Harley Davidson 1943 MOTORCYCLE SOLO Tm9 879Harley WLA, HD 1942 Solo WLA, 1942 Solo WLA Service Manual

TECHNICAL

No,

MANUAL

9-879

WAR

Washington,

DEPARTMENI

18

October

1943

MOTORCYCLE,

(Norley-Davidson

SOLO

Model

WLAj

*TM 9-&79

RESTRICTED

TECHNICAL MANUAL ) WAR DEPARTMENT

9-879

No.

J

Washington, 18 October

1943

MOTORCYCLE, SOLO

Section

(Harley-Davidson Model

DUs«m!nation of restricted

strictad documents^

materiel, may be given to any person irnown

United States, and

the

are cooperating in

who

municated to the public

public relations

tary

28 September 1942.)

the essential

and

persons of undoubted loyalty

to

Government

or to the press

agencies, (See

matter.

—

Tho information contained in re-

characteristics of restricted

work,

except

paragraph 18b, AR 380-5,

also

CONTENTS

PART

ONE-VEHICLE OPERATING INSTRUCTIONS

I IntroductioQ i-2

II

Description and tabulated data

III

Controls and

IV

First

echelon preventive mainte-

nance

operation

services

V Lubrication

VI Tools and equipment stowage

on the

vehicle

WLA)

to be in ffie

but will not be

by

servica

and discretion

authoriied

Paragraphi

S-13 9-19

14-18

19-20 30-34

21-23 35-38

S—

of

com-

mili-

Page»

3-6 7-8

20-29

Section

*For

supersession

PART

TWO-ORGANIZATIONAL MAINTENANCE

VII

Maintenance

VIII Second echelon

maintenance

IX Organization tools

ment

X Trouble shooting

XI Engine

XII

Engine—removal and

Xni

Clutch

of

quartermaster manuals,

allocation

preventive

services 26

and equip-

installation

-.

refer

to paragraph

24-25

39-44

45-59

27 60

28-38

61-71

39-44 72-77

45-46

47-52

2.

78-34

85-95

TM

9-879

MOTORCYCLE,

Section

XIV

XV Chains and sprockets

XVI Fud system ..

XVII Intake

SOLO (HARLEY- DAVIDSON MODEL

CONTENTS—

Transmission SS-SS

exhaust system

and

Cont'd

P=,cgrc.ph.

59-66

67-74

75-51

WLA)

p.^»

96-104

lOS-114

115-121

122-128

XVIII Ignition system 82-89 129-141

90-95 96-97

98-101

. . , 102-Ul

,112-118

U9-121 191-192

122-12?

I42-I4S 149-153

154-166 167-180 181-190

193-199

200

XXIII Battery,

XXIV Instrument panel

References

XIX Generating system

XX Brake system

XXI Steering control

XXII

Sheet

metal and

lighting

equipment.

system, horn.

XXV Tires, wheels, and hubs

Index 201

PART ONE-CPERATING INSTRUCTIONS

TM

9-379

1-2

Section

I

INTRODUCTION

Paragraph

Scope

Supersession of quartermaster manuals 2

SCOPE.

1.

This technical

a.

guidance of

the

maintenance, and minor

In addition

b.

cycle, this

identification,

into

operating

gives vehicle maintenance

manual contains technical information required for the

use,

two

parts. Part

instructions.

with the responsibiiity

diction.

c. In

all

cases

adjustment is beyond the ordnance

suitable tools and equipment

issued.

2.

a.

service should

SUPERSESSION OF

This

technical manual,

manual*

using

arm personnel charged with the

repair of

to a description

and

care of the materiel. The manual is divided

One, section I through section VI, gives vehicle

Part Two, section VII through section XXV.

instructions

of

doing

where

the nature of

scope

be

and replaces the following

TM

(1)

10-1175— Maintenance

Davidson (Modei 42-WLA),

TM

(2)

10-1177—Maintenance manual, motorcycle, solo, Harley-

Davidson

1941,

TM

(3)

10-1331—

Maintenance

Harley-Davidson

TM

(4)

10-1359— Instruction

Harley-Davidson

November

TM

(5)

lQ-1361-rnstruction folder (4S-B)

Harley-Davidson (Model 1941

November 1941.

provide operating Instructions with

*To

published

been

will be

corrected

in advance of

by changes

complete

or.

published for the

is

this

materiel.

the Harley-Davidson motor-

of

to using

maintenance work within their juris-

repair, modifications, or

the

or facilities

informed

be

may

of the unit,

so that

provided, or proper

QU.ARTERMASTER MANXJ.4LS.

together

Quartermaster Corps publications:

(Models

1941.

if ex:enstve,

with TM

manual,

motorcycle, solo, Harley-

1940-41-42),

motorcycle,

(Model 42 WLA, solo),

folder

(45-A) motorcycles,

(Model

the materiel, this technical

cechnicai review,

an early revision.

by

information

operation,

arm personnel charged

the responsible

trained personnel with

instructions

9-1S79,

11

1941 WLA

motorcycle, solo,

,

.\ny

supersedes

September 1941.

September

II

chain

45),

WLA

errors or

45).

manual has

omissions

1

and

drive

solo,

25

'

9-879

TM

2

MOTORCYCLE,

FUEL

SHUT-

OFF

FRONT

HAND

LEVER

HEADLIGHT \

DIMMING

SWITCH

SPARK

CONTROL

GRIP

HORN

BUTT'

GEARSHIFT

LEVER

GASOLINE

TANK

CLUTCH

FOOT PEDAL

CARBURETOR

CHOKE

VALVE

BRAKE

LEVER

SOLO

^

{HARLEY-DAVIDSON

MODEL

STEERING

WLA)

NSTRUMENT

SIGNAL

OIL TANK

DAMPER

PANEL

LIGHTS

THROTTLE

BRAKE

CONTROL

IGNITION

LIGHT

REAR

FOOT

GRIP

AND

SWITCH

(ServiceJ

PEDAL

SPEEDOMETER

LIGHT

-«5= CAUTION

STARTER

SWITCH

PLATE

CRANK

Figure

I—

Top View

of Motorcycle

4

RA

?0 315708

INTRODUCTION

TM 9-879

2

9-879

TM

2

MOTORCYCLE,

SOLO (HARLEY- DAVIDSON MODEL

WLAl

Section II

TM

9-879

3-4

DESCRIPTION AND

TABULATED DATA

Paragraph

Description 3

Data

3. DESCRIPTION (figs.

This 2-cylinder solo

a.

cooled

principles.

and head

excessive

should be

in

4.

gasoline

engine,

Air-cooled

radiating

heat. Motorcycle engines, therefore, under no

ftns, and upon

operated

motion.

DATA.

Vehicle Specifications.

a.

I,

2. and

3).

inotorcycle

operating on conventional 4-stroke, 4-cycle

engines rely upon movement of air

more than 1 minute

for

is powered by a V-type,

circulation

oil for dissipation

of

when motorcycle is not

over cylinder

conditions

Type of engine 2-cyiinder, V-type L-head, air-cooled

Cylinder bore

Stroke

Engine number (serial) left side engine

base,

below front cylinder.

Wheelbase

4 ft U14 in.

Length over-all . 7

Width

over-all

(handle bars)

Wheel size

size

Tire

Tire type Drop center

Weight of vehicle

Ground clearance

Kind and grade of

(without

(skid plate)

fuel Gasoline: 72

rider or

armament) 540 lb

4.00 x 18 in.

octane or

High gear ratio

Engine

Countershaft

sprocket

Rear wheel sprocket 41

in.

23/^

in.

3^%q

ft 4 in.

in.

3 ft 5

18 in.

in.

4

higher

4.59:1

31-tooth

l7-tooth

-tooth

4

air-

of

Performance.

b.

Maximum

Miles

per gallon

allowable speed

(hard surface) 35

7

65 mph

TM 9-879

4

MOTORCYCLE,

Cruising

Fording depth

c.

Fuel capacity (left tank) 33/g

Oil tank

Transmission capacity

range

Capacities,

capacity (right

SOLO (HARLEY- DAVIDSON

(without refill) 100 miles

(carburetor)

tank)

MODEL

154

WLA)

18 in.

gal

U.S. ^'S- gal

Va

P^

Section III

TM

9-879

5

CONTROLS

AND

OPERATION

Controls 5

Engine prestarting instructions 6

Starting the

Stopping

engine

the engine

-^

Operation of vehicle

Driving

precautions

Stopping and parking vehicle 11

Towing

vehicle

to

start

engine 12

Running-in new engine (or vehicle) 13

5uc<owT

UtADUGHT

uoHT

swnCH

CMMMIKG

swrrcH

neEM. aSNEuATO"

lED, on

STEERING

ClRCUUnON

OamBES control

SIGNAL

SIONAl

Paragraph

7

8 9

10

irOHT

UGtIT

TANK

GASOIIHE

Foot «OAl

ClLTTCH

CAfiBOflETOH CMOKE LEVtR

3. CONTROLS (fig.

a. Controls are peculiar

thoroughly

familiar

before attempting

b. Gasoline Valve

tank,

forward. Valve is closed

Turning

left opens valve. Valve

to

with

to

4).

operate

figure

the motorcycle. The

to

location and use of

the

vehicle.

(figs. 5 and

Contro/s

4—

Gasoline valve is

6).

turning

by

is in normal

to the

imON

AND UOHI SWttCH

.PEEDQWHEB

SEA? 3SAXf fOOI f£0*L

RA

UCHI

CADTIOH ^lATE

310201

PD

SWnCM

rider must become

control devices

all

located in left

right, finger tight.

operating position

9-879

TM

5

MOTORCYCLE, SOLO

FUEL

SUPPLY

VALVE

(HARLEY- DAVIDSON MODEL

RAPD

WLA]

310202

Figure 5—Fuel

figure

when

turned

leases emergency

Throttle. The throttle is controlled by right handle bar grip.

c-

Turning

Spark, Spark is

d.

grip inward advances spark,

Qutch

e.

pedal, connecting

Pedal is

downward (toe)

(heel) position of pedal disengages clutch.

friction

to left, with

inward opens

grip

(fig,

located

device to

supply

with

on

position

retain it in

Fuel

6—

valve

of fuel

throttle,

controlled by

turning

7). Clutch is operated

steel cable, which actuates clutch release lever.

left side

of motorcycle above footboard.

of pedal engages clutch. Rear downward

either engaged or disengaged position.

Suppiy

Supply

head

quarts).

(3

turning it outward closes throttle.

it

Valve

Vaive Poslflons

down. Lifting valve

left

handle bar grip.

outward retards

left foot Crocker-type)

by

Foot pedal provided with

10

head re-

Turning

spark.

Forward

PEDAL

CLUTCH

ENGAGED POSITION

CONTROLS AND OPERATION

CLUTCHPEDAL

OlSeNGAGEO

PCS1^0^

9-879

TM

5

-

'^^

*'*

^"""

1—LOW GEAR

N—NEUTRAL

2—SECOt^D

3—HIGH

Figure 7—C/ufeh

Pec/o/

Postiions

-RAPD 310205

Figure 8~Gear

Shiffer Lever Positions

11

9-879

TM

5

MOTORCYCLE,

f. Service Brake

side of motorcycle

Auxiliary

g.

by hand lever located

with service brake,

while starting engine on grade. CAUTION: Brake is to

lightly and cautiously on wet and slippery roads.

Gear'Shifier (fig.

h.

SOLO (HARLEY-DAVIDSON MODEL

(Rear

forward end

at

Brake (Front Wheel). Auxiliary brake

as an

Wheel). Foot

of footboard.

on left handle bar.

emergency

8). Shifter

brake, or for holding vehicle

lever

pedal is located

is used in

It

located on

is

WLA)

on right

is operated

conjunction

applied

be

tank, for-

left

ward position, and operates within a guide. Shifter lever guide is

notched for positive location of gears and each position is identified,

front to rear: "1"—low gear; "N"—neutral; "2"—

direct high gear.

second

gear;

"3"—

CHOK6

NORMAL SUHNtNG POSiTrON

i. Steering

device to

damper turning action of forks, steady front

prevent wobble in

top of steering head

to apply desired friction,

Foot Starter

j.

right side

on

position, and clutch

DOWN

Figure

9—Carburetor Choke

Damper. Steering damper

rough terrain or at high

in center of handle bars.

Crank (fig,

of motorcycle.

foot pedal in forward engaged position,

using foot starter crank.

tion. Straddle motorcycle,

IN CHOKED

LEVER

Lever

Positions

adjustable

is an

speeds, and

Move

The foot starter crank

1).

Gear shifter

Starter crank

place right foot on starter crank, and

lever must be in

normally

is

;.RAPD31020t

TOSfFION

wheel, and

located on

is

handle to

is

in upward

friction

right

located

neutral

before

posi-

shift

weight of body for forceful downward crank operation to start engine.

k.

switch

forward

Ignition

lock, later models are nonlocking. Switch is off

position.

and

Light

Switch.

First

position to right

Earlier

models are provided with

is for engine ignition

straight-

in

only.

T2

CONTROLS AND

Second

vehicle

position,.

oil

engine

tion

the

position

service

Instrument Panel Signal Lights. Instead

1,

pressure gage, signal lights indicate

pressure.

Greer: light is located on left side of instrument panel. When

(1)

(2)

m.

running,

is

light

Red

running,

is

Carburetor Choke (fig.

when all the

down.

way

right is for ignition

to

lights,

depress button

and light is out. it indicates

located on

is

light is out,

and

way up, and

right side of instrument panel.

it

9).

in

TM 9-879

5-6

OPERATION

blackout lights.

and

to

turn switch

generator

to third right

of an

charging, and engine

generator is

indicates

Choke

engine oil is circulating.

lever

in full prime posi-

is

normal running position when all

To

ammeter

charging.

use

and

When

ENGINE PRESTARTING

6.

Before the

a.

outlined in

ice

starting

habits,

able

well as to a seasoned rider:

bars.

while

and warming-up period

b. The

and

way. The following pointers will be

Mount (straddle) motorcycle to obtain

(1)

Leave

(2)

operating

Engine starting will be benefited

(3)

operated brake,

starting kicks. This

incline or on

The procedure

c.

cold, warm, or hot engine:

Place gear

(1)

See that

(2)

Engage clutch

(3)

Spark

(4)

advanced position,

Foot starter crank

(5)

engine.

ing

kick, using

engine starting

engine is

paragraph

rider

must

learn

to do the job the quickest, easiest, and most depend-

side

stand (jif^y stand)

foot starter

to prevent

soft,

uneven surface.

shifter lever

gasoline

control

or nearly so,

See that

a

a full vigorous starter stroke

full swing

practice.

started, perform

acquire correct motorcycle

crank

especially helpful if

is

outlined below is preparatory

shut-otT

(fig.

7).

(left) grip must

may travel

(not a jab) of right leg

INSTRUCTIONS.

the Before-operation Serv-

15. Special care must

avoid unnecessary

to

helpful

firm grip on

outward

with right foot.

by use of front wheel, hand-

vehicle from rolling

vehicle is parked -on an

in

"N" (neutral) position (fig.

valve is open (fig.

turned inward

be

way downward

^

13

be taken during

engine

wear.

engine starting

to the

beginner

handle

to support vehicle

shifting

or

starting either

to

5).

is used. A

and hip, is

during

8).

to fully

before start-

vigorous

correct

as

9-879

TM

7

MOTORCYCLE, SOLO

STARTING THE

7.

a. Procedure

differs.

6

for

Therefore,

to cover

b. Siartina;

correct procedure

some time,

for starting cold.

following instructions are used with paragraph

Cold Engine. When vehicle has not been operated

and

engine is

[HARLEY-DAVIDSON

ENGINE.

warm, or hot motorcycle engines

all three cases.

in

normally cold, follow progressive pro-

cedure for easiest starting.

Set carburetor

(1)

Open throttle wide by turning right

(2)

will go.

Prime cylinders by

(3)

strokes.

Set carburetor choke lever in

(4)

weather starting:

choke lever in full upward (closed) position.

operating

closed (or leave fully choked) for extremely

y^,

^

foot

to

weather starting. CAUTION: It is only in

(hat engine

have

will

started.

is

(5)

(6)

(7)

(8)

may start best

n:ioved from

to be

Set throttle (right) grip to slightly open position.

ignition

Turn

Start engine v/ith

When engine starts,

warming up. or until

engine

ture,

oughly warmed up,

position.

when

carburetor choking

closed).

open

unnecessarily.

After engine

(9)

gradually move choke

Starting Warm

c.

halfway between hot

Lift choke

(1)

Set throttle (right) grip

(2)

Operate foot

(3)

Set

(4) (5)

(6)

(7)

(8)

throttle

Turn

ignition switch

Start

engine

Soon

after

(downward)

Turn throttle

engine

position.

switch

vigorous

ready to

warms up.

move

Engine.

must be

to first upward

lever

starter crank one

grip to

with vigorous

starts, choke

grip to control

choke

with

this

first right position.

on,

throttle

set

and

lever downward. After engine has

fuIJy dosed,

position immediately

strokes of foot starter crank.

for moderate idling

vehicle in motion. Do not

misfires due

choke lever

Following

cold.

and

With engine in this

handled cautiously.

fully

to

between

on.

closed

two strokes.

or

and

^

strokes of foot starter

lever

idling

14

MODEL

grip inward

starter

J/^

crank one

closed position for

extremely

WLA)

as far

cold

and even then it

alter

overrich mix-

to an

fully

to

instructions apply to

position from normal

(outward) position.

open

Y^

must

speed

of

(downward)

open

condition,

position.

crank.

be moved to

engine.

as

or two

nnild

cold

weather

engine

speed for

race

thor-

engine

(^

fully

it

CONTROLS AND

Starling Hot Engine. If engine

d.

period and is near

brief

to use carburetor choke lever. With some engines,

;sry

carburetor condition

uoon

dependable if foot

—ore

r-ming

strokes

Viooded)

i-ide

itarts.

iTig

£.

generator (green) signal

tr.gine

-jmp.

acteristics of both

r.rcuit

ignition

Close

(1)

Turn

(2)

Operate

(3)

When

(4)

of the foot starter crank, it

condition, and

so that more air can enter: close throttle

CAUTION:

temperature, do not

] -minute interval.

Starting Engine with

e.

