel

in the inspection hole (11)

The narrow lobe cam
point

at

that opening and closing of valve can be

is

on compression stroke (just after front

which contacts

is

not available, approximate

1/2

revolution)

as

shown.

is

now at the approximate

(10)

open and front cylinder

until

is

aligned

(11)

piston

wide be opens

ition occurs

Connect a circuit tester such

the contact points to determine the exact point of

contact opening. Loosen circuit breaker plate

(6)

screws

(8)

using a screwdriver in notch

will

mark

in figure

(This procedure
and engine can be operated in an emergency for

short period until advanced position timing can

obtained with a strobe timing light.)

At regular intervals

a

year, have your dealer check ignition timing and,

if

necessary, readjust circuit breaker setting to
compensate for wear on circuit breaker that may
have caused a slight change in timing.

just enough to shift circuitbreaker plate

open exactly when piston top center timing

(13)

is

aligned in inspection hole

11.

will

result in approximate timing

of

5000

as

alightbulb across

(9),

so

contacts

(11)

as shown

be

miles or at least once

.

a

38

Tappets are self-adjusting, hydraulic type. They
automatically adjust length to compensate for
engine expansion and valve mechanism wear, and
thus keep the valve mechanism free of lash when

is

the engine

quired only in a new engine assembly and when

the engine

readjustment of tappets

When starting an engine which has been shut off

even for
tend to
completely refill with oil.
than for

is

noisy,

hydraulic units may not
Always check the lubricating oil supply in the oil
tank
normal circulation of oil through the engine
necessary for proper operation of the hydraulic
units.

be

passages leading to the lifter units. Oil tank
(2,

be

started, valve mechanism becomes abnormally

it

first

If

functioning properly due to dirt

figure

running. Tappet adjustment

is

reassembled

a

few minutes, the valve mechanism may

slightly noisy until the hydraulic units

a

short period immediately after engine

is

an

indication that one

if

the valve mechanism

there

is

oil in the tank, the units may not

1)

and tappet oil supply

after

repair.

is

required.

If

at any time, other

or

be

functioning properly.

is

in

the oil supply

filter

is

re-

No

further

more of the

noisy, since

is

filter

screen

(3,

figure

speed to the nearest arley-Davidson dealer for

further attention.

The need
be indicated by the clutch slipping under load or
dragging in released position.

first

controls.

Normally the only attention the clutch hand control
requires
adjusting sleeve
mately
handlebar before clutch

Should the need of major readjustment be indicated
by

by excessive gear clash when shifting,or sleeve
adjustment
adjustments should

9)

may require cleaning. Drive at moderate

of

attention to clutch and controls will

In

either

thing to be checked

is

occasional readjustment of control coil

(1,

figure

1/4

inch free movement for hand lever on

a

slipping clutch,

is

completely taken up, the following

or

be

1.

Move end of lever on transmission forward

a

position where

to

is

the adjustment of

12)

to maintain approxi-

starts

made in the order indicated.

it

to disengage.

dragging clutch indicated

becomes firm indicating

case,

the

39

1.

Clutch Control Cable Adjusting Sleeve

2.

Locknut

3.

Bracket

4.

Starter Motor

5.

Clutch Actuating Lever

6.

Clutch Adjusting Screw Locknut

7.

Clutch Adjusting Screw

8.

Clutch Plate Spring Tension Nuts

(3)

40

FIGURE

12.

CLUTCH CONTROL ADJUSTME

that

all

slack in the actuating mechanism has
been taken up. Measure clearance between
starter motor (4) and clutch lever

1/2

inch.

If

should be
obtain this position of lever follow the instruc­tions in the next step.

necessary to readjust to

(5)

which

Check to determine that foot shift lever positioni

is

mark
Foot pedal can be raised
clevis on shifter rod end.

aligned

with

clamping slot of foot lever.

or

lowered by adjusting

Steps

2.
actuating lever

Loosen control coil adjusting sleeve lock nut (2,

figure 12) and turn control coil adjusting sleeve

(1,

3.

Remove clutch cover, loosen push rod adjusting
screw lock nut
screw

the rear; out (counterclockwise)

lever forward. When 1/2 inch clearance between

lever and

tighten lock nut

Turn

4.
clutch hand lever has

before releasing pressure
When adjustment
nut (2). IMPORTANT

air

2, 3 and

figure

(7)

in (clockwise) to move end of lever to

12)

4

are

required only

is

not positioned correctly.

all

the way into bracket

(6)

and

turn

push rod adjusting

to

starter

adjusting sleeve

tight with cover reinstalled.

motor has been attained,

(6)

and reinstall cover.

[l)

outward until end

1/4

inch

free

is

applied to clutch.

is

attained, tighten lock

-

Chain housing must be

if

move end of

movement

clutch

(3).

of

Proceed

1.