Behavior

f.

oil pressure (red)

Rider

and pressure in engine

When

(1)

preparatory to

shoujld

=::er light

oil

cold

both

signal

brought

go

engine has been primed

not light at once,

may

pressure built up by cranking, and

weather.

'2)

With

signal lights

light

to

slow

At

(3)

road speed

and

on

.~.ash

low

very

'.ight

^snerator ts either

:o

and unsteady.

fail to

normal, and

switch on.

throttle grip by turning fully outward.

ignition

foot

hot

of Instrument

must, therefore,

signal

ignition light switch is turned

starting engine, both

on, CAUTION

engine started and running

should

to

fail

attention of unit mechanic.

idle speed,

(in

high gear), generator

off, because

go off

not charging

generator should

normal operating

adjustment,

and

starter

switch

starter crank to start

on.

engine does not start readily after two

proper procedure then

the

Alter

engine has warmed up to a norma!

engine

allow

Dead Battery. See

depends

light

signal light depends upon action of oil feed

thoroughly

lights to judge

oil circulating system,

When

:

by

but will light after

go off, CAUTION: Should

go off

speeds above

at

under

or

at that speed

CAUTION:

at

speed above

at all,

be given attention at once.

15

OPERATION

has been shut off for

temperature, it is not

hot starting is easier

crank

Panel

switch

cranking,

approximately

(green)

approximately 20 miles

operated

is

engine.

usually due

is

one stroke

to an

is to

quickly

to stand

Idling

lor

paragraph

Signal Lights.

upon

action

cut-out relay;

of

understand operating char-

condition

of generator-battery

first

to

(right)

green and red signal lights

turned on, immediately

!S

red (oil pressure) signal

few seconds, due to

a

is most likely to be noticed in

at medium idling

pressure (red)

oil

idling, conditions must

20 miles

signal light will

generator voltage

Should generator (green)

or its current

output is not

TM 9-879

7

only a

neces-

depending

and

before

or three

overrich

open throttle

after engine

operat-

longer than

12.

Function

per hour

normally

output

per

of

position,

speed,

be

is

signal

hour,

up

9-879

TM

8-10

MOTORCYCLE, SOLO

(HARLEY- DAVIDSON MODEL

WLA)

STOPPING

8.

Stop engine only by

a.

(straight-ahead) position,

coil primary circuit.

spark

OPERATION OF VEHICLE.

9.

a. Starting on Level Ground.

up and

in riding

of

of left foot.

to maintain engine

checked for

position)

Transfer

(1)

Fold back side stand (jiffy

(,2)

Disengage clutch by depressing clutch

(3)

foot.

left

Shift gear shifter lever into

(4)

Slowly

(5)

When

(6)

Accelerate gradually to between 12 and 15 miles per

(7)

THE ENGINE.

turning ignition

to prevent discharge of battery through

The engine having been

satisfactory operation, the vehicle (with operator

is

body

engage

clutch starts to "take hold," open

speed.

motion as follows;

put in

weight to

clutch

by

right

leg.

stand).

"1"

depressing clutch foot pedal with toe

low gear.

Close throttle quickly.

(S)

Disengage clutch.

(9)

through

Shift

(10)

Reengage clutch and

(11)

Close throttle quickly.

(12)

Disengage clutch.

(13)

Shift into

(14)

Reengage

(15)

Starting

b.

If standing on

(1)

engine

pressure on front brake hand

vehicle starts in forward motion.

power

It may

(2)

Open throttle

(3)

"3"

clutch

on Uneven or Soft Ground.

will be required

necessary to

be

(neutral)

"N"

accelerate

(high) gear.

and accelerate

incline or in

an

to start vehicle without stalling engine.

keep vehicle

lever. Brake pressure

and engage

position

clutch

power needed for starting, without racing

(4)

cation

Motorcycle starts should

power, with

of

consequent unnecessary spinning of rear wheel.

be made without excessive appli-

and light switch to

foot pedal with heel

(low) gear

to about 25 miles per

desired

to

loose,

from

at

engine unnecessarily.

position.

throttle sufficiently

"2"

into

(second) gear.

speed.

heavy ground, more

rolling by keeping

released after

is

same

time to

warmed

hour

hour.

provide

off

in

10.

DRIVING PRECAUTIONS.

a. Practice will enable

TT^otorcyele

should be moving before he

a

rider

16

to

judge

what

at

shifts from

rate of

a lower to htfher

speed

the

TM 9-879

10-

11

CONTROLS

gear, and engine should a shift of gears, higher to

Operator

(1)

gears, but keep his eyes

must not

The operator's foot should rest on clutch foot pedal only when he is

operating it. When shifting

gear damage and shifting

missions are ruined through failure to disengage

shifting gears.

1). Braking. Rear wheel service brake must be in such condition

that medium-hard

tion of service brake should

application

accomplish desired result.

Auxiliary

(1)

service brake,

or slippery roads.

After

(2)

and the

vehicle operated for

been generated

.Avoid Low

c.

gear

possible, consistent with tactical situation, speed required, power

required, and kind

heating of engine.

d. Hiirh

high-speed riding.

front wheel brake, when used in conjunction

must be applied with caution, especially on

passing through water, the brakes should be set slightly,

dry the brakes.

to

Gear

Speed Tips. Only experienced riders should indulge in

A

speed must be given closer than ordinary attention to avoid serious

engine overheating with consequent

service,

instant when

to piston and cylinder and assists

warmed

parts before oil is

apply the following suggestions:

Develop habit of frequently snapping throttle shut for an

(1)

running at high speed.

(2)

In cool

up.

weather, operate engine slowly until

to

avoid, damage to pistons, rings, cylinders, and other

warm enough to circulate freely.

(3)

If handle

bar

more likely to overheat with

this carefully.

Adjust "steering

(4)

sistent

with

riding

speed and condition and nature of road.

never be permitted to labor

lower, would

look down at gear shifter

on the road ahead. Do

gears, disengage

difficulties. CAUTION:

will cause rear wheel

be

short distance,

a

Operation. Always

nature of

and

motorcycle operated for long distances at high

windshield

continued high-speed riding.

damper" for best control of motorcycle con-

OPERATION

AND

unduly,

improve operation.

when

shifting

not ride the clutch.

clutch fully to avoid

Many trans-

clutch fully when

lock. Applica-

to

gradual, with just enough force tc

wet, muddy,

sufficient heat has

until

road

damage.

This

in cooling

and leg

operate

substance,

vehicle

prevent over-

to

For better motorcycle

draws additional

engine.

it is

shields

are used, engine is

highest

in

lubrication

thoroughly

Watch

when

with

11. STOPPING

a. Stopping Vehicle. Rider

quicker

vehicle:

if he will

AND PARKING VEHICLE.

apply the following instructions upon stopping

will make a "restart"

17

easier and

9-879

TM

n-T2

MOTORCYCLE,

Close

(1)

Disengage

(2)

Apply

(3)

tire.

Just

(4)

position

tral)

be made,

to

remain in

with engine

Continue

(5)

After vehicle slows to

(6)

steering,

by

can be

foot

idle engine

Stop engine by turning ignition

(7)

Parking \'ehicle,

b.

Lean motorcycle on side

(1)

Shift

(2)

Engage clutch so

(3)

Shut

(4)

against its

tight

(HARLEY-

brakes) to slow

complete stop, shift

CAUTION: //

"!"

(low) gear

throttle.

brake (or

before

and

shift

into

SOLO

clutch.

coming to a

engage clutch.

disengaged position. (Rider

running.)

brake application to

point where it can no

place left foot on ground

removed from brake

lon£er than I minute.

"'1"

into

off gasoline supply by

(low)

vehicle cannot roll.

seat.

operating pedal.

(jiffy) stand.

gear.

DAVIDSON

vehicle without sliding

MODEL WLA)

rear

into "N" (neu-

immediate restart

and allow

will

be

ciurch foor pedal to

motorcycle

mounted

on

complete stop.

balanced

be

to maintain

longer

balance until righr

CAUTION: Do nor

switch ofT.

turning valve (to right) finger-

is

TOWING VEHICLE TO START ENGINE.

12.

In emergencies

a.

crank, it can

(!)

(2)

(3)

(4)

(5)

10 and 15 miles per hour,

engine starts.

Engine Starting with

b.

ing

with

charged battery,

battery

(1)

of

motorcycle.

(2)

(3)

re prevent

be started by towing the motorcycle.

Set gear

shifter lever

Disengage clutch.

Choke carburetor.

Turn ignition

After

momentum of

dead

be towed

is to

Disconnect

Tow

motorcycle

After engine

switch on.

battery

by

or

battery negative

is

damage to

when engine

engage clutch, and continue procedure untiJ

can

towing

for engine starting,

for engine

started, reconnect

electrical system.

cannot be started with foot starter

"2"

in

towed motorcycle reaches between

the

Dead Battery.

effected by

be

outlined

as

starting.

18

(second) gear position.

Emergency engine start-

making use

above. If vehicle

proceed

wire from ground on

battery ground wire

follows:

as

freshly

of

dead

with

right side

frame

to

CONTROLS AND OPERATION

RUNNING-IN

}3.

new motorcycle engine

a. A

proper

given

of service. Failure to do this

miles

1.200

will put

engine out of active service within

h. At

the

make sure they are

necessary, have chain oilers

cation.

Drive chains must be mspected

attention by

front and

in

needs to be

tightened.

sion

screws,

engine or newly overhauled

as

If

unit mechanic as

At ftrst 500 miles, drain

c.

rear

Maintenance Operation section.

<]. After a

thoroughly checked over

Particular

mounting bolts and nuts, and

Following

e.

not

Do

(1)

Do not exceed 35 miles per hour

(2)

Do not exceed 40 miles

(3)

not

Do

(4)

Avoid use of low

(5)

possible.

-NEW ENGfNE

"break-in"

first

chains (step h above). Thereafter, follow instructions

new

pointers must be observed

exceed 30 miles per

<;xceed

consideration for

250 miles, check front

receiving required

motorcycle

attention must

engine:

miles per hour

50

gears

(OR

VEH\C.LE).

or newly overhauled

least the

at

may

short period

a

and

amount

for

correct adjustment, and be given

of

adjusted

engine must be

result in damage

rear drive chains to

oil for

unit mechanic.

by

needed.

oU tank and refill

has

been run

with

fresh oil. Check

500 to

and any loose screws and nuts

given engine

be

rear wheel

to

during

hour

during next

per hour during

during next 500

during

break-in operation

when

first

mounting socket

running-in

100

200 miles.

400

9-879

TM

13

1.000 to

first

that

time,

of

ample lubri-

1.000 miles it

new-

miles.

miles. miles.

as much

19

9-879

TM

14

MOTORCYCLE, SOLO [HARLEY- DAVIDSON

Section IV

MODEL

WLA)

FIRST

ECHELON PREVENTIVE

MAINTENANCE SERVICES

Paragraph

Purpose

Before-operation service 15

During-operation

service

At-halt service 17

After-operation and weekly service IS

PURPOSE.

J4.

a. To insure mechanical efficiency it

systematically

be

weekly, so that

result in serious damage or failure.

services will

set forth

operation, during operation, at

h. Driver preventive

of "Driver's

in

W.D. Form

peculiar to specific vehicles,

covered

related.

vehicl'' involved

the manual. Every

in performing

whether or not they are

c. The items

vehicle

for

are arranged

driver,

on

those

(1.

porting

whether

or

(1) The

Visual

safe

further

in manual procedures

Certain items listed

are expanded in

accomplishment

and are not necessarily in the same numerical

W.D.

Form

shown

The general

member

the

excessively

inspection

or

serviceable

by

the

inspected

defects may be

performed

be

this

section are those

intervals each day it is

at

discovered and corrected before they

at these

halt,

maintenance

Trip Ticket and Preventive

No. 48, to cover vehicles of

not listed on

but

under

on the

are eliminated

organization

the maintenance procedures

listed

listed on W,D. Form

this manual

of the inspections and services. These

facilitate

to

No.

48. The

from

must

specifically on W.D,

inspection

numbers, however,

item

on that form,

mspection

or connection, and generally, includes

item is in good

of each

condition, correctly assembled,

worn.

for "good condition"

to

determine whether the

limits.

following:

The term "good condition"

not

bent or

performed by driver or

is necessary that

the vehicle

operated

Certain scheduled maintenance

designated

after operation, and weekly.

services are listed

intervals. The services

crew

before

on the back

Maintenance Service Record."

ail

the items to which they are

form that

procedures

the

thoroughly school

and

types

models. Items

W.D. Form No.

do not pertain to the

as written into

each

forth

set

in manuals,

48. are

driver

Form No. 48.

No, 48

to provide

and conserve

item applies

twisted, not

that apply

specific procedures

the time

order as shown

are identical with

also to any

a check

is usually

unit is damaged

chafed

an external

is

or burned,

to this

services

of the

to see

secure,

beyond

explained

20

14

16

and

sup-

FIRST ECHELON PREVENTIVE MAINTENANCE

broken or

not

torn or cut.

not

The

(2)

usually an

is

normal

usually

assembled position in the vehicle.

The inspection of a unit to determine

(3)

an

check for

washers, lock

lock

"Excessively worn" will

(4)

to, or beyond, serviceable limits,

replaced before

Any defects

e.

the scope of

opportunity to

BEFORE-OPERATION SERVICE.

13.

This inspection schedule is designed primarily

a.

vehicle

the

that

After-operation

have rendered

may

of the driver

duty

to

dition

will not be entirely

Procedures. Before-operation Service consists

b.

listed below

items

or reporting

ing

results

authority.

vehicle in general,

should be reported promptly

Item 1.

(1)

cracked,

inspection of a

external visual

external visual examination, a hand-feel, or a

looseness.

the next

first

echelon to correct must be reported at the

the designated individual in authority.

has not

Service

carry

out

any

Tampering

caused by tampering,

parking

since

loose

(2)

fuel or oil

Item 3.

vehicle. Look

lines, or any disconnected

Fuel

not bare or frayed, not dented

unit

to see that it is "correctly assembled"

inspection to see

whether it

if it is

Such an inspection should include any

locking

nuts,

scheduled

or unsatisfactory operating characteristics

wires, or cotter

understood

be

and likely to

inspection.

pins

to

result

been tampered with, or sabotaged since the

was performed. Various

vehicle

the

determine whether

to

mission

any

omitted,

according to

deficiencies.

unsafe

to which it is

even

in extreme

the

and

its accessories or equipment, that may

sabotage, collision,

for

loosened or damaged

and Oil.

Inspect

for operation and it

or

procedure

Upon completion of

to the designated

Damage.

falling

linkage.

tanks for

combat

not

the vehicle is

assigned. This operation

tactical

described,

Look for any

debris, or

fuel

add oil -and fuel as necessary. Any appreciable change

performing After-operation Service

ported to designated authority.

Item

(3)

such as carburetor,

connections,

drive) for free

sprockets. Total

inch, nor less

cation.

4. Accessories and

cleaner,

loose

air

mountings,

generator, and cut-out relay for loose

or leaks. Examine rear chain (final

up-and-down movement (slack), midway between

up-and-down

than

^4

inch. Inspect rear chain

movement

should be

Drives. Examine all

investigated and

must

not be more

for

21

TM 9-879

SERVICES

or collapsed,

"secure"

brackets.

used in

mean

in a

as a

situations.

assembly.

worn

failure if not

check to see

conditions

inspecting

of

and correct-

the service,

individual in

injury

have

shell

accessories,

and oil levels,

levels

in

accessories

adequate

14-15

is

in

pry-bar

close

beyond

earliest

is.

the

in con-

been

fire

since

re-

than

lubri-

its

is

to

I

9-879

TM

15

MOTORCYCLE, SOLO

Item 6.

(4)

vehicle for

oil from chains

waste

Item U,

(5)

view mirror; inspect

rear

Item 12.

(6)

blackout and

tions, and go

and that

lenses are clean

ments of service headlight operate when dimmer

bar

moved to its respective

is

Item 13, Wheels, Axle

(7)

Leaks,

indications

Glass.

Lamps,

service

out

when switched

(HARLEY- DAVIDSON MODEL WLA)

General.

of fuel

may be

Clean

glass for breakage.

If tactical

lights operate

and not

Examine vehicle and ground

or oil leaks. Normally

expected to drop from skid plate.

glass on instruments: clean and adjust

situation

with

off. Also

broken. Observe whether both fila-

positions.

permits,

switch in

see that

switch on left

Nuts and Screws.

wheel mounting socket screws, front and rear axle

fork rocker

screws for

tightness.

CS)

in treads

be 18 pounds front, and 20

caps for

(9)

springs for secure mounting

saddle to test

(10)

ing head

bar grips, and observing

in bearing.

is compressed before

released with lever in

for full, free action;

throttle, and full advance and retard of timer.

(11)

Safety Guards, and

tion and secure

(12)

ment for presence,

in par.

(13)

dency toward hard

throttie to

Set

instrument indications

CAUTION:

stud nuts

secure

for tightness. Observe

locking. Inspect

Item 14. Tires. Examine tires

or carcass.

time permits, check

If

pounds rear

presence and

Item

15,

for full

Item 16, Steering

bearing

Operate

Item

21, Tools

21.)

Item

7,

moderate

Do

secure mounting,

Springs and

action of saddle

Suspension. Examine front fork

good condition. Push down rear of

and

and Handle Bar Controls. Test steer-

adjustment by

steering damper lever

lever

left-side

also test

Fenders (Mudguards), Luggage Carrier,

17,

Stands.

mounting.

serviceability, and

exerting strong

whether

or not

reaches right-side

position.

for

complete

Examine

Equipment.

and

Engine Warm-up.

starting, or improper

idle speed. Listen

engine

and

not

idle engine longer

spokes

for

post

there is

Test handle bar

these items

proper stowage. (See

Start

action of foot starter

performance, such as misfiring.

than

rear chain adjusting

for

cuts or

pressure, which should

air

cold). Inspect valve

(tires

spring.

upward puil at handle

observe that

and

position, and is

opening and closihg of

Inspect tools and equip-

engine,

unusual noises. Watch

for

minute with

1

under

few drops of

a

observe

its respective

lights are secure,

whether

posi-

handle

Examine

nuts, and front

rear

good condition and

imbedded objects

any noticeable play

damper

fully

grip controls

for good condi-

tool list

noting any ten-

crank.

vehicle

32

FIRST ECHELON

Item

(14)

required

(15)

idling at moderate

is

and green

operating speeds

not operate engine with

Do

(16)

(17)

Accelerate and

indicate compression or exhaust leaks, worn, damaged,

inadequately

smoke

26,

and

ation

In

16.

knocks, squeals, or

detect any

brakes,

or

from exhaust.

Item

(18)

AND Vehicle Ma.nual,. These items must

safely

Item

(19)

Service should

nature

the

DURING-OPERATION SERVICE.

While vehicle

a.

or clutch,

other signs of trouble.

vehicle turned,

unusual performance. Watch

promptly any

trouble in system to which the instrument applies.

Procedures. During-operation Service consists of observing

b.

items listed

8,

to prevent excessive choking and dilution

Item

9,

light (indicating generator action) should

Item

10,

Item

22, Engine

decelerate, listening for any unusual noises that

lubricated

23,

stowed.

25, During-operatiOn Service, The

of

a

odor

o( overheated components

unusual

below

PREVENTIVE MAINTENANCE SERVICES

Choke, During idling of engine, reset

of

engine oil.

Instruments. When switch is turned on and engine

speed both red light (indicating oil

be

generator-indicating

red

li^ht on

light may flicker.

(no

pressure).

oil

Horn. Tactical situation permitting, test

Operation. Engine should idle

engine parts, or

accessories.

Note

Drivek's Permit, Accident Report

present on

be

start immediately after vehicle is put in

road test,

is in motion, listen for any sounds such as rattles,

hums

fuel vapor from a leak in fuel system, exhaust gas,

that

may indicate trouble. Be

units

or

such as

Any time the brakes are used, gears shifted,

consider this

instrument indication that may signify possible

according

test and notice any unsatisfactory

a

the instruments constantly.

to the procedures

following

and investigating any indications of serious trouble.

denciencies

(0

operate

inch. Normal

:

lever

ease

for

(2)

pedal

J4

(3)

quietly, and not

to be corrected or reported

scheduled

Item

smoothly

for free

and

Item

travel.

Item

halt.

27, Foot and

and effectively, leaving

free

play

play,

which should be 14

smoothness

28, Clutch. Inspect

Clutch should not chatter,

29, Transmission.

jump

out of mesh during

Hand

before operation

operation.

of

Brakes.

clutch

Gears should shift smoothly,

earliest

at

opportunity,

The foot

reserve pedal

1 inch.

is

of total handle travel.

disengagement

for

squeal, or

operation.

Test

slip.

If

23

9-879

TM

15-16

choke

pressure)

At: lower

out.

CAUTION:

horn.

smoothly.

may

loose,

any unusual

Form No,

vehicle

During-oper-

motion.

alert to

generator,

Notice

each item,

Notice

brake should

minor

usually

travel

brake

hand

Test

about

at

operate

transmission

as

or

of

9-879

TM

16-17

MOTORCYCLE, SOLO

jumps out of

mesh in any gear, this indicates need of shifter

{HARLEY-

DAVIDSON MODEL WLA)

adjustment.

Item

(4)

engine performance such as

noise, stalling,

smoke.

Notice whether engine responds to controls satisfactorily,

Engine and Controls.

31,

indication of engine overheating, or unusual

lack of

Be alert for

usual power,

deficiency in

misfiring, unusual

whether controls appear to be m proper adjustment and are

ciently tight.

Item

(5)

of normal functioning

(a) Speedometer

vehicle

record trip and total mileage.

operation. If light goes on,

failure.

miles

ing friction. Observe vehicle

speed without

(b)

Oil

(c) Generator Signal Light. Green

per hour. Battery discharge is indicated

Item 33, Steering. Adjust steering

(6)

Instrltments. Observe

32,

of systems to

Odometer.

and

excessive noise

Pressure

Signal Light. Red light should be off during

stop

vehicle

steering

instruments

for indication

which they apply.

Speedometer should indicate

fluctuation. Odometer shoul^d

or

and investigate for oil

light should be off

green light being on.

by

damper to desired

for

wander, shimmy, leading to

one side, or wheel hop.

(7)

wheels,

Item 34, Running Gear. Listen

or

axles,

suspension parts that

for any unusual noises

might indicate

looseness or

damage.

Item

(8)

accessories,

Chassis. Be alert for noises

35,

controls, attachments,

that might indicate loose

or equipment.

conCroi

exhaust

sufn-

pressure

above

steer-

from

20

17.

AT-HALT SERVICE.

a.

At-halt Service

procedures

even

or omitted

b.

ficiencies

ing

to

cies

found.

to

the

CI)

required

fuel;

right

only

fuel

(2)

drums

and

though

altogether.

Procedures.

noted

the procedures

Deficiencies

designated

Item

38. Fuel and Oil.

to

reach

tank is for

tank

Item

39, Temperatures.

for

overheating.

may be regarded

should be performed

more extensive

At-halt Service

during

operation, inspecting items listed beiow

followmg

individual

next refilling

oil. Filler

cap is

vented.

maintenance services must

not

corrected should

in authority.

as minimum

under all tactical

the

consists

items,

investigating

of

and correcting

reported promptly

be

Replenish fuel and

point. CAUTION:

caps

should not be interchanged, as

Hand-feel

Left tank is

wheel hubs

24

maintenance

conditions,

slighted

be

any de-

accord-

deficien-

any

oil

may be

as

and

for

brake

ECHELON

RRST

'5)

Item 40,

oil feed

chain

rear

:r.-

and

zrov.t

(-i)

Item 42, Springs

fork.

tc

Item 43,

;3)

—

riding.

g

Item 44,

(6)

broken,

for

wheel

7tBr

:'7)

Item

Jlemovc

Item

(S)

oil, or

fuel,

Item 47,

(9)

connections, loose

".cose

for

dnain

jxinnecting

(10)

-=ssages

—emely

jtrvice as

Safety

dusty or sandy

(LI)

Guaj^ds,

brake side

rear

Steering.

bent, or

mounting

45,

foreign matter

46,

battery

broken rollers, broken

link spring clips.

Item

48,

in good

required.

Item 49,

iamage.

Item 52, Appearance and

;i2)

mirror, and light lenses;

-.-.ew

£"achment,

and broken

PREVENTIVE

Vents. Make

are clear. Make sure grease

pipe

covers

and

Investigate any

Wheels and

spokes. Also, look

loose

screws. Inspect

Tires.

Leaks,

Accessories ajjd

Examine tires for low pressure or damage.

tire treads; inspect

from

General. Inspect vehicle for

leaks.

MAINTENANCE SERVICES

that

sure

are open

Suspensions.

MotjNTrNG

and clean.

wheel

Chain.

mountings, or damage. Examine rear

link side

plates, and broken, or

Inspect chain for adequate lubrication.

Cleaner. Air cleaner must

Air

condition

Fenders

and clean. When operating

conditions,

inspect

air cleaner frequently and

(Mudguards),

and Stands. Inspect these

Glass.

inspect for

glass.

9-879

TM

17-18

crankcase breather outlet

drains

Look for broken springs

difficulty

Screws,

for

rims for good

Examine accessories

developed dur-

Inspect wheels

loose axle nuts

condihon.

for cuts.

indication of

for

drive

missmg

secure, with air

be

ex-

Carrier,

or

Luggage

for looseness

items

Clean

good

windshield, rear

condition, secure

under

in

or

AFTER-OPERATION AND

18.

After-operation Service is

a.

time the driver inspects his

this

developed,

have

—ay

should report promptly, to

He

results of his inspection. If this schedule is

vjc

vehicle should

the

be ready

corrects' those he

and

to roll again

3efore-operation Service, with

ascertain

to

left upon completion

rt-as

operation

tactical

services outhned for the At-halt Service,

b.

driver must remember

whether

Service

situations,

Procedures.

should never be entirely

vehicle is

the

of

but may be reduced

When performing

consider

and

WEEKLY

particularly

vehicle

the designated

few

a

exceptions,

in the same

the After

any irregularities noticed during

25

SERVICE.

important,

to detect

any deficiencies that

is permitted

individual in authority,

performed thoroughly,

on

a moment's

is then necessary

condition in which it

-operation Service. The .After-

omitted, even in

to

the bare

if necessary.

the After-operation

because

handle.

to

notice. The

only

extreme

fundamental

Service,

at

the

9-879

TM

18

MOTORCYCLE, SOLO

the day in the Before

ices. The

the

are marked with an the procedures for which are indicated in

item.

(1)

within

tank; do not

extreinely dusty

oil as

(2)

idle without stalling. Accelerate and decelerate engme, noting any

tendency to miss or backfire, unusual

indicate worn parts, loose mounting, incorrect fuel mixture, or faulty

ignition.

istics noted during operation. Learn to

loose primary

up-and-down motion

engine knock.

(3)

(4)

blackout and service lights operate with

tions,

and lenses clean and not broken. Observe

service

moved

(5)

struments

30 seconds,

signal

after this

(6)

ment,

(7)

(a) Inspect

ing.

spect

been

water

(b) Weekly.

bring

water.

After-operation Service consists of

following

Those items of the

items.

Item 54, Fuel

inch of top;besure to put oil

I

interchange caps. CAUTION; When operazini under

conditions, drain

frequently

Item

55,

Investigate

excessive contamination

as

Engine

(front)

Remove

Item

57, Horn. If tactical situation permits, test horn.

Item

59, Lights.

and go

headlight operate when

to its respective positions.

Item 56,

to see that indicator

lights turn on.

test.

Item

and light glass.

Item

Inspect

for any

overfilled,

unless actually

electrolyte level

Clean terminals or

when switched off.

out

Instruments.

turn on switch

Glass. Clean rear

58,

62, *Battery.

battery carrier

electrolyte level

signs

of

poorly

Clean

(HARLEY- DAVIDSON

-operation, During-operation.,

After-operation Services

asterisk

(*)

require

additional Weekly services,

step

and Oil. Fill fuel and oil

in right

engine oil

Operation. Test for

noises, or

any unsatisfactory engine

recognize

drive chain. Slack

cause

can

inspection

If tactical situation

excessive noise

cover for examination of chain.

dimmer

Before stopping engine,

lights are

see

to

that oil pressure and generator

CAUTION: Be sure

Examine for secure

for good

(should

leakage

sealed, or damaged. CAUTION:

needed.

dirt

to

^/ig

of electrolyte indicating

from

top of battery, remove battery

inch above

posts if

corroded;

in excess of

switch in its

Also see that lights are secure,

whether both filaments

switch on

still out.

to turn

view

mirror,

mounting and breakage.

condition

s/jg

be

plates, using clean, drinkable

MODEL WLA)

and At-halt

inspecting and servicing

of

(b)

each

tanks;

tank and fuel in left

and renll with fresh

tank

the oil occurs.

of

satisfactory engine

vibration that may

operating

noise

54

which

permits, observe

respective posi-

left handle bar is

Stop engine. After

off ignition switch

windshield,

and

secure mount-

above

inch

Serv-

applicable

fill oil tank

character-

caused by

J-^ch total

sounds like

whether

inspect in-

instru-

plates).

battery has

Do not add

caps,

sure

be

felt washers are

that

In-

26

of

FIRST

terminals

on

loose. Clean

::

<8)

(a)

loose connections, mountings, or damage.

:or

chain

missing

free

for

maximum

(b)

excess

inspect

(9)

(a)

cleaner is

cup with fresh oil. Dip elements in oil in oil cup, replacing

refill

ments

replace.

to clean

sary

for leaks.

hose

(b)

sively

clamps. NOTE: Early-type, round

hose

removable

ECHELON PREVENTIVE MAINTENANCE SERVICES

and

properly oiled;

and

Item

Inspect carburetor,

for broken rollers, broken

*Accessories and Chain.

63,

battery carrier if

paint

air

connecting link spring clips. Examine rear

up-and-down movement (slack) midway between

total allowable deflection

Weekly. Tighten any accessory connections found loose, Wipe

dirt from rear chain. Check

for proper lubrication.

Item

*AiR Cleaner.

65,

Examine oil cup for excessive dirt and correct

excessively

and

attaching oil cup immediately. If gaskets

dirty, clean

Under extremely dusty or sandy conditions

and refill the air cleaner more than once

Weekly. Inspect

dirry oil. Clean and service air

Alter elements.

air cleaner for proper

Complete cleaner

tighten terminal

corroded.

cleaner, generator, and cut-out relay

Examine

link

side plates, and broken or

1 inch, minimum,

is

chain for adjustment, and

front

elements

in dry-cleaning

oil

cleaner, tighten mounting and

air cleaner does not have

must be

element.

Item

(10)

Clean cap

(a)

Weekly. Clean

(b)

bowl drain plug, and drain off

careful to avoid

being

(U) Item

controls

lack of

tire treads. Inspect

also

front, 20 pounds rear,

studs, and

lubrication.

(12)

(a) Remove foreign

for presence

(b) Weekly.

(13)

(a) Inspect

66, *Fuel Filter

and screen of fuel

cap and

cross threading.

67, Engine Controls. Examine

damage

for

Item

to wires

68, *Tires.

matter

tires for abnormal

and

tightness

with tires

Replace

Item

69, *Springs

front

fork for broken

nuts.

screen

water

or for disconnected

such

valve

of

cool.

badly

worn

and Suspension.

(Gasoline Strainer).

filter.

fuel filter, remove carburetor

of

and dirt. Be

as nails, glass,

tread

caps. Inflate tires

otherwise

or

or sagged

sure to

throttle

linkage. Observe for

wear, cuts, or bruises:

unserviceable tires.

springs, loose bolts,

27

TM 9-879

18

bolts

cautiously,

rear drive

chain

oil

are

it may be

daily.

level and exces-

removed

replace

or

to

drive)

(final

sprockets;

inch.

^

level.

solvent,

damaged,

neces-

Inspect

to wash

spark

and

stones from

18 pounds

air

If

ele-

plug,

9-879

TM

18

MOTORCYCLE,

Weekly. Tighten wheel axle nuts and

(b)

Also tighten rear

Item 70,

(14)

SOLO [HARLEY-

wheel mounting socket screws

Steering. Inspect steering head for proper adjust-

ment of bearings. Examine steering

Item

(15)

(a) Make sure

supply pipe are

side covers are open and

*Vents,

72,

that crankcase breather outlet and rear chain oil

clear.

Make sure

clean.

DAVIDSON MODEL WLA)

rear

very

damper

grease

drains in

correct adjustment.

for

front and rear brake

(b) Weekly. Clean crankcase breather outlet, rear chain oil

pipe, and grease

Item

(16)

beneath' vehicle for indication

around brake drums for

Normally

(17)

with

to

level of filler plug

^ear oil.

(18)

Safety

tion

(19)

a few drops

Item

vehicle standmg

Item

Guards, and Stands. Examine

secure

and

Item

(a) Inspect

tightness.

(b) Weekly.

Driver is cautioned

about the

(20)

(a)

cation; wipe

circuit

Item

Lubricate all

drains

in front and rear brake

Leaks,

73.

evidence of

of oil

Gear Oil Levels. Inspect transmission

74,

on rear stand

opening

Fenders

76,

mounting.

82. *Tighten.

frame

all

and

Tighten all

not

to

breaker,

*Lubricate

83,

all dirt from

as doing so may

parts

General.

of fuel, oil, and

may

Look

grease

expected

be

(not jiffy

with engine

(Mudguards), Luggage Carrier,

assembly nuts, bolts, and

vehicle assembly

tamper with

as Needed.

where

inspection

fittings before applying

side covers.

around

grease

drums

in

drip from skid plate.

to

stand) ; refill, if required,

oil. CAUTION: Do no:

these items for good condi-

mounting

or

or tighten screws

disturb ignition timing.

reveals

lubricant. Report

any missing fittings.

(b) Weekly. When

of

miles so that it is

cate according

tion

directives. Refrain

brake

side cover bushing,

to Lubrication

camshafts.

Item

(21)

(a)

(b)

Do

not

ir.

a

stream, care

be£r:r.gs.

Clean

Weekly

rub lustreless

84, *Clean Engine

dirt and

breather

Wash vehicle

should

due for a

pamt

valve,

vehicle

from

and front

trash

enough

be taken

or brakes.

has been

regularly scheduled

Guide

overlubricating

driven a sufficient number

manual

in

and rear brake

and Vehicle.

from

vehicle

if possible. If

to

that

cause

water

and remove

not.

shine- If

or

CAUTION:

lubrication, lubri-

and current

wheel bearings, front

wipe

vehicle

dirt

does not

It is extremely

28

brake sleeve nut.

securely,

supply

mechanism

leaks.

or

screws

cap

need

operating lever

excess

off thoroughly.

is

and

Examine

on linings.

level

oil

use

for

nuts.

nuts

or

for lubri-

lubrica-

grease.

washed

get into

im-

ECHELON PREVENTIVE MAINTENANCE

FIRST

rvrrranf

against

;>an.

=r.G

L.-:e!ding, and condensers

C'esn as

shielding or bonding defects, except cleaning

referred

present,

-.-ehicie stowage list

:cois for

serviceable items to

that hi

^h- pressure

wheel hubs, brakes,

(22) 'a)

''b)

Item 64,

Inspect all

not damaged.

and

Weekly.

"Electrical

ignition

Inspect

supported, that insulation is not cracked

required.

to signal corps

Item

(23)

'a) See

in good condition,

Weekly.

''b)

good

that

Tighten any

85, *Tools

all tools

Check

(par.

condition

designated

streams or steam should not

carburetor,

air cleaner, or

Wiring.

wiring to see that it is securely

wiring to see that

all

good condition and

are in

loose connections

personnel.

Equipment.

and

equipment

and

properly

and

tools and

21)

proper stowage.

and

to see that

authority.

stowed.

equipment

9-379

TM

18

SERVICES

directed

be

electrical

units.

connected,

is

it

securely connected

or chafed, that

securely attached.

carefully. Radio

or tightening,

assigned

to

to vehicle "with

loom,

must be

vehicle are

they are present. Inspect

Report missing or un-

-

29

9-879

TM

19-20

MOTORCYCLE,

SOLO

(HARLEY- DAVIDSON MODEL

Section V

LUBRICATION

Introduction

Lubrication guide

INTRODUCTION.

19.

Lubrication

a.

termining to a

LUBRICATION

20.

a. General. Lubrication instructions

in

dated

lubricated,

be

Intervals indicated on

conditions, high speed, heat, mud, snow, rough roads,

change

items on the guide, brake, gear shifter, clutch

hinges

b.

plete assortment of lubricants called for

to meet the

use of those

consultation with responsible

in

c.

cation Guide (fig. 10). All note references in the guide

the steps below having the corresponding

(1)

operating cams

ing out of these bearings

Lubrication

a

engine oil and lubricate more frequently. In

must

Supplies. In the field

Lubrication Notes.

Brake Fittings. Exercise caution

brake efficiency.

make sure not to overlubncate

Brake

(2)

and "oiler"

at

ends of

(3)

general purpose grease, No.

zero,

use lighter grease. This

cover- Bearing outer

end

aside for access to bearing. If

specified intervals, at least

applied to hole in

TION;

mounted

control

Generator

Generator regulating brush

is an essential part of

great

extent serviceability of

GUIDE (fig.

Guide

periods

the

the guide are

lubricated

be

recommendations.

available,

subject to inspection

and frorit brake cover bushing, as excess

(fig.

of lubrication, and the

frequent intervals.

at

may not

it

will

It

ordnance personnel.

following

The

is likely

CAUTION: When using air-operated

brake fittings.

Hand

Lever Oilcan

on

cable

housing.

cable housing.

Commutator

2. at temperatures above zero.

operation requires removal

grease

outer grease retainer.

retainer must be loosened

not convenient

lubricate

preventive

10).

for

this

These specify the

10).

for normal service.

possible to supply a

be

by

be necessary to

by the

notes apply to

number:

when

onto brake lining,

to get

Po[nts. Oil hand

Oil front brake control cable

Bearing. Hand-pack with

End

with a few

Do

not

plate

must

30

maintenance, de-

parts and

materiel are

lubricant

addition to the

control linkage, and

the Lubrication

officer

lubricating

grease bearing at

to

drops of

overlubricate. CAU-

not be

WLA)

Paragraph

19

20

assemblies.

consoli-

points

to

used.

be

For extreme

dust, etc..

com-

Guide

make the best

concerned,

the Lubri-

itself are to

brake

grease work-

reducmg

grease gun,

lever fittings

Below

generator

of

swung

and

engine oil

shifted while

to

:--i.X.S CAMSHAFT

(NOTE

1)

COVER

;;j>.K£

-Z^<

-KZHT

-CSK

:.^<E

-cNERATOR

BEARING

[NOTE II

ROCKER

BRAKE

SHaCKLS

SPRINS RODS

HANDLEVER

(NOTE

2]

[NOTE

LUBRICANT

PLATE

3)

LUBRICATION

•

)NT£RVAL INTERVAL

•

LUSWCAKT

FORK SOCKER PLATE

TANK. ENGINE

TM 9-879

20

WHEEL SEARINGS

[NOTE i)

STEERING HEAD

BEARINGS

(NOTE

7)

—

DAILY

[NOTE

OIL

3)

CONTROL GRIP

^AflK

iODLEARM

i. CLEANER

POST

i-ACDLE

BEARINGS

'WEEL

(NOTE

41

—

OAILY

(NOTE

51

61

OE

—

CG —

WB

— GREASE, GENERAL PURPOSE (No.

LUBRICANTS

OIL. ENGINE (CRANK

GREASE, GENERAL

No. I (ABOVE +iT]

I OR No, (+32''TC-(-IO-)

No. No,

(3iBELOW+IO°l

CASE

PURPOSE

KEY

GRADE]

THROHLE CONTROL

GRIP

[NOTE

4)

BRAKE PEDAL SHAFT

CROSSOVER

BRAKE

SHAFT

TRANSMISSION RLLER

OPENING (NOTE

CLUTCH RELEASE

BEARING

HEAR

(NOTE

BRAKE CAMSHAFT

(NOTE II

'A

'/!

!

b

-L

2)

DRIVE

CHAIN

10)

9)

9-879

TM

20

MOTORCYCLE,

bearing

outer grease

requires no

SOLO (HARLEY- DAVIDSON

retainer

attention, since it

is loose

(par.

lubricated

is

92).

through engine.

Spark and

(4)

disassembly.

cating

and

reassemble (par.

(5)

correct

be necessary

Refill oil cup to indicated level with engine oil-

refill

oil cup every 250 miles, depending upon

Twice a

need of

Air Cleaner. Examine

level.

oil

to

Throttle

year,

lubrication,

101).

Control Grips.

whenever

or

remove grips,, clean

oil

grips do

cup daily

Under extremely dusty or sandy

clean and refill the air cleaner more than

Every 1,000 miles (oftener if necessary), remove

units, wash

76). NOTE: Early type round cleaner

element. Complete

(6)

500-mile interval,

This

amounts

four

strokes with a

operated in water, wheel hubs

immediately

lubricate

linings,

gun, it is

(7)

and lower

fork

for repair or replacement

(8)

cycle.

Empty tank holds

oil

as necessary

(dip

stick) is located directly

to

"REFILL"

oil

tank every

located

service,

(a) Winter

internal

formed

Some

of

When

getting

starting

enough

outside

oughly

in dry-cleaning solvent,

cleaner must be removed to wash

Wheel Bearings.

^

to about

1

When wheel hubs are

ounce of grease

15 shots of the standard

-pound, hand-operated

submerged, apply

afterward

(or

soon as situation permits).

wheel hub bearings, as excess grease

reducing brake

easy to

Steering

Tank,

overlubricate

Head

bearings, or whenever there

Engine Oil. Oil tank

to refill

efficiency.

wheel hub bearings,

Bearings.

(par.

1

U. S. gallon.

tank within

below tank cap. When oil

mark on gage rod.

1,000 miles and refill with fresh engine oil. Drain plug

on underside

in

and

winter

Caution. Water is

combustion

would

equal approximately

this water vapor escapes

tank in forward

of

weather,

engine. In a condensed

change oil oftener.

and warming up in

into

crankcase condenses

to exhaust

breather.

warmed

the vapor, without

If

engine is

up frequently,

driven

most of this

lubricate, and reassemble (par.

did

not

with

each

gun.

When using

Every

2 U. S. quarts may

a by-product of

the quantity

past

cold weather,

to water before crankcase

50,000

occasion to remove rigid

is

98).

is located

on

Check

1 inch

of top.

position. In

state, the

rings into the crankcase.

the

inside

condensation,

enough to get

water is

32

MODEL WLA)

Generator drive

by oil circulating

These grips require

not turn freely, indi-

psrts, apply grease,

excessive

for

conditions it may

once daily.

Drain, clean,

operating conditions.

air cleaner

have removable Slter

element:

lubricated at regular

greasing is sufficient.

1-pound

If vehicle has been

air gun, or

hub greasing service

Do

work

may

air-operated

miles, repack

right side of

daily and add engine

Oil level gage rod

combustion

of gasoline burned.

considerable

into brake

level

be added. Drain

extremely

water vapor

crankcase

again vaporized

dirt and

filter

over-

not

grease

upper

motor-

is down

dusty

in any

vapor

is hot

through

thor-

end

and

LUBRICATION

blown out through

and

driven engine, making

thoroughly

of water in oil tank.

or ice

warmed

and. if allowed

with resulting damage to engine. Also,

forms

time,

harmful

briefly, an

weather

tank to remove any

of

Transmission

(9)

mission

level up to filler

tances,

in

inspect more

straight upright

mission case. Use

winter. If gear shifting

tremely cold

cleaning solvent. Every

level of transmission

Transmission

oil.

remove

not

lubrication by engine

need

filler plug

leave motorcycle

(10)

Front

(a)

occasional

heavy

a

to bearings

engine

requires

case every

that is used

frequent oil changes along with thorough

250 miles

opening. If

same grade

weather,

holds

and lay motorcycle on right side. CAUTION: Do

Drive

Chains.

and rear drive chains are

readjustment

varied operating conditions.

conditions are

ating

chain for adequate lubrication

(b) At every

tional lubrication as

cleaning solvent

engme oil for

chain bearings.

(par.

ment of

(par.

63).

61).

(This

chain

chain oiler supply

d. Before Applying

cation fittings

Lubricate

all chassis

been operated

TION; It is

1,000-mile

and

a short

Drain

attention

oilers

CAUTION:

pipe

or plugs

in streams

extrennely

outside breather. However,

short runs now and then, and

only

likely to accumulate

up. is

water will, in freezing weather, become slush

This

to accumulate too

sludge

and other

of considerable

internal

only for

accumulated sludge.

Filler

Opening.

add engine oil as necessary to

and

motorcycle

frequently. Motorcycle must be on

position when checking

of oil used

difficulty is

oil with small

thin

1. 000 miles, dram and refill

pint of oil.

y^

longer than

opening

to

filler plug

on side

oil pumps. Chain oilers

Every 1,000

extremely

follows: Remove chain,

severe)

(fig.

period rear drive

hang it up to dry.

period of time to allow

chain and

wipe

is not required

must be made only

Inspect frequently

clear,

is

Lubricanl. Always

so that dirt will

points after washing

important

not bent or

or extremely

that high-pressure cleaning

33

9-879

TM

20

moderately

a

seldom

increasing

water

engine

caused

amount of

an

long, may

block oil lines

mixed with oil for some

content that is very

acid

parts. To sum

runs during freezing

short

Check

is run

oil level in trans-

unusually long dis-

level or

oil

in engine,

oil congealing

by

kerosene or dry-

amount

flushing

rear stand

filling

trans-

summer, and

in

transmission

with specified

drain transmission case

To

minutes.

two

grade

of engine

automatically supplied v/ith

adjustable and

are

meet lubrication requirements

(or more often if oper-

miles

inspect front primary drive

36).

chain should

wash thoroughly

soak chain

Then

oil to penetrate into all

ofT excess oil. Install rear

have

addi-

in dry-

in SAE 10

chain

by front chain.) Readjust-

organization

by

mechanic

and make sure that rear

damaged.

wipe dirt from the lubri-

not

vehicle

muddy

enter with

after vehicle

or

slushy

or

lubricant

the

roads. CAU-

streams

up

it

bring

ex-

to

may

of

has

9-879

TM

20

MOTORCYCLE^ SOLO

or steam should not be

cover bearings, air c/eaner, handle bar g'rips, or

side

do so will seriously

To

parts.

these

e. Oilcan Points. AH brake, transmission,

points not fitted with grease connections should

engine oil. Front brake control cable,

wires

must

washing vehicle,

after

battery

corrosion of connections.

'Vl'arning

f.

red

by

familiar with operating

condition

oiled

be

at

terminal felt washers saturated

Light.

signal light in instrument panel.

engine

of

oil

(HARLEY-

directed against

affect correct

the ends of their

after operating

or

Action of the

characteristics of this

circulating

DAVIDSON

lubrication and

respective

engine oil feed pump is

system (par. 7

ends

spark, and

it in

with engine

Rider must

MODEL WLA)

of ivh&el hubs, brake

electrical sysrem.

functioning of

clutch control

and

lubricated with

be

throttle control

housings, especially

wet weather. Keep

oil to prevent

indicated

be thoroughly

f).

light,

to judge

signal

34

A

Section V(

TM 9-879

TOOLS

AND

EQUIPMENT

Vehicle tools Vehicle equipment

Vehicle spare parts

Figure M—Vehicie Tools

VEHICLE

21.

Kits. Included

a.

L«oand

Lsfiar for N</mb»r

I

Fig.

1 Tool Carri

Tool roll

A

Irons, tire

B

Handle, chain cool

'C

D Wrench, y^-'m- by

Wrench.

E

Wrench.

F

Wrench.

G.

Wrench,

H

(valve tappet).

I Wrench,

Wrench,

•J

(rear 3.\'!c

*£XCEPTION:

irems marked

the

TOOLS

in the

,

H-^n.

}4-'m. by %-'m.

by Jo-in.

Iij-in.

by ^•^-in.

^•iVin.

%-in. by

adjustable. . . .

?-^-in.by l^^-in.

nut

"iViri-

, .

and

trans.)

Earlier

by asrerisk.

models furnished

(ftg.

•d Number

STOWAGE ON

II).

tool

assembly

kit

M^r'.

11819-44

IISSI-X

11817-40

11804-44C 11804-44B

1804-44

I

11804-44

11905-X

118L3-44

11814-35

35

^itb smaller

the following:

are

Fadwo) Stock

Numbar

41-1-773-75

41-H-1S10-400

41-W-19S9-850

too/

THE VEHICLE

Poragroph

PD 310208

RA

Carried

In saddle bag

In cool roll

roll

In tool

roll

In tool

roll

In tool

roll

In tool

roll

In tool

tool roll

In

roll

In tool

roll

In tool

contain

kit

and

roll

21

22

23

9-879

TM

21-23

MOTORCYCLE,

L*ganil

L«tt«r for

1 Tool

1

Fig.

SOLO {HARLEY- DAVIDSON MODEL WLA)

Numb#r Mfr't

CarTi*d Number

TOOLS AND

WINDSHIELD

NITON

AMMU

CARRIER

BOX

EQUIPMENT

REAR

STOWAGE ON

VIEW

MfSSOR

THE

TM 9-879

23

VEHICLE

SADDLEBAG

REAR

SAFETY

SADDLEBAG

FRONT SAFErr

Figure ?2—

GUARD

SHIELD

LEG

GUARD

Ve/i/c/e Equipment,

REAR VIEW

(RIGHT)

Figure 1 3-~Vehicle

MIRKOR

FRONT

SAFETY

Equipment,

37

RA

Left Side

WINDSHteiD

SCABBARD

GUARD

Right Side

RA

PD

CARRIER

PO

310216

310217

9-879

TM

23

MOTORCYCLE,

50L0 (HARLEY- DAVIDSON

MODEL

WLAJ

23. VEHICLE

Spare

a.

f

Roll, parts kit

A

Plug, spark (and

H

Link, rear chain

F

Link,

G

Lamp-unit,

K

Lamp-unit,

J

Lamp-unit,

L

Lamp bulk kit,

B

tire repair

Kit,

C

I Tape,

SPARE

Parts.

Jlem

front chain repair

tail

stop

tail

friction

D Caps, tire valve

Cores, 'ire valve

E

tEXCEPTION:

repair link only

No

spare

Figure M—

PARTS

gasket)

repair

blackout

and stop

lamps,

head

box)

in

(5

in box)

(5

parts

spare

iurnished.

part

Vehic/e

5

kit

supplied

Spare

(fig. 14).

bulbs . , .

with

B

Parts

Numbar Whwt

C«rTi*d CarTi«d

. .

ear/j'er modslz.

CD

RA PD

3102OT

In saddlebag In kit roll

kit

In

roll

In kit roll In kit roil

In kit roll

kit

In

roll

kit roll

In

In kit roll

kit

In

roll

kit

In

roll

kit

In

roll

Rear chain

38

TM 9-879

24-25

PART

TWO-VEHICLE MAINTENANCE

Section

V!l

INSTRUCTIONS

MAINTENANCE ALLOCATION

Paf agraph

Scope

Allocation of maintenance 25

SCOPK.

24.

The scope of maintenance and repair by

a.

units of

tools,

time

and

25.

a.

and

personnel. Replacements

ordnance

personnel when circumstances permit, within

the

availability of necessary parts, capabilities of the mechanics,

available,

no exact system of procedure

ALLOCATION OF MAINTENANCE.

Indicated below

parts have been provided

maintenance

commander concerned. Echelons and

maintenance allocations

and

First

Second

Table

AR

Third

Echelon:

III

850-15

Echelon:

Table III

850-15

AR

Fourth Echelon:

III

Table

850-15

AR

Fifth Echelon:

(2)

III

850-15

and

(3)

Table

AR

Service:

(Including preventive

maintenance)

using

and the

par.

in part

arms

is

tactical

are the

and

personnel may

are

24

a

determined

by the

situation. Ail of these

can

prescribed.

be

maintenance

for

the using arm

repairs which are

be

words as used in

defined as follows:

Operatmg organization driver,

or crew,

battalions, squadrons,

separate

(first and

Technical

nance

shops.

Technical heavy maintenance and

depot units including designated post

companies and

second echelons, respectively).

tight

units, including post and

and service command

Technical

base

Checking and replenishing fuel,

grease,

battery

nuts and

water and antifreeze, air, and

liquid:

bolts: cleaning.

AR 850-15

39

availability

duties for

performed

and

units.

checking

crew and other

the

maintenance

and

responsibility of

the

by

discretion

the

detachments,

regiments,

detachments

medium

shops.

and

suitable

of

are variable

which tools

using arm

of the

this

list of

operator

mainte-

tightenmg

24

and

port

field

oil,

9-879

TM

25

MOTORCYCLE,

Replace;

24 a

Par.

850-15

AR

(5)

SOLO (HARLEY- DAVIDSON MODEL WLA)

To remove an unserviceable part,

sembly,

and replace i:

or subassembly

Repair: To restore to a

Par.

AR

24

a

850-15

in part such parts,

(6)

as

pletely

can be

assemblies or subassemblies

accomplished without

disassembling the

subassembly, and

or precision machining,

ing, or alinimg is not

Rebuild:

24

Par.

850-15

AR

Consists of

a

(6)

reconditioning

able condition any

able part,

the vehicle,

stripping and

subassembly, or

including welding, riveting,

machining, fitting, alining, balancing,

assembling,

Reclamation:

850-15

AR

Par. 4 (c) in part CIR. vehicles,

75,

dated 16

March

'43

Salvage of

repairable

includes the process which recovers

and testing.

serviceable

units and parts

their return to

and

and/or reclaims unusable

component parts thereof and

them

serviceable condition.

in a

as-

from

a vehicle

with a

serviceable one.

serviceable condition.

com-

assembly

heavy

where

fitting, balanc-

required.

riveting,

completely

and replacing in service-

vehicle

or unservice-

assembly

economically

or

removed

stock.

articles

places

from

This

or

of

NOTES: (l)

Operations allocated

indicated by

Operations allocated to

(2)

performed

be

Operations allocated

(3)

echelon operations.

fifth

echelon, unless the unit

chief of the

X.

service concerned.

by

vi!l normally

the third

these

uniis in emergencies onJy.

to the fourth

They will not be performed by the fourth

expressly authorized

is

performed in the echelon

be

echelon

as indicated by E

echelon

by

are normally

E

to do so by

ECHELONS

CLUTCH

Bearings, clutch release—replace

Clutch—replace

Hub, clutch—replace

Hub, clutch—repair X

Sprocket Sprocket assembly, clutch—repair

and/or repair

assembly,

(reline) . X

clutch—replace

. . .

2nd 3rd

X

CONTROLS AND LINKAGE

Zcntrols

Controls

and linkage—service and/or replace. ...

linkage—repair X

and

40

X

4th

may

the

5lh

X

TM 9-879

MAINTENANCE

ALLOCATION

ECHELONS

ELECTRICAL GROUP

Ssttery—

iisttery—

Battery—

Cables,

Zz-.l.

Head, Head, Head,

Horn

Hsm

L:ght assemblies—

l:ght

rsnel, ?3nel,

A-itch assemblies—

S

5vs-;tch assemblies—

".'iring— replace

service (recharge) and/or replace

repair

rebuild

battery—replace and/or repair

ignition—replace

speedometer—replace

speedometer—repair

speedometer—

assembly—replace

assembly—repair

assemblies—

instrdment—

instrument—

rebuild

service

repair

and/or replace

replace

repair X

replace

repair

2nd

X X X

X X X X

X

3rd aih

X

X X

X

ENGINE

(V-45"-TwiN

S-tarings,

3=arings, connecting rod—replace

Breaker

Breaker assembly, circuit— repair X

Breaker

l=rburetor—replace

Carburetor—repair

I-arburetor—rebuild X

-'saner, air—service

Z'.taner, air—repair X

Z'.eaner, air—rebuild X

Zyiinder assembly— Cylinder

Cylinder

Crndenser—replace

''B-gine assembly—

main—

replace

assembly, circuit—

assembly,

circuit—rebuild

and/or

replace

assembly— assembly—

repair

rebuild

replace

Engine)

replace

(recondition)

X

*

X

25

E

X

E X

X

E

:ih

X

'Tr.e second echelon

_.-.ha-rify

However, when

-^sk.

:-

new or rebuilt

a

zr, asterisk may be

has

been obtained

is authorized to remove and

is

it

necessary to

part, subassembly

removed from the

from a.

replace

unit assembly,

or

vehicle

higher echelon

41

reinstall items

an item marked by

by the second

of maintenance.

assembly

the

echelon only

marked by

asterisk

an

marked

an

alter

9-879

TM

25

MOTORCYCLE,

ENGINE

Engine assembly—

Gasket, cylinder

Gears, timing—

Generator

Generator assembly—

Head,

Lines and connections—

Lines and connections— repair

Pistons, rings and pins

Plug, spark—replace

Points, circuit breaker—service

Pump

Pump assembly, feed—

Pump

Pump assembly, oil—

Pump Pump Pump

repair

assembly—

cylinder—

assembly, feed—

assembly, oil—

-assembly,

SOLO (HARLEY- DAVIDSON MODEL

(V-45"-TwiN

repair X

rebuild

head—replace X

replace E

replace

oil

scavenger—replace

Engike) (Cont'd)

replace X

repair X

rebuild X

'or repair X

and,

replace X

assembly—

replace

and/or

replace

repair

rebuild X

replace X

repair X

rebuild X

Pump assembly, oil scavenger—rebuild

Rod. connecting—

(recondition)

Sprocket,

Strained

Valves—

engine—replace

gasoline-replace

service

replace and/or rebuild

and/or repair X

replace,

and/or

, , X

, . . . X

X X

WLA)

ECHELONS

2nd 3rd

X

E

X

4ih Sfn

E

X

E

X

X X

X

EXHAUST

MufBer and exhaust

Murfler

Bars, safety—replace Bars, safety—

Boxes, Boxes,

Carriers, Carriers,

Frame—

Guards,

and exhaust pipe—repair , ....

MISCELLANEOUS

repair

ammunition, ammunition,

luggage

repiace and/or rebuild

mud—replace

and and

GROUP

pipe—replace

'

battery

scabbard -replace

scabbard—

tool—replace . .

and

and tool- repair, . ,

repair X

42

,

. .

, , X

,

X

E

X

TM 9-879

MAINTENANCE ALLOCATION

ECHELONS

MISCELLANEOUS (Cont'd)

mud—

C-uards,

skid—replace

?:ate,

slcid—

riste,

Saddle—

Saddle-rebuild X

Springs,

Tank,

Tank, Tank, Tank,

replace

repair

fuel—

fuel—repair X

oil—

oil—repair X

repair X

saddle

post—replace

replace X

replace

2nd

X

3rd

X

4ih

25

srh

SUSPENSION

handfe—replace

Bars,

handle—repair

Bars,

Damper,

Zrum,

Tork,

"ark,

~ork, front

?ork,

"orlc,

Tzrk.

Plate, ?:ate,

Shoe

Springs,

steering—

brake—

assembly—replace

front

assembly-repair

front

assembly—rebuild

spring—replace X

spring— spring—rebuild

rocker—replace X

rocker—repair

assembly, brake—service assembly, brake—repair

cushion

replace

replace X

repair X

and rebound—replace

(FRONT)

and/or

(reline)

replace.

SUSPENSION (REAR)

Ihains,

~^rum,

"-uards, chains—replace I-uards.

Shoe

Sprocket,

V\"n eels—

.-.'heels-

'.-.lieels-re

all—replace and/or repair

brake, rear—

chains—

assemblies, brake—service

assemblies,

rear—

replace

repair

build

replace X

repair X

brake-repair (reiine) X

replace

and/or

43

replace

. X

X

X X X

X

X X

X

E

9-879

TM

25

MOTORCYCLE, SOLO (HARLEY- DAVIDSON

MODEL

WLA}

ECHELONS

TIRES 2nd

Casings

Casings—repair E X

Tubes, inner—

and tubes—replace

repair X

3rd 4lh

X

TRANSMISSION

... X

X

*

X

E X

Spring, kick starter—replace

Sprocket,

Starter, Starter,

transmission countershaft—

replace

kick—replace X

kick—

repair X

Transmission—replace

Transmission—repair X

Transmission—rebuild

VEHICLE ASSEMBLY

Motorcycle—

Motorcycle—rebuild

assemblies)

service X

(with serviceable unit

X

5lh

E

echelon

second

"The

asterisk.

with

by

authoriry has been obtained

However,

new or rebuilt

a

an asterisk may

is authorized to remove

when

part,

be

removed from the vehicle

reinstall

it

necessary to replace an item marWed

is

subasscmbiy or

higher echelon

from a

and

sssembly, the asse.TibSy

unit

by the

maintenarKe.

of

items

second

echelon oniy a/rer

marked

by an

by

asterisk

marked

an

44

Section

TM 9-879

26

VIII

SECOND

r:ond

;

-..

echelon

SECOND

ECHELON

preventive maintenance services 26

ECHELON PREVENTfVE

SERVICES.

Regular scheduled maintenance inspections

=,

preventive

2.

BESponsibility

)

1)

:tr-.'ices

irmai

^;r. as

-tressary

2)

their vehicles and assist the mechanics while periodic second

^TiV

s:helon

driver

•:zt

-fcance

!_"-.

and

z:r.

^-culd

rf

zljes

.T^iures

-.iintenance

:

i

not be washed

defects,

are

'3)

follow, are

-.'ch

vehicle operator's

The

:ssignated individual

-) General Procedures. These

ziir^ctions which are

the

zsz

rer^onnel must be thoroughly

_;.

-

apply

'=)

When

ler.ciencies.

:z.?:alled.

When tnsralling

'b)

-iricant

maintenance function of the using arms, and are

of commanders of operating organizations.

Frequency. The frequencies of

outHned herein

operation of

extreme

temperatures, and dusty

perform

to

are considered a

vehicles. Under unusual operating

certam maintenance services more frequently.

First Echelon Participation.

preventive

should present

service in a

not caked

servicing

such as cracks,

more evident

instructions

If

in paragraph

service,

maintenance

the vehicle for

reasonably

with mud or grease to such an extent

will be

seriously

or wiped

leaks, and' loose

if the surfaces

other than

or the

(4)

required

for the

or for correction of

manual

authority, should

in

to be followed

listed

items

them

care should

properly

in the

automatically.

or

new

overhauled subassemblies

lubricated,

specific procedures.

be taken to see

new lubricant retamer seals, a coating

should

be wiped over

PREVENTIVE

MAINTENANCE

MAINTENAiXCE

and services are

preventive maintenance

the

minimum requirement for

or sandy terrain, it may be

drivers should accom-

The

services

a

clean condition;

hampered. However, the vehicle

thoroughly

are

those

contained in the general pro-

specific

correct performance of a preventive

pertaining

general

when performing the

trained in these

that they are

adjusted.

and

sealing

the

performed. Ordinarily

are

scheduled

clean, since certain types

or

slightly soiled or dusty.

procedures in

deficiency, other sections

a

to the

be

preventive

that is, it should be

that

shifted parts

paragraph

item involved, or

consulted.

procedures

second

The

procedures so

installed

are

clean,

surface of the lip

Paragraph

the

conditions

main-

inspec-

or

assem-

(5)

basic

are

services

echelon

that they

correct

to

correctly

the

of

of the

'::)

The general

r:rting member or

inspection of each item applies

connection, and usually

includes a check to see

45

also to any sup-

9-879

TM

26

MOTORCYCLE, SOLO

whether the

or excessively

following explanations of

the

/. The

visual inspection to determine

beyond safe

plained

burned,

collapsed,

2. The

is usually

normal assembled position

its

The inspection of a unit to determine if it is

3.

external visual examination,

an

looseness; such

item is in good

worn.

inspection for "good condition"

or serviceable_ limits.

further

by the following: not bent or

not broken or

not torn or cut.

inspection

an external visual inspection to see

an

inspection should

(HARLEY-

condition, correctly assembled, secure,

mechanics must be

The

these terms:

cracked,

of a unittosee

in

DAVIDSON MODEL

whether or not

The term "good

not bare

the vehicle.

hand-feel, or a

a

or

that it is

include any

thoroughly trained in

usually

is

the unit is damaged

condition" is ex-

twisted, not

frayed, not

"correctly

whether or not it is

"secure"

pry-bar check

washers, Jock nuts, locking wires, or cotter pins used in assembly.

4.

"Excessively worn" will be understood to

or beyond serviceable limits, and likely to

mean

result m

replaced before the next scheduled inspection.

(d) Special

numbers

ices are to be

to receive certain mandatory services. For example, an item number

in one or both

actual tightening

ices include:

Adjust.

/.

pertinent section of the vehicle operator's manual, special bi^Hetins,

or

2. Clean.

other

current

remove excess

parts are

them thoroughly. Take

and

other material

ing

that do not appear on the

that

tion with

bled for

such with

certain to keep

be

from

3. Special lubrication.

do appear on

inspection or service.

4.

Serve.

as replenishing

oil.

Services.

the columns

in

performed,

columns opposite

of

Make all necessary adjustments

directives.

These are indicated by repeating the

show

which

show

and

Tighten procedure, means

a

the object must be performed. The special

interval at which the

the

that the parts, or

in

Clean units of the vehicle with dry-cleaning

lubricant, dirt, and other foreign

cleaned,

new parts,

rinse them in clean dry-cleaning solvent, and dry

care to keep the parts ciean

dry-cleaning

which

it will damage. Clean the protective

since

this material is not a good lubricant.

solvent away

This applies both to lubrication

water,

Lubrication

if

and

draining and refilling units

Guide, and to

parts have to be disassem-

such

the maintenance

This usually

battery

vehicle

guides, but should be performed in connec-

operations,

consists of performing special operations,

accordance

material.

until

WLA)

external

an

chafed or

dented or

assembled"

usually;

is

brackets, lock

worn, close to

failure if not

a

item

serv-

assemblies, are

the

that

serv-

with

the

solvent

After the

reassembled,

from rubber or

coat-

grease

operations

items

46

in

for

to

SECOND ECHELON PREVENTIVE MAINTENANCE

Tighten. All

wrench-torque (force on the wrench handle)

icient

according to good

it

where specified.

rench

distortion. Tightening will

cause

correct installation of lock

It

rvided to secure the

conditions

When

's)

maintenance

itive

ir.dled in

-

rtk

-jtili^ed, if

;

:

—Dieted.

tr/ices

':)

;.low

-:ch is the

vc'.es. Certain items on the work sheet that

tuicle are not

-.;

numerical

-.anual

er/ation of

5)

trr.

:.

'.owing

sections, planning

if possible.

When limited

in the columns should

numbers of the preventive maintenance

The

are identical with

Preventive Maintenance

procedures,

the mechanic's

Specific Procedures.

in the

1,000-mile

chart.

rrresponding

tightening operations should

mechanical practice.

not overtighten, as

Do

washers,

tightening.

it difftcult

make

procedures at one time, these can sometimes be

complete ail operations within the

to

All available

necessary,

time at halts and in bivouac areas

to assure that maintenance operations

by the tactical situation, items with special

given

be

those outlined

included

sequence

of items on the work sheet is followed in the

in the

procedures

but in some instances there

time and

effort.

procedures for performing each

The

maintenance procedures are described in the

Each

to

the 1,000-mile maintenance.

page

of

the chart has

always

be understood to include

lock nuts, and cotter

perform the

to

first

W.D. AGO Form No. 463,

on

Service Work Sheet for Motor-

in this

a

TM

be performed

to tighten

Use torque-indicating

this may

consideration.

do not

manual.

is

column

strip threads,

complete

procedures

apply

In general.

deviation for con-

left

at its

9-879

26

with

pins

pre-

must

that

this

to

edge

the

are

000

**"*

NOTE: If tactical situation

perform items

sHght or no movement of the vehicle.

possibJe.

Before-operation

i

Service

and Preventive

in

dition

Ease

2

starter. Note if

Oil Circulation.

3

oil

When

R(UD TEST

does not permit a full

2. 3. 4,5.6. 7,

shouJd

it

for preferably

be

inspection. Perform

listed on W.D. Form

Maintenance Service Record"

par.

IS), to determine if

to make

the road test

of StarUns. Start engine and observe action of

engine responds readily.

Oil circulation is

signal light

light

red

light) in instrument

(red

on, oil is not circulating. Observe

is

47

9. 12,

8.

No.

418, "Driver's

vehicle

safely.

14, which

and

When

5. and not

Before-operation

is

satisfactory con-

a

in

normally

panel

road test

a

over 10 miles.

Trip Ticket

(described

indicated,

being

road

require

test.

is

by

out.

for

9-879

TM

26

MOTORCYCLE, SOLO

1000

Mile

MaintAnance

excess smoke in exhaust. CAUTION:

out

^o

Refer

Instruments. Observe instruments for proper

indication and functioning

Speedometer and Odometer. Speedometer must

vehicie speed without excessive noise or fluctuation; odom-

must record trip

eter

Oil Pressure Signal Light, Note whether oil signal light

(red

turned

on, indicating no oil

go

light should go out.

Generator Signal Light. With switch

starting engine, the green signal

cating

engine speed

should

CAUTION: Continue observation of

tery.

road

ing

cated

report

Brake

reasonable distance. Note squeaks or chatter that rmg"ht

indicate wet,

improper adjustment.

only in

operates

Clutch Operation. Before

clutch pedal has

disengage

reaching end of travel;

in

clutch-release

serve whether clutch grabs, chatters,

engaged.

Gearshift.

observe'

and

clashing

tion that might indicate loose engine or transmission

mountings.

Unusual fVoises. During

noises that

ciently

in

larly

(HARLEY- DAVIDSON MODEL

after

engine

to paragraph 30

//

red light fails

been started, stop engine at

has

possible causes.

for

of

system

to

which

WLA)

normal

or

they apply.

mdicate

total

and

light)

on,

indicates

before

and

discharge

to a

then

test,

above,

trouble to proper authority.

out. indicating generator is charging bat-

go

and if lights should fail to

stop engine,

correctly;

starting engine,

circulation. When

of battery.

medium fast

miieage.

After

light

After

investigate cause,

ignition sw-itch

the red

should

starting engine,

green signal

idle;

light should

engine is started,

and before

on.

on, indi-

go

increase

signal

lights dur-

operate

and

indi-

as

correct or

Operation. Test foot brake for safe stop within

dirty, or loose lining, damaged drum, or

oily,

conjunction

effectively in

satisfactory free tiave! before

clutch;,

Apply hand-operated

rear

with

assisting to make a quicker stop.

brake and

moving

that it

releases clutch completely before

that

and

there are

observe whether it

vehicie. make

no unusual noises

front

sure

it

brake

begins

mechanism. When starting vehicle, ob-

or slips

through entire

Shift

whether

or jumping

might

lubricated parts in the entire motorcycle, particu-

mechanism

out of

indicate worn,

gear.

entire road test, listen for unusual

engine and accessories,

range

gear

operates freely

any

Note

damaged, or insuffi-

loose,

or in

when fully

transmission

of

without

unusual

the power train.

vibra-

44

to

once.

is

light

that

to

SECOND ECHELON

looo

,'^''*

CAUTION: Loose

in excess of V-, inch

excessive noise which sounds like engine knock. Remove

inspection cover for examination of chain.

Steering. Observe steering mechanism for indication of

9

looseness

With hands

vertical position, observe whether there

pull

to

Note any

Balance. If vehicle does

10

inspect for misalinement

11 Speedomeler

to one side when operating at

excessive binding through full turning range.

or

resting

indication of

PREVENTIVE MAINTENANCE

primary (front)

total up-and-down motion,

lightly

Odometer. Inspect speedometer

and

on

steering

balance properly

not

rear wheel.

of

drive

handle bars

instability

proper operation, excessive fluctuation,

Observe odonneter

mileage.

12 Throttle and Spark Controls. Set throttle

low speed needle adjustment so

smoothly

and will

correct recording

for

not stall

at

that

idling

running at a speed of 30 miles per hour,

gear, turn

positions and

throttle changes. Turn spark control grip and note whether

fully

it

Power

13

power,

throttle

advances

and Operation.

and good operating

control

note

and

grip to

whether engine responds instantly to

retards ignition timer.

"OPEN"

Observe engine for

characteristics

from first to high gear. Also obsep/e whether engine misses,

stalls, knocks excessively, or makes any other unusual

noise.

14 Carburetor

than

idle adjustment as performed

Adjustment.

No carburetor

in item

on this vehicle.

Brake

15

completing road

Drum and

Hub Temperature. Immediately after

feel front and rear brake drums and

test,

wheel hubs for overheating.

Power

16

heating.

Train Temperatures. Feel transmission

9-879

TM

26

chain, with

and

any tendency

is

a

reasonable

higher speeds.

at

in

unusual noise.

or

trip and

of

stop

engine will operate

speed.

With vehicle

faster,

or

"CLOSED"

and

normal

in each speed,

adjustment,

12, is required

slack

cause

can

vehicle in

speed.

operation,

total

screw and

high

in

pulling

other

over-

for

17 Compression

pression

for

18

Transmission.

cure

with starter. If engine lacks compression,

leaks.

mounting,

MAIA'TENANCE

With

Test.

Inspect transmission for

OPERATION

throttle wide-open,

and leaks. Inspect oil level.

49

good

Drain arid

test com-

inspect

condition,

se-

reftll

9-S79

TM

26

MOTORCYCLE,

looo

."'**

„

22 Battery

23 Elepirical

24 Generator Drive

transmission to

with

transmission immediately

agitated by operation of engine.

is

completed

cant. Tighten

Kn^ine

20

tank. CAUTION; Fill to wiihin I

filler

diately after engine operation and refii} as soon

is completed, to avoid hazard of operating

canr.

21 Baiiery and Carrier. Clean top of batter^'.

tery

securely mounted. Remove eel! caps: make

are open.

readings on work

ings below 1.225

ure. Variation between cells of more then

reported. Read ing is normal). Bring electrolyte to

plates, using clean, drinkable water. If SAcessiys looseness

of battery in

pad in

stalled on

condition and

wire

is in

for worn spots

erator for

assembly, remove

tator fat

commutator is

paper.

bad condition

move

anism,

or

dirty. CAUTION; Do

clean

25

Timer (Circuit

See

that wiring

SOLO {HARLEY-DAVIDSON

level

specified grade of

avoid

to

mounting and assembly

a!!

Oil.

Inspect oil

with specified weight of oil. Always

cap

and carrier are in good condition, and

Test

specific gravity

sheet, W.D.

indicate

and

case is,

bottom

Wires

insulation.

good

of case, and make sure rubber pad

top

of battery,

and

secure

Oil the felt washers on battery terminals.

Wirjiip;,

condition,

Inspect

in insulation.

and Mounlincr, and Relay. Inspect gen-

secure mounting. After removing left

generator and

cleanliness,

dirty,

Blow out

relay cover,

with compressed

or excessively worn, replace generator. Re-

being careful to avoid damage to mech-

and inspect for cleanliness.

it in any

other manner.

Breaker).

leads are securely

transmission

of

engine oil.

hazard

tank

CAUTION:

after

;r

Refill as soon as

operating

of

for oil

inch

with hydrometer

AGO Form No. 4^3. Resd-

need for recharge,

record voltage of

noted, check for presence

when battery service is completed.

Terminals. Inspect battery

connections. Look

all eUetrie winng

securely attached,

cover.

good condition,

it

must

not

cleaned

be

air.

Blow out

attempt

Clean and remove timer

connected

50

MODEL WLA)

filler plug opening

Always

has been

level; drain

ef

battery

yi,-,

and

or

If

to adjust

warmed and

without lubri-

bolts securely.

opening

filler

drain

as

wiThou:

See

that carrier :s

sure that vents

and

or battery fail-

0.025

(6-volt

above

inch

of

worn

for

ste

XQ

connected.

footboard

Examine

excessive

No.

with

commutator

with

air if

relay,

and that in-

drain

draining

refill

and

imme-

draining

lubri-

bat-

that

record

must be

read-

tops

rubber

is

good

for

spots in

thfit

Look

commu-

wear.

sand-

00

is

wet

or to

cover.

and

of

in-

it

If

in

PREVENTrVE MAINTENANCE

tight.

is

install new timer.

Breaker

from

by hand-feel to see whether it is

1000

MiU

Maini«nanc*

SECOND

side of the

they are

excessively pitted, burned, or

mounting

its

if breaker arm spring exerts

Examine

cessively worn in its bushings; if camshaft bushings

ECHELON

timer is ctean. Inspect

clean, well-lined, engaging

screw

pivot and well insulated

camshaft

worn excessively,

burned or pitted, dress them

points

aline of oil

cam and tben coat with

unserviceable, install a new set. taking care

are

and to adjust

them

breaker arm pivot pin. Use clean cloth

to

gap to

very light film of light

a

CAUTION: Be careful to avoid getting oil or grease

brea-ker

25 Spark Plugs, Rem'ove

cleaner,

trodes

inch.;

with new

good condition

27 Ignition and Light Switch. Make sure

in good, condition

28 Lights,

in

Tactical situation

positions and observe

operate properly,

off.

whether

brake

operation.

ftector

29 Horn. Tactical situation

normal signal. Examme

mounting,

30 Cylinder Heads.

leakage, tighten head

should

41-W-IS25)

tightened without

tanks

points.

spark

and inspect for cracked

for good condition and adjust gap to O.025

replace faulty plugs, Be sure to install new

plug. Inspect radio suppressors

and secure

attachment.

and operating properly

Service and Blackout.

good condition,

properly aimed, and securely mounted.

permitting,

whether service and blackout lights

and whether fhey go out when switched

Operate dimmer

"

it depresses beam of service headlight.

for check of both blackout

Inspect lenses for

for discoloration.

switch on

breakage, and

Clean

al'

permitting, sound

horn for good condition, secure

and tight wiring

installed.

be

is available

If cylinder

connections.

head

bolts:

if leakage

A

head bolt

with which head

removing tanks for

are removed

to permit

taking

51

TM

breaker points

squarely,

worn. See

lever should

the pivot pm.

normal force

If points

with

a. fine file. If

0.022

inch. Apply one

plugs, clean with

insulators; inspect

on

that the

in all

See that ail lights are

turn

switch to' each of

left

handle

and service stop

lenses.

gaskets

persists,

wrench

wrench clearance.

off heads and

to see

and are not

that condenser

be

Determine

against

are

sandblast

plug cables for

positions:

bar to

Apply

headlight re-

horn to test

show

new

(Fed. -Stock

bolts

9-879

26

that

free on

arm.

ex-

are

slightly

breaker

drop

wipe

to

grease.

on

elec-

0.030

to

gasket

switch is

clean,

its

see

foot

light

for

signs of

gaskets

No.

be

can

install-

to

If

9-879

TM

26

MOTORCYCLE, SOLO (HARLEY-DAVIDSON MODEL WLA)

woo

,'

u

31

32 Enp:ine Mountings.

33 Engine Crankcase. Examine engine crankcase for

34

35 Muffler and Exhaust Pipes. Inspect muffler and exhaust

36

37

38

39 Filier

new

Ing

.3. torque wrench to a tension of

or 65

Cylinder

is

evenly when engine is cold. If

new gaskets

base nuts

and

seating of

for effective

mounting bolts

condition and for leaks. Make sure timing

screws, and oil feed and scavenger pump nuts,

Intake Manifold.

and secure mounting. Make sure

pipes

Be sure tail

Valve

pet

on on

tion and properly secured; that valve tappet adjusting

screws and'

covers are

Starter,

condition, correct assembly, and

should

bring starter crank to its disengaged position

pressure is

crank pinch

of vehicle

Engine Cooling

condition

ter.

of

they

gaskets, bolts should then

foot-pounds

Hol<l-<lown Nuts. If

excessive

are loose,

bolt for

the engine bracket mounting bolt is a necessity

maximum, when

these nuts are

oil leakage around cylinder bases, tighten

should

good condition and security.

radio bonding. Inspect four

for

installed.

be

perform item

Inspect

signs of looseness. Tighten as required.

top

Examine manifold for

for

Mechanism, When

clearance

intake valve; 0.006-inch mmimum. 0.007-inch maximum

exhaust

Examine

operate without

condition, secure

good

pipe opening is

0.004-inch minimum, 0.005-inch maximum

to

valve. See

lock nuts

good condition,

in

pedal, crank,

not

engine

valve

that

are in good

secure,

binding,

tightened evenly

be

foot-pounds minimum,

60

engine is

excessive leakage

cold.

loose, or

CAUTION: If cylinder

36 before

engine mounting bracket

starting

CAUTION;

lower

gear cover

are

good condition

manifold

mounting,

restricted.

is cold, adjust

springs are

condition;

and return

secure

and

nuts are tight.

and for leaks.

valve

in good condi-

and that valve

and not

leakmg

spring for good

mounting. Starter

return spring should

when

sure

that starter

see

fuel

Do not

Caps

fuel

are in

removed.

bolt is

when

cleanliness. Remove

and

apply paint to

and

oil

good

tanks.

CAUTION;

installed with

crank is

Fins.

Vents.

condition. Note

in upright

Inspect engine

cooling

Wipe

Inspect caps

Make

of bolt toward rear

head

position.

cooling fins for good

dirt or foreign mat-

all

fins.

dirt and dust from filler

and gaskets to

whether vent in

52

with

there

nuts

persists,

engine.

Tight

engine

good

tight-.

tap-

oil.

foot

caps

that

filler

SECOND ECHELON

300

Hii&

^3p is open. Reinstall caps,

erly

TM 9-879

26

PREVENTIVE MAINTENANCE

observing

on filler neck. Do not interchange fuel and oil tank

that

each

locks prop-

-.0 Fuel Tank Valves

good condition, secure, and not leaking. Test fuel

in

valve for ample friction to hold valve in

that valve

See

-1

Oil System Leaks. Examine oil tank, oil lines,

connections

and

for leaks.

Carburetor

42

carburetor

ine

nections, and

filter (strainer) cap and screen. Wash cap and screen in

dry-cleaning

flush filter body.

careful not

sary. Drain water and

to damage

by removing bowl drain plug.

flush

to

being

shut-off valve and

-3 Air Cleaner.

carburetor bowl while

careful

anti

Lines. See that

lifts freely enough

for good condition, secure

and Fuel Filter (Gasoline Strainer),

and fuel filter for good condition, secure con-

for leaks. Shut

solvent,

off fuel

open shut-off valve slightly to

and

Reassemble screen, gaskets, and cap, being

gaskets.

foreign

Use new gaskets if

matter from carburetor

Open shut-off valve slightly

plug is out. Replace

avoid crossing

to

oil cup;

leaks,

inspect

check for

Remove

valves and lines are

reserve

operate satisfactorily.

to

attachment, and

tank valve and

threads. Open

condition of oil, and

amount of sediment. If service is required, remove filter

elements, clean

ments

pressed air.

assemble

in dry-cleaning

immerse each element in oil in cup, and re-

elements and oil cup to air cleaner

immediately. Make sure

NOTE: Early type

filter element;

be removed

44

Gearshift

and

linkage are in good

sively worn. Lubricate all

oil. Adjust

position in shifter guide on

to full

45

Primary Drive. Remove

chain guard.

tral, rotate

chain for ^-inch

to wash element.

Lever and Linkage. See

shifter lever so that

engagement in corresponding

With clutch engaged

primary chain

and fill

therefore, the complete

deflection.

cup

solvent,

NORMAL

to

gaskets are

round cleaner

condition, secure,

joints with

tank,

inspection

to position

Deflection

level. Wash

dry thoroughly with

in good condition.

does not have

cleaner body must

that gearshift lever

and not exces-

a few drops

when moved

the transmission

gear.

cover

hole

and

transmission in

of least slack. Check

measurement

53

shut-off

position.

vent line,

Exam-

remove

neces-

bowl

plug,

tank

fuel

ele-

com-

body

removable

engine

of

to any gear

shifted

is

from front

neu-

should

TM 9-S79

26

MOTORCYCLE,

1000

M.ie

Mamtenonce

t^e total

adequate

a^^jQgfirig screws

Idle engine 1

force.

SOLO

up-and-down free

lubrication. Loosen front and '

This

chain oiler pipe.

46 Clutch

Pedal and Liiikasf. Inspect

connections and cable to see that they

and

tion

pedal to pedal in

clutch release lever

by

tion, clutch release lever must have between

free

joints

each

47 Rear Chain and Guard. Inspect

condition and secure mounting.

oughly in

that

has

engine oil

trate

not excessively

make sure it is

fully

about

'

movement

with

end

of cable housing.

dry-cleaning

chain

is in

no broken

for a short period

into

all rollers: drain

Inspect countershaft

that they

see

that rear sprocket

and

chain until

chain, make

securely

and

spring

chain

48

Final Drive

is

50

PainI and Markings.

and see

bare

markings

51

Frame.

whether

52

Steering:

by

clip

(paragraph

made when- performing

that

spots

that might rust or reflect light. See that

are

Examine frame for

it

seems to be sprung out

Head

placing

blocks under skid plate. Complete

items to and ground. Examine

(HARLEY-DAVBDSON

Cwo tutns each. Do

minute,

operation serves to flush

then

disengaged

must

inch; with foot pedal in fully engaged

j,,

on end of

a few drops of engine oil.

solvent,

good condition,

rollers on side plates. Soak

sprocket, and rear

are in good

7 1 has

item

sure that

locked.

is trailing

connecting

See

in

60).

Sprockets. Inspection of

Examine vehicle

paint is

legible.

not

and Fork Stem. Raise

including

item 71, before

steering head

54

rftOML WL&)

movement.

tighten

worn.

within specified limits.

position

clear sprocket cover stud and nut

foot pedal

screws firmly,

Check

(heel

rear

Remove

and hang

not

of

time to

chain,

condition^

rivets

are tight. Do

performed. When reinstalling

been

link is

that open end

direction of chain travel. Adjust

item 47,

rubbed

to

good

of

and

Inspect chain for

rear chain oiler

not remove screws.

but

control

valves and

clutch

free travel of'clutch

are

pedal

in good

With

against footboard)

j4-inch

and

5^-

cable.

chain guard for good

excessively worn, and

and

not excessively worn.

final drive sprockets

a polish, and has no

condition; observe

alinement.

front

fork

Lubricate all

incfuding cable

chain, wash thor-

it

chain

allow

wipe

wheel

in

of

connecting

for

good

up to

in

oil to

e.xcess

off

sprocket to

not

condition

good

condition

dry.

SAE

reinstall

vehicle

end of vehicle

following

ail

lowering

vehicle to

stems for good

do not

clevis

condi-

pene-

rear

foot

posi-

at

See

10

oil.

link

SECOND ECHELON PREVENTIVE

looo

Mile

Mami*non«e

condition.

by

^^^g^

indicate

Handle Bars. Examine handle bars for good

53

secure mounting.

Thrattle Control. See

54

throttle opens

extreme positions, and that control wire

good condition

rear of grip

in

not rotate

spiral

55 Spark Contml.

spark

to its extreme positions;

in good condition

are

hole

does

spiral

Kfar VifW

57

for good

From Fen<Ier

58

condition and secure mounting; see that fender does not

scrape tire.

Weapon Carrier. Inspect weapon carrier

59

tion and secure mounting.

60 .Ammunition

in good condition

Frimt

61

are in good condition, correctly assembled, and secure.

62 Front Forks.

and securely mounted.

63 From Fork Rocker Plates

foric

excessively

From

64

condition

friction disks

worn.

65 From Brake

operates

age

Note whether

loose bearings.

g^d obscrvc

improperly adjusted

and

to

freely,

control parts.

See that

fully advanced and retarded as the

is

rear of

in

not

control parts.

grip

rotate freely, disassemble

Mirror. Clean rear

condition

Mu<i«uar<I)

(

Box. See that ammunition box and

Springs.

rocket

See

plates

worn. Tighten

Fork Damper.

and

to

are

see that

glazed,

and Coti(ro( Linkage.

freely, that all connections

TM 9-879

^

26

MAINTENANCE

there

Move

if there is any binding which might

that

closes completely as grip is turned

secure. Lubricate lightly through hole

avoid rusting and "freezing,

disassemble

that

secure. Lubricate lightly through

and

to avoid rusting and "freezing." If grip

secure mounting.

and

and securely attached.

that front

that

front forks are in good condition,

are

good

in

rocker plate stud nuts securely.

Inspect steering damper for good

operates

it

coated

55

up-and-down

is

handle

or

bars through

defective

play caused

complete

bearings.

condition

grip

in good condition, that

is

and housing are

'''

grip

If

clean, and lubricate

grip,

grip is in good condition,

grip

is turned

control wire

the

ciean. and lubricate

grip,

view

mirror

. Examine front

springs and

Rocker .\rms). See that

C

condition, secure, and not

freeiy. Observe

with grease,

fender for

for good

their mountings

or excessively

See that

tight, and that

are

housing

and

examine

cover

whether

control link-

condi-

and

to

does

that

good

are

front

its

in

9-879

TM

26

MOTORCYCLE,

1000

Mil*

'^''*

Mainlsnoncfl

brake

travel before meeting

of a cracked

loose, or

cations, remove wheel for closer inspection.

SOLO (HARLEY- DAVIDSON MODEL

adjusted so that

is

or

excessively

grease-saturated linings, [f there are any such indi-

end

resistance.

worn

worn brake side cover bushing, shackle

brake operating stud bearing. Apply a

or

gine oil to control cable,

at left handle bar. and

•nfi

Front Wheel .\linenient and Spokes.

spokes for presence, good spokes are

found,

tighten

rim oQt-of-round. or

good condition, and

ciable

run-out.

67 Front \^'heel Bearings. Inspect wheel

ings are

of

excessively

side play at rim. Spin

which might indicate

Observe for excessive grease

only

slight cone readjustment to correct excessive bearing

play, remove wheel

If indications are found that hub

replace wheel.

Each Sixth

front wheel, axle

1,000-Mile Maintenance

sleeve

especially

pin joints.

to

condition,

evenly,

cause

to

wheel to see that it has no appre-

spin

Wheel should have slight amount

loose.

wheel and

or defective bearings

dry

leak.

make this

and

bearing,

and

hub. clean thoroughlyindry-cleaning solvent. Inspect parts

for good condition:

good condition and

neither excessively

bearings, hub, and

CAUTION:

clean, and

Reassemble and

paragraph

in

aZined.

streams,

cant, this service

Front Wheel Axle

68

that cotter pins

be anchored

69 Tires,

front,

stems

that valve caps are

Make sure

that grease is forced between balls onto the cone.

If unusual

have indicated probable

on extended

Front and

and

20 pounds rear

are

in

inspect brake drum. Inspect lining

secure

attachment,

worn nor soaked with grease. Repack

sleeve

axle

hands

that

adjust bearings according to instructions

126. taking care

operating conditions, such as fording

should

Nuts.

are

installed.

Rear.

good condition and

present

performed more

be

Tighten

end

Gage

(cold).

and

56

of hand

Look

brake

lever has

for .any indications

drum: badly worn,

Look

bushings

few

drops of en-

control housing oiler

at

Examine front wheel

tightness.

and

taking

run-out.

If wheel is found

is

with specified lubricant.

to see that

Slot

of left-front

tires and inflate

secure. Examine

care not

Examine

see whether bear-

to

for unusual noises

listen

adjustment (par.

otherwise in

Service. Remove

together

and.

and see that it

grease

and

contamination

axle

in stabilizer plate

Make

correctly installed,

are

wheel

frequently.

nuts,

making sure

rocker plate stud.

to IS

sure

WLA)

free

y&

badly

for

studs,

and

loose

If

distort

to

for

rim

races.

or

need

to

126).

order,

bad

wheel

with

for

perfectly

is properly

lubri-

of

must

pounds

valve

that

and

tires for

is

ECHELON PREVENTIVE MAINTENANCE

foreign matter

for excessive or irregular tire wear. At any inspection

or irregular tire

1000

''*

,

„

'f

Maintenance

SECOND

cuts, bruises, breaks,

nails, or other

treads

when unusual

change front and rear

70 Rear

71

Wheel .41inement and

stand, inspect in

If it is necessary to

sprockets and chains

same

Rear Wheel Bearings

whether bearings are

slight amount of play at

a

unusual noise which might indicate dr>' or defective

ings. Also observe whether there

Test for

siderable side

bearings,

excessive

there

or

end

play at rim, indicating

is

order otherwise, replace wheel.

inspect brake drum and

cated

in item 75,

Make sure that wheel mounting socket screws are

Rear Wheel

72

good condition and

Rear Fender (Mudguard).

74

condition

Rear Brake

75

linkage

Look for indications of badly

ings. If brake operating

vertical, excessive

worked out between brake

saturated

should be

cracks or excessive

screws

clevis,

and for missing washers

drops of engine

have 1-inch

ance. Adjust

provide

to

Footboard and

77

condition and

78 Saddle Spring and Hinge.

dition and secure

.\xle Nut.

securely

and secure attachment.

Conirol

and

operates

freely,

lining wear

linings are indicated.

removed for closer inspection. Inspect drum

wear. Make sure wheel mounting

are tight.

Examine

oil to

travel before

free

length

1-inch free

Rest.

secure

mounting, paying particular

and

blisters; remove imbedded

tire treads

°

_

tires.

from

wear

Spokes.

becomes evident, inter-

With vehicle on

manner as front wheel (item

aline

wheel in frame, make sure

are in correct

and

excessively

play.

evidence

lining

before

reinstalling wheel.

See

aUnement.

Seals. Inspect wheel to see

loose (wheel should

rim). Spin

If wheel is found to

of hub

If

for good

that rear wheel axle nut is in

tightened.

wheel

excessive grease

is

excessively worn

assembly being in bad

wheel must

condition,

Inspect rear fender for

Linkage. See that brake

and

that all connections are

worn or

lever stands considerably

is

drum and

linkage for

or cotter pins.

all linkage

grease-saturated lin-

indicated. If

brake cover, grease-

either case the

In

loose or

joints. Brake

brake begins to meet

of brake

pedal

Examine

rod at brake operating

travel.

footboard and rest for

attachment.

Examine saddle for

57

9-879

TM

26

glass,

; observe

rear

66).

have

listen for

and

bear-

leak.

have con-

replaced,

be

indi-

as

CAUTION:

tight.

good

control

secure.

ahead of

grease has

wheel

socket

worn pin

Apply a

pedal should

good

attention to

few

resist-

lever

good

con-

for

or

9-879

TM

26

MOTORCYCLE,

1000

"'''

u

Horn leather, ripped seams,- sagging or broken

post, and

sure

hinge

79 LiigKajrc

tion and secure mounting.

80 Sa(i(He Baj;s. Examine saddle bags for good condition.

cleanliness,

particularly

and buckles missing

Timls,

SI

tire

,

ness,

tire pump is securely clamped to motorcycle

all items with stowage list (pars. 21. 22 and 23). Make

that

are present on

82 Safety' Guanls. Inspect

SOLO (HARLEY-DAVIDSON MODEL WLA)

excessive wear

ihat spring wire

clevis

pin.

(Carrier.

Examine

and secure fastening to luggage

whether leather is torn, seams

or damaged.

Tire Piieii|K and Kqiiipmenl. Inspect

pump,

and other equipment

serviceability,

vehicle manuals and

and proper

vehicle and legible.

front

in

dip

hing^

properly

luggage

locks

carrier for

for good condition, cleanli-

stowage. Make sure that

Accident

safety guards for good condition

Report

spring

CAUTION:

the saddle

good condi-

carrier.

ripped,

•

too!

frame.

Form

and secure mounting,

83 Lep:

84

85 \>hicle Lubrieaiion.

Shields.

secure

mounting. 'NOTKi-.MotorcycJes opejating in warm

weather

seriously hamper engine cooling.

Plaie.

Skid

secure mounting. CAUTION: Skid plate must be'

Inspect leg

should not be

Examine

accordance with instructions in this manual,

Guide, current

following instructions:

lubrication bulletins or directives, and the

shields for good condition and

equipped

skid plate for good condition and

Lubricate

with le^

all points

shields, as they

of vehicle

Lubrication

Any unit that required disassembly for inspection pur-

poses

must be

be

deadlined for the repair of

bricant.

used

Keep all lubricant

during lubrication. Before

wipe dirt from

will

not

plugs are

hole

after

which

in

the new

Lubricant must

bushmgs,

or

However, lubricate sparingly the

hub, front

wheel

lubricated correctly unless the vehicle is to

that unit. Use only clean lu-

containers covered except when

applying lubricant, always

lubrication fitting or

the

enter with the

missing or

the fitting

fitting has been

damaged, replace them. Clean the

be applied

apply lubricant until

brake side

lubricant. If lubricant fittings or

is to be installed, and lubricate

installed.

properly.

cover

bushing,

plug

unsealed joints

On

appears at openings.

it

wheel hub, rear

front

front brake oper-

so that

58

in seat

M^e

rear

Note

or straps

kit, tools,

Check

sure

26

No.

present.

dirt

in

9-879

TM

26

SECOND ECHELON PREVENTIVE

1000

.

..

ating lever stud, and rear brake operating lever stud,

'*

prevent grease

advised whenever

that during the next road operation he

so

reaching brake linings. Rider should

wheel bearings are

whether bearings or brake

overtight

Do

generator

failure of the

Wipe

brake

vehicle's appearance.-

adjustment

not apply more than specified amount of

timer (circuit breaker).

or

unit.

oft' excess applied

or operating surfaces,

bearings, or a dragging brake,

of

lubricant

Parts or assemblies that have already been lubricated

while

disassembled for inspection,

been drained and refilled as mandatory items in

cedure, and

lubrication,

vehicle.

the

FinaJ

86

Kua<l Test. Make a final

to 16. inclusive. Be

2

that lubricant

this

road test

satisfactory observation. Correct or report

parts that have been indicated for special

those

will be omitted from

sure

at correct level

is

the minimum distance necessary

to

found during final road test to designated

MAfNTENANCE

serviced

drums are running hot. due

To

that

clothes, or detract from

soil

gear

the general

test, reinspecting items

road

to

recheck transmission to see

and not leaking. Confine

or adjusted.

may

determine

lubricant

may

do so

cause

may drip onto

that have

cases

the pro-

lubrication of

to make

all deficiencies

authority.

to

be

to

59

9-879

TM

27

MOTORCYCLE,

SOLO (HARLEY-DAVIDSON

Section IX

MODEL

WLA)

ORGANIZATION TOOLS AND

Tools and equipment

27. TOOLS

Refer

to SNL-N

to

Speeial Tool

Description

a. Refer

echelon.

b.

echelon.

Hydrometer,

Tool, repair, drive chain,

motorcycle universal

Tool, spoke tightening,

special, 3^-inch, for

small

diameter spokes

Wrench, Wrench,

cyl. base nut,

head bolt

Wrench, manifold. Wrench,

Wrench, Wrench,

spark plug .

spoke nipple, front wheel

spoke nipple, heavy

duty rear wheel

Wrench,

open-end

tappet and dbl-head

"^i^-

AND

list given

battery,

45-in.

and lyj-in

EQUIP>IENT.

19

for common hand

below

for all special

special

twin

. . , . HRD 11831-X

twin

EQUIPMENT

,

tools available to second

tools available

Manufoeturor's Federal Slock

Number

HRD 12039-X

IMC 7-T-3259

12650-29 2941-W-872-10

HRD

12047 -30A 41-W-1525

HRD

HRD 12003-X

HRD

11929-40 41-W-3334

12032

HRD

-X

12033-39 41-W-3340

11806-31

>....,.. 27

Number

I8-H-1242

41-T-3320

4I-T-3368-20

41-W-1570-10

4i-W-3339

41-W-3617

Paragmph

to second

60

TM 9-879

28-29

Section

X

TROUBLE SHOOTING

Paragraph

Introduction

Engine

Fuel

Ignition system

lubricating

system

Generating system

Electrical

system

Transmission and clutch

Wheels and chains

Brakes 37

Steering

28. INTRODUCTION.

Trouble shooting for

a.

engine trouble shooting paragraph

The

affecting

trouble sary

defective

shooting

b.

die

perature

his

engine performance:

to one or more defective components

to refer to the pertinent paragraph of this section when the

system

paragraph.

The material given

vehicle under

occur,

vehicle

for

system 30

entire vehicle

the

example,

for

or systems have been located in the engine trouble

in this section applies to

is given in this section.

traces trouble to a system

a system,

of

ignition.

operation

the

it is neces-

fuel or

normal conditions. If extreme conditions

it is assumed the operator of the vehicle has

use for the conditions encountered.

prepared

To trace

of tem-

28 29

31 32

33

34

35

36

38

of

ENGIN1E.

29.

Instruction. This subparagraph

a.

affecting engine performance.

determine the mechanical

:o

b refer to step

step

paragraphs in

a special unit

cates

this section for

for

c

engine mechanical troubles, or to pertinent

is faulty, to the

manual.

Engine Does

(1)

Not Turn

Operated.

Clutch

(a)

(b) Sheared engine

Starter

(c)

proper grade

(d) Starter clutch

slipping.

clutch stuck

of oil.

worn. Refer to

Check adjustment (par.

sprocket key. Replace

traces troubles

a system

to

Step b below gives simple engine tests

condition of the engine. References in

system troubles, or when

pertinent paragraph

test indi-

a

in

Over When Foot Starter

48).

(par.

65).

by congealed oil. Free

maintenance

starter clutch. Use

personnel.

61

this

Is

9-179

TM

29

MOTORCYCLE,

Engine locked

(e)

Engine

(2)

(a) Fuel supply

(b) Empty

(c) Fuel system

SOLO (HAKLEY-

Turns Over When

valve closed. Open valve.

fuel tank. Fill tank.

faulty. Refer

(d) Ignition system faulty.

(e) Battery weak

(f) Insufficient

Weak Compressjon. Refer

(3)

Improper

(a)

Valves sticking.

(b)

guides.

in

(c) Fault>'

lubrication.

or

compression.

valve

(seized). Refer to

Refer

dead. Refer to

tappet adjustment. Adjust (par.

Use dry-cleaning

Refer to paragraph 20.

DAVIDSON MODEL WLA)

organization mechanic.

Cranked

paragraph

to

to paragraph 32.

paragraph

Refer to step b,

step b below for test.

to

solvent

Does Not Start.

but

31.

34.

below.

to free

43).

valve stems

(d) Loose cylinder head bolts and/or faulty gasket. Tighten head

bolts or replace gasket (par.

Overheating.

(4)

(a) Faulty fuel system.

(b)

cylinder head.

on

(c) Defective lubrication

on cylinders.

Dirt

(d) Defective ignition

(e) Idling engine without having

exigine

for

longer

Valve tappet

(f)

test,

Drive

(^)

than 1 minute.

paragraph 43

to

chains

adjustment

too

(h) Excessive carbon deposits.

Lack of Power.

(5)

(a)

Defective fuel system.

(b)

Defective ignition

(c) Overheating. Refer

(d) Defective lubricating

(e) Poor

(I)

(g)

(6)

(a)

buretor. Drain

Cb)

(step

b

compression.

Drive chains too

Brakes

Popping

Water in

Incorrect

(1)

dragging. Adjust

and Spitting

fuel. Water

and

refill fuel tank

valve

below).

Adjust tappets

41).

Refer

paratraph 31.

to

Clean ftni on cylinder, especially the fins

system. Refer to paragraph 30.

system. Refer

incorrect. Refer

for adjustment.

tight. Adjust

Refer

to paragraph 31.

system.

to step

Refer

(4)

system.

Refer

to step

tight.

Adjust

(pars. 96 and 97).

paragraph 32.

to

vehicle in motion. Do not idle

(pars.

to

paragraph 32.

to

above.

Refer

to

above.

(3)

(pars.

to step b

and

59

organization mechanic.

60).

paragraph

59 and

60).

(U

30.

Through Carburetor.

may

be present in fuel tank and

and carburetor bowl.

tappet

adjustment or

(par.

43).

sticky

valves, Test

63

below

car-

TROUBLE SHOOTING

Defective

(c)

Defective fuel

(d)

Weak

(e)

Spark

(7)

Defective

(a)

Excessive carbon deposits. Refer

(b)

(c) Defective fuel system. Refer

Defective lubrication

(d)

Pounding and Excessive

(8)

(a) Front drive

(b) Engine sprocket loose

(c) Excessively loose valve

(d) Engine mounting

Transmission

(e)

Spark timing incorrect.

(f)

Internal parts

(i)

ignition system.

Refer to

system. Refer

and/or broken valve springs.

Knock.

ignition

system. Refer

Metallic Noise.

chain

too loose.

bolts

mounting stud nuts loose. Tighten (par.

of engine

Refer to

on shaft.

tappets.

loose. Tighten.

Adjust.

worn

mechanic.

Tests to Determine Mechanical

b.

Rings and Valves. This is

(1)

possible, make this test with the engine warm.

off. Crank engine slowly, placing

be

crank.

size

Engine

rider

compression should sustain the

several seconds before

crank

range of its travel. If engine offers

testing either

:n

sion is not adequate in one or both

clearance

cient

seating

piston rings badly worn and/or broken: cyUnder

worn,

external checks

right,

::eposits.

;s

not

the

poorly; eyiinder heads leaking;

or

lack of lubrication could cause

and

In extremely cold weather,

increased

mistake

Abnormal Engine

C2)

motorcycle, correct

ponents is necessary for

Many motorcycles have

because simple

have been neglected.

speed riding is usually caused

drive chains, or by

or both cylinders, it is

cylinders. No clearance or insuffi-

valve tappets: valves sticking in guides:

at

first: See that oil is in tank, that spark plugs

examine around cylinder

by "stiff"

this condition to

oil

in engine and transmission. Therefore, do

indicate actual engine compression.

Noise.

Owing

adjustment of

smooth and

been

tune-up service and

normally quiet engine

"deadlined"

correct adjustment

Rough, jerky,

by excessively loose

transmission

a

being

paragraph 32.

paragraph 31,

to

Refer to higher

paragraph 32.

to

step h

to

paragraph 31.

to

to paragraph 30.

paragraph 36.

Adjust (par

or broken. Notify organization

Condition

a simple compression test.

entire weight of body on starter

passes through complete

resistance

little

indication

an

spark plugs

above condition. Make

the

heads for

resistance to

constructional

to

several units

the

and engines

noisy

and

loose

in its frame mounting.

63

TM 9-879

29

authority,

below,

(2)

43).

60).

of Engine.

Ignition

weight of an

signs of leaking oil

engine action

switch must

to starter

that

loose

pistons badly

and

the

starter

components

of

front and

average

crank

compres-

valves

in heads;

crank

design

and com-

operation.

exchanged

at

If

are

of

low

rear

i

9-879

TM

29-30

MOTORCYCLE, SOLO (HARLEY- DAVIDSON MODEL

Fast

the false

ment service.

noise similar to that of badly

idling

impression

of engine

Engine

chain is too tight, or engine sprocket

grinding

loose valve

timing

cause

gear

rough

results,

noise

tappets will cause abnormal metallic noise

train and engine crankcase.

engine performance

pounding, and overheating. Engine

with

consequent noise, result from

mounted

in gear case.

give

to

30. El^GI^X LUBRICATING SYSTEM.

a. Action of the oil feed

located

grounded

up several

of

oil dripping from

oil tank,

pump

it is possible (due to

affecting

in right side of instrument

by the oil pressure

pounds, diaphragm

the scavenger (oil return)

back

just

scavenger

and

engine oil

the vent pipe

"breather" nature; its

Before

rider must

panel

Switch

switch

attempting to

familiar

be

lights

signal

b. Red Signal Light

is Turned On.

Check other lights

(1)

wiring

and

good order. See that

oil pressure switch

indicates

is faulty,

(2)

from switch

light burns

burns,

replaced. If light

lamp

that either the

Test

to eliminate

terminal;

with

it indicates

is burned out.

with

the front drive chain too loose, may give

that the engine bearings and

sprocket loose on its shaft

worn

seeming

insufficient

to come

at low speeds as

loose

gear-tooth clearance will cause "howl"

pump is indicated

panel. (Red signal light

switch. When oil pump pressure

opens

^g-inch

of oil

pump

pressure

(small

diagnose

(par.

connections

wire

terminal.

ignition

that oil

does

not bum in

Remove

pump

hole

gage rod

are separate

faulty

with

unit) for either

and return

pipe) located

function

and understand indications

7 f).

Fails to

to determine

connection

Failure

lamp

the

ground wire

and

light switch

pressure

panel cover

is indicated (engine running) by

in

oil return tube (large tube) inside

(dip stick) tube. Since the

not being

trouble in

Burn When Ignilion

between

of light

is burned

oil pressure

on

switch is faulty,

making

engine bearings. If front drive

and chain

from the engine. Excessively

Spark

pounding and rough operation

mounting

the

signal

units, operated individually,

of oil to the tank. Action of

within the oil

indicated in any manner.

engine lubricating system,

if batteri'

battery and switch

is secure

to bum after

out

switch

switch body

in "ON"

this test,

(par.

64

pistons

will

advanced

well

by

light

function

to

need

cause a pounding

are badly worn, a

in the

too far

as spark knock,

bolts. Generator

the

red signal light

is

circuit.) Action

alone, thus

tank is of a

by instrument

and Light

is "up" and that

and screw

or oil pressure

is tight on

these checks

by removing

and

note if red

position.

and

it indicates

119) and replace

WLA)

replace-

valve

will

normally

is built

feed

oii

are

switch

wire

If light

must be

that

lamp:

in

TM

TROUBLE SHOOTING

Continues

Signal

Red

c-

Above Idling

ated

Check oil supply

(1)

warm,

is

to

system,

(2)

Remove

ignition

short

condition, leaving oil

(3)

light

trouble in oil pressure

burn, it

(1.

from

scavenger

to tank.

or after

locate

trouble,

or fault in

Test

wire from oil

and light switch

circuit in wiring

Install

out

goes

indicates

Excessive

Gear Case Breather Outlet. This

pump

With

Remove tank

permitting), observe whether or not oil is

oil return tube.

in

back of oil

hole and

tank,

incorrectly

be

feel

scavenger

Light

Speeds

tank.

in

minute

1

as

signal circuit. Eliminate

oil pressure

of operation,

indication points to

signal switch to

pressure switch

and observing red

exists. If

pressure switch of the

oil pressure switch and

new

engine is operated

after

signal switch. If

trouble

in oil feed pump.

Smoke Issues from

is not

engine running

oil

gage rod

for pulsation of oil pressure. If

pump

timed, smoke will issue from

draining engine

at

cap,

Hole is

with

and

on under side of

tube. If observation is

faulty, Should the

is

to

If light

light

does not

above idling speeds, it

Exhaust and Oil Spray

speed, examine oil return

idle

a small

noticeably as when scavenger pump is not working. Refer to

below for this condition.

Smoke

e.

Exists Around Cylinder Exhaust Ports (where

enter cylinders).

valve

are

pinion

shaft

breather valve

engine lubricating

removed

is

(within the

timed breather

smoke,

sive

ports.

besides

oily

Issues from Exhaust and Excessive Oil Condition

Engine

one

unit, operated

gear. AUhough scavenger pump

sleeve which drives

system.

from

engine base,

gear

case) when

valve will force

forcing

condition

around

scavenger

worm

by

it

for

If

any reason the

breather valve

the

pump assembly

oil past piston

out

oil

through exhaust ports,

exhaust pipes where

pump and crankcase breather

must

After Engine Is Oper-

Burn

fails to go

further checks

faulty engine

the signal system

out after

must be made

lubrication

panel signal light

If light

indicates

light

turning

continues

terminal by

signal

light.

burn,

it

signal circuit tq be

start engine. If red

red signal

Replace pump (par,

is an indication that the

crankcase

flashlight (tactical

dripping

tube

poor,

oil

crankcase

the

exhaust, but

returning

and

^-inch

from

place

located

finger over

and is

does not

breather valve

exhaust pipes

located

gear

timed

be

scavenger

behind engine

is not "timed,"

to balance

pump

must be retimed

is

replaced. Incorrectly

rings, causing some

causing exces-

they

enter

9-879

30-31

engine

first.

circuit.

bums,

normal

tested.

signal

indicates

44).

Issues

in tank.

situation

hole

just

return

not

step

the

unit

cylinder

on

to

oil

to

as

e

FUEL

31.

a. Many

system are. in

SYSTEM.

symptoms

reality,

which

might be attributed

due to faulty

65

ignition. Before

to the air-fuel

attempting any

9-879

TM

31-32

MOTORCYCLE, SOLO (HARLEY-

but the

thoroughly.

its

h. Shut

open

remove,

c.

(1. Hard

Fuel.

replace screw. Take care

placing. If there is still evidence of water, dirt,

after bowl is drained, replace carburetor (pars. 70 and 7!).

air cleaner oil cup and inspect for evidence

clean, refill to correct level mark, and

obviously required

Gasoline tank supply valve

operation is explained in paragraph 5 b.

off gasoline supply valve.

valve, and

clean out,

Remove,

Remove drain

observe

and

disassemble, clean, and

Starting,

screw from

procedure fail to eliminate

plug located under tank

refill tank

e.

with

fuel.

Hard Starting,

buretor low speed circuit

high

f. Impossible

Lean Spot Between

speed

circuit is

controlled

lo

Obtain Satisfactory Carburetor .\djuslmeal;

Idling and

Carburetors in service

in the

difficult,

valve, incorrect

70 and

cup

throttle barrel,

not impossible.

if

Fuel Leaking from

g.

float

71).

Difficult Starting,

h.

overfilled,

or cleaner

level,

adequate air supply to

level is correct, remove,

adjustments, check the ignition

fiow

free

replace.

Spituns. and

not to

trouble, drain

in forward

or Missing at Idling and Low Speeds.

in need of

by a

for some time become dirty and

making satisfactory low

Replace carburetor

Carburetor. Evidence of dirt in float

or faulty float.

Fuel Mixture Too

elements

carburetor. Check the oil cup level. If oil

clean, and install cleaner elements (par.

DAVIDSON

is a dual purpose

Disconnect

fuel from

of

install

iMisfiring

carburetor

cross drain screw threads

replace

fuel tank

position.

adjustment.

Bxed jet.

30 Miles

to

Up

Replace carburetor (pars.

exceptionally

MODEL WLA)

fuel line

pipe. If line

fuel strainer

Caused by

bowl, drain

other foreign

or

water in oil.

of

Should

cup.

removing drain

by

Replace drain

(par. 68).

Hour Speeds.

per

crust forms

speed

(pars.

Rich. Air

70 and

dirty, choking

adjustment

system

valve, and

at strainer,

is plugged,

72).

(P^r.

"S^'ater in

bowl,

and

when

re-

matter

Remove

Drain,

above

plug and

Car-

Carburetor

71).

cleaner oil

oft

cup

76).

32. IGNITION SYSTEM.

When

a.

checking

ignition system for trouble,

obvious and simple checks

light switch, observe lights

check

to see that current

Faulty spark

ignition troubles.

blast cleaning

spark plugs must

Remedy

b.

plugs are

There

and correct

be replaced

all poor

responsible for the great

is no service for spark

connections in ignition

first.

ascertain battery

to

is reaching spark coil,

For

example:

Turn on

plugs other than sand-

adjustment of electrodes.

(par. 83).

wiring system (fig. 48).

66

the most

make

ignition and

current supply: then

circuit breaker,

majority of

etc.

engine

Questionable

TROUBLE

Remove

r.

Dedal,

Correct

upon

(xindenser,

ing

serviceable

other

and

point

inch.

0.022

is

Testing

(1.

condition and

ignition system is best

the

unit by

each

Remove

(1)

cable

current): turn engine until circuit breaker

sion

ignition

T-rn

-.

inch

and

nnger

ignition

cates

No

(2)

secondary

cable end

hold

the bit of a screwdriver, n:\ake

with

rreaker

:btained

—

.ade

jjar. 84).

or par. 85)

movable

by screwdriver

If circuit breaker

(3)

very weak

a

circuit

observe

gap when

For adjustment

for

condition of

and

replacement

units which were

spark

and plug connected (to effect ground

and

from cylinder:

observe spark

primary

spark

circuits.

Yt,

at high-tension cable terminal gap when ground connection

and repeat test under

breaker

opening

breaker

Tension

Hiph

operation of

plug cable terminal from

switch on; hold

light

open and close circuit breaker

jump

and secondary circuits are

at high-tension gap calls for testing of

Turn engine until breaker points are held

from cylinder: turn

inch

(lever) point,

broken, clean

is

points

spark) occurs at high-tension

SHOOTING

cover, operate

and closing

lever fiber is on

refer to

spark coil and

until trouble is

removed.

paragraph

Spark. Spark at

circuit

done by

at gap.

and

are

means of

a good

the ground. If a good spark is

or replace

in good condition, but no spark

step

(1)

rGndenser does not remedy trouble, replace

If tests made

(4)

.^nition system to

ignition trouble still

and

ienser.

r:;ad

and

:aulty.

and spark

test made with each

remedied.

Ignilion System Tests

e.

'verheats

or Misses. Clearly

Remove

between 0.028 inch

with

plugs

f.

T'.acement

".en

:enser

ipark

new

Engine Misses .\fler

of spark

either

first

coil

(par.

the. condenser

under

steps d

(1),

be in good order (no units having

exists, it means that breaker points, con-

coil must be replaced with

replacement until trouble has been located

Salisfactory

an indication

spark plugs,

to 0.030

ones

of correct

clean with

inch

and

(No.

2)

heat range (par.

Warm-up,

plugs

85).

89).

should

If new

remedy this

or spark

condenser

coil is

fails to

67

9-879

TM

32

engine

circuit

of

highest

84.

breaker

points, condition of

high-tension cables. Test-

located; then

either plug,

high

tension

If

spark

with starter

breaker points-

point of cam

plug gaps

elimination, testing

depends

replacing

leaving

return of

points are closed:

jumps

high-ten-

terminal

cable

points with

gap,

it indi-

complete.

primary and

open;

ignition

switch on and

ground connection between

faulty

breaker points

gap. replace

condenser

above. If replacement

coil

spark

(2),

and

new

(par.

(3)

been

units

89).

above show

replaced),

engine

and

bui Engine Starts Hard,

that

sandblast,

reinstall.

or

Replace defective

When Quite

trouble.

at fault. Replace

correct trouble, replace

spark

regap

If it does

plugs are

points

S3).

Hoi. Re-

of

not.

con-

9-879

TM

33-34

MOTORCYCLE, SOLO (HARLEY-DAVIDSON

GENERATING SYSTEM.

33.

a. Panei Green

Miles per Hour.

battery and

and. if necessary,

generator. Clean commutator

of

sticking

b.

generator. Refer

in holders or badly

Generator Output

Green Signal Light Behavior

not hold charge, or is defective,

used most of the

increase the generating charging

tator of generator. Clean

brushes are

93 and

badly

94).

Signal

Correct

replace

time for

worn or

Light Continues lo Burn Above 20

faulty wiring

to figure

(par. 95).

Inspect brushes and commutator

necessary (par.

if

worn, replace

Fails to Keep

Is Satisfactory. Test

replace (par. 113).

night operation, have a higher echelon

rate.

commutator if

sticking in holders,

MODEL

and connections

55. Inspect condition

91).

generator (pars.

WLA)

between

of relay

If

brushes are

93 and 94),

Battery Charged Although

battery:

If the machine is

Inspect brushes and

necessary

replace generator

(par.

if it

commu-

91

(pars.

will

) . If

34. ELECTRICAL

a. Panel Lamps Do

SYSTEM.

Not Light When Snitch

Ej:amine each lamp and if

battery; if discharged, replace

and connections

116). Test blackout light

lamp (par.

h. Lights

Engine Is

fully charged, replace

tions, and

again after

increased (refer

Lights

c.

Examine battery;

wiring

of the

Light. If

pedal

all

Turned

on lights.

tive wiring

adjustment,

and connections (fig.

lamp body.

d. Blackout

the unit

is not operating

faulty wiring

Horn

e.

On

If

(fig. 71). Test

switch

114).

Burn Dim

.Accelerated. Test

(par.

switches in circuit

a short period

to a higher

Exceed Normal

if defective,

Slop Lamp

is burned

switch,

and

connections

Does

Not Sound

and Horn

lights

and

connections

replace

Button

are dim,

(par.

replace

117).

Is Turned

burned out.

(par. 113). Remedy defective wiring

light

(in lamp body):

but Brighten

battery with hydrometer.

113).

(fig.

of

operation, have the generator

echelon).

Brilliancy

replace (par.

73). Do

and/or Service

out replace

remedy

(fig.

When

Is Pressed. Test

(fig.

73). If the

replace

switch:

(par. 120). Examine

defective, replace

if

if defective,

Considerably

Up

Remedy defective wiring,

If the battery

73).

When Accelerating

113). Remedy

not forget the ground

Stop Lamp

it (par. 115). If

the faulty operation.

73).

Ignition and

battery (par.

horn

Light

battery

113). Remedy

does

not

by

respond

68

On.

(par.

replace

When

If

it is not

connec-

runs down

output

Engine.

faulty

connection

Fail to

the

brake

Remedy

Switch

turning

defec-

to

Is

TROUBLE

TRANSMISSION

35.

Need for attention to

a.

slipping

and

to

usually

adjustment

when

This warning

(par. 48).

slips,

(2)

(par. 4S).

(3)

Idling.

Refer

(4)

under load or

clash)

be

when in disengaged

checked is adjustment

needed. Indication that

is when transmission

accelerating vehicle

must not be disregarded.

Clutch Slips

CO

Adjust clutch spring tension

replace either

Clutch Drags When

Adjust spring tension (par. 48).

Clutch Rattles When in

In this case,

to paragraph 51 a.

Transmission

Vehicle, or When

linkage

IS

tension (par. 48). Make sure the

units are tight

correct

(par,

54).

Transmission

(5)

Fully Disengaged. Adjust clutch

(pars.

lubricant

symptom, refer to

AND CLUTCH.

clutch and

dragging

position. In

of controls:

when under

or

When Fully Engaged.

the disks,

the

Under

(fig.

a higher authority.

springs, or

clutch probably was not

"Jumps"

Heavy Pull. Adjust shifter

Gears

57

Shift Hard or Clash When Clutch

and 58).

If the above

10).

TM 9-879

SHOOTING

controls is indicated by

(transmission gears

either case, the first thing

this being the

gear shifter

gears

controls are

"jump" out of engagement

heavy

(par.

48).

both

(par. 48).

Fully

Disengaged.

Disengaged

Out of Gear Upon

control

transmission mounting bolts and

Drain and

fill

methods

will shift hard

attention

in

pull, CAUTION:

Adjust clutch

clutch still

If the

Adjust control

Position, Engine

properly

assembled.

Accelerating

lever control

linkage

and spring

transmission

fail to

cure the

35-36

clutch

need of

control

with

WHEELS

36.

Transmission Countershaft and Rear

a.

Excessive Wear

Show

rear wheel axle

of the

mission sprocket (par.

of alinemcnt, and the

out

authority.

Chains Produce

b.

Vehicle

to

of

If

on Rear Stand.

proper

dirt and grit.

either

chain is dry,

and sprockets will cause

placed (pars. 62 and

Front

c.

chain in

this condition

.\ND CHAINS.

tension (pars.

If dirty, clean and lubricate

63).

Chain

Dry

One Side of Teelh.

on

to aiine the rear wheel

If they cannot be alined, the

60).

trouble must be

Grinding Noise with Engine Idling

If cither chain is adjusted too tight, adjust

59 and 60).

adjust chain oilers (par. 61). Badly worn chains

this symptom:

and/or Red (Rusty)

has

not been receiving enough lubrication.

69

Examine

the

Wheel

Adjust

sprocket with the trans-

SproekelB

position

the

frame is

referred to

a

higher

and

chains

both

them

worn parts

in Appearance. The

for presence

(par.

must be re-

20 c

(10)).

9-879

TM

36-37

MOTORCYCLE, SOLO

oiler (par. 61). If the

Adjust

oil,

too loose. Adjust (pars.

cones (par.

replace wheel (par.

.\oise (not in Itrake). The wheel bearings are

wheel

hub

Axle. The thrust washers of hub are worn, or damaged.

(par. 127).

(chain removed). Tighten

correct noise,

37. BRAKES.

If

pressure to the brake

adjust brake rod length (par.

stands ahead of

brake does

plate

operating camshaft

assembly

(par. 96).

replace

replace the brake drum and

(par.

age (par.

Adjust

a

If brake

still drags, equalize

linkage assembly

chain

replace (par.

<L

Koufrh

Exfessive Side PUy al

e.

f. Front Wheel Si>inninp Test Produces Grinding.

(par.

o.

Rear Wheel Has

bearings are

Rear Wheel

h-

Rear Wheel Spinning

i.

Rear Brake

a.

the brake linings are

62).

or Jrrk>' Wliicie Operation at

If

126).

125).

defective.

replace wheel (par.

Does Not

the

not hold, replace the defective brake shoes (par.

Rear Brake

h.

sleeve

nut. If it is loose. Adjust shoe position

Squeaks or

and/or side cover bearing

(par. 96).

If

the lining on the

shoes

(par.

95).

Rear Brake

c.

If

96).

Front

d.

brake

short

distance with

does

Front

e.

f. Front Brake

Drags (vehicle

it still

drags,

Brake Does Not

control

slight pressure on brake lever

not hold,

Brake Drags.

shoes and readjust control linkage

Action

(par.

(HARLEY-DAVIDSON MODEL WLA]

chain

damaged from lack of

Is

Low Speed. Chains are

59

and

60).

of Front Wheel, Adjust

Kim

the

cones and^ or

E.xcessive Side Play at Rim

hub races are badly

defective. Replace

Replace wheel (par. 127).

Has

Side P(ay in Excess of 0.010

Test Produces Grinding.

wheel mounting screws.

127).

When Foot Pedal

Hold

wet, operate the vehicle and apply a slight

pedal to dry out linings. After drying

96 b).Ifthe brake

vertical

If

position with brake applied, or the

Chatlers

the brake shoe spring is defective, replace

brake shoes

If

the brake drum is worn or

W^hen

is loose, worn,

Used.

worn, replace the

is

sprocket assembly (par.

rear stand). Adjust

on

equalize

shoe

assemblies,

Hold When Hand Lever

(par.

replace shoes

If brakes

97).

(par,

are wet. operate

97).

Adjust control linkage

to

(par.

Rough and /or Chatters. Adjust control

If malfunction continues, examine

97).

70

bearing

worn,

Grating

of Wheel. The

inch on

Replace wheel

Grating Noise

If

operating lever

does

this

Depressed.

Is

the

96).

linings

Tighten side

defective,

or

If the

(par. 96).

damaged,

96).

linkage

and adjust link-

Operated.

Is

vehicle

dry out linings.

If brake

97).

(par.

97).

brake

not

TROUBLE SHOOTING

spring, camshaft bearing and side

shoe

shoes,

defective parts

any

STEERING