2.

as

follows to adjust foot control:

With the foot pedal in the fully engaged position

(toe down) the clutch lever should have 1/4
inch clearance with

foot pedal rod end should have

in

clearance

To

adjust, remove the chain housing cover,

set

the foot pedal in the fully engaged position

down),

(toe
and readjust the push rod adjusting screw
with a screwdriver
is

about 1/2 inch away from
Be sure that clutch lever rod end has 1/8 inch
free movement in lever slot before clutch dis­engages. IMPORTANT
be air tight with cover reinstalled.

lever slot.

loosen the lock nut

starter

drive housing, and

1/8

(6,

figure 12)

so

that the end of the lever

starter

-

Chain housing must

free end

(7)

housing.

41

If,

after

readjusting the clutch controls, the clutch

still

slips, increase the spring tension by tighten-

ing (turn right) the three nuts

all

three nuts one-half turn at a time until clutch

after

holds. Test
gine. Usually
slippage when cranking the engine also holds on

the road. Do not increase spring tension any more
than

is

actually required to make clutch hold.

A

new clutch

so

that the distance from the inner edge of the
shoulder on the spring collar to the outer surface
of the outer disc
that this distance
probably cannot be fully released.

If

it

is

necessary to tighten the spring tension
beyond the limit indicated above,
sary to disassemble the clutch for inspection of the
clutch discs. Some of the discs may be worn and
require replacement
and in need of washing and drying.

each half turn by cranking the en-

a

clutch that holds without noticeable

is

originally assembled and adjusted

is

1-1/32

is

less

or

(8,

figure

inch.

If

than

7/8

it

they may

12).

Tighten

compressed

inch, the clutch

will be neces-

be

oil soaked

so

It

is

advisable,

your motorcycle to your arley-Davidson dealer.

The hand shift normally requires readjustment only
to compensate for
lever position, proceed

1.

Move the shifting lever to third positian on
four-speed transmissions and to second posi­tion on three-speed transmissions.

2.

Disconnect shifter rod from shifter lever;
with slight backward and forward movement

carefully

exact position where the shifter spring plunger

(inside transmission)

ing notch.

Turn the clevis in

3.

shifter rod to the shifting lever without dis-

turbing the shifting lever's

if

the above condition exists, to

wear.

''feel"

To correct hand shift

as

follows:

the transmission lever into

seats

fully in

or

out, carefully

exact

take

its

retain-

refit

the

positioning.

42

Inspect the adjustment of the rear chain at
mile intervals and the front chain
intervals and readjust them

at

if

necessary.

2000

1000

mile

Ad-

justment of front chain can be checked through

(1,

inspection hole
If chains are allowed to run too loose they

figure 8) after removing cover.

will

cause the motorcycle to jerk when running at low

speed, and both the chains and sprockets

will

wear excessively.

Adjust both front and rear chains

so

they have

the correct amount of free movement up and down,

Do

midway between sprockets.
because running chains too tight
harmful than running them too loose.

stretch and wear in service, they
at one point on the sprockets than

not adjust too tight,

is

even more

As

chains

will

run tighter

at

another;

always check adjustment at the tightest point.

links

in

bad

Inspect chains occasionally for

tion.

If

any are found, replacement of entire chain

is

recommended. The rear chain can be taken apart

condi-

and removed after locating and taking out the spring­locked connecting

The front chain

ting link. Therefore,

link.

is

not provided

it

is

See "Rear Chain Repair."

with

such a connec-

necessary to remove the

engine sprocket, chain adjuster and clutch before

off

the chain can be taken

for replacement.

To disassemble chain housing cover, for access
to chain, remove rear pivot bolt from left foot­board and swing rear end of footboard down, away
from chain housing cover. Remove 8 cover attach­ing screws and remove cover.

is

Front chain tension
shoe

(5)

which

is

the chain to tighten or loosen

adjusted by means of

raised or lowered underneath

it.

The shoe support

bracket (8) moves up or down in slotted backplate

(9)

after loosening center bolt

Adjust shoe support

as

necessary

(7)

in

backplate nut.

to

obtain specified

up and down free movement in upper strand of

chain, midway between sprockets and retighten bolt
securely.

Front Chain Adjustment

5/8 to 7/8
3/8 to 5/8 inch chain slack

inch

chain slack

with

cold engine

with

hot engine

a

43

Shoe support bracket
two sets of shoe attaching holes

(8)

and outer plate

(A

and

B)

(6)

so

have

that
entire assembly can be inverted to accommodate
various sprocket sizes

To

change over, remove center bolt

two shoe attaching capscrews from

(A),

invert shoe and attach to alternate set of

holes

(B)

with capscrews. Invert support bracket

or

chain lengths.

(7),

set

remove

of holes

and outer plate and reattach with center bolt
engaged in backplate nut.

Important

!

Chain housing must be airtight with cover

reinstalled - use new gasket and gasket sealer.

en8

(see

Remove

the

rear axle nut

and loosen brake sleeve nut

stud nut

adjusting screw

(5).

Loosen the lock nut

(7)

on both sides

figure:

15)

(3)

and lock washer,

(4)

and brake anchor

(6)

of

motorcycle.

on wheel

Turn adjusting screws as necessary to correctly
readjust the chain. Turn each screw an equal

of

number

turns in oraer to keep wheel in align-

ment.

A

correctly adjusted rear chain should have

1/2

inch free up and down movement half way between

transmission sprocket and rear wheel sprocket.
chain. When readjustment

is

completed, be sure to
securely retighten the sleeve nut, axle nut, anchor
stud nut and adjusting screw lock nuts in order.

rear

To repair

chain in an emergency, remove

the damaged links by pushing out the riveted link

a

pins with
er). Then

is

also used to remove press

chain repair tool (obtained from deal-

fit

the necessary repair links. This tool

fit

connecting

link

sideplate when replacing entire rear chain.

Check correct alignment

of

the wheel to see that

the tire runs about midway between rear fork and

also that the rear sprocket runs centrally in the

When the front wheel brake

is

properly adjusted

the hand lever will move freely about one quarter

its

of

take

To adjust brake, loosen lock nut
sleeve

full movement before the brake starts to

effect. B adjusted tighter,

(2)

and turn lower nut

the

brake may drag.

(1)

on adjusting

(3)

in toward the cable

44

support tube to decrease the free movement of

(1)

the lever

(3)

away from

free

the

free

movement
quarter
curely against

The

rear

When the

and tighten

the

movement of lever and loosen brake. 'When

of

its

full movement, tighten lock nut

the

wheel

is

brake

pedal will move freely approximately

before the brake starts to

of

the

brake shoes

brake.

Turn

the

lower nut

cable support tube to increase

the hand lever

adjusting sleeve nut

is

about one-

(3).

(1)

se-

equipped with a hydraulicbrake.

is

properly adjusted, the foot

1-1/4

inches

take

effect. Adjustment

is

required periodically to
compensate for lining wear. Pedal adjustment
may also be necessary due to pedal linkage

ear

wear.

Remove chain guard rear mounting bolt and swing

rear end of guard upward as shown in illustration.

46

FIGURE

14.

FRONT

BRAKE

ADJUSTMENT

To

adjust brake shoes,

raise

rear

wheel

so

it

can be turned freely by hand. Two adjusting cam

FIGURE

15.

REAR BRAKE SHOE

47

square head nuts
shoe, are located on the outside of the brake
backing plate. Using
cam shoe nut, turn
counterclockwise until lining contacts drum, caus­ing a noticeable drag when wheel
wheel back and forth to center the brake shoes.
Next, back off cam approximately 1/32 turn, until
wheel turns freely. Repeat this adjusting proce­dure on rear shoe cam nut (2), turning the
shoe cam clockwise until lining contacts drum
and brake drags; rock wheel, and back off cam
1/32 turn until wheel turns freely.

Work brake pedal (1) back and forth by hand to de­termine free play before push rod contacts piston
in master cylinder. Free play of push rod should
be approximately 1/16 inch. Adjustment
by loosening master cylinder rear bolt

brake

plate (3) down to decrease free play,

crease

pedal stop plate bolt

free

play.

(1)

and (2), one for each brake

a

square end wrench on front

brake

front shoe cam

is

turned. Rock

(2).

Move front end of

or

(1)

rear

is

made

(4)

and

up to in-

Front and rear wheels can be detached when
necessary to remove for wheel
When detached from drums, wheels are inter­changeable.

or

tire

service.

ear

Support
off the ground. Remove two

der

five socket screws that secure wheel to brake drum.
The socket screw wrench can be inserted only
the

to bring each screw to this position.
Remove

axle

wheel hub and right

to hold brake drum securely while pulling wheel
away from brake drum. Wheel
come out to rear with fender end raised

rear

end of motorcycle with rear wheel

rear

screws from fen-

support, and

rear

of

axle

axle

(1)

and then remove spacer

Foot Brake Lever Locking Tool,

95875-58,

use tool, raise right
tool over brake lever stop pin, depress

raise

so

nut (3) and

end of fender. Remove the

the wheel will have to be turned

axle

nut lock

axle

clip. Apply rear brake

(2).

(5)

from between

is

then

Part

can

be

used to lock brake.

side

foot board, slip

Remove

free

as

shown.

No.

To

at

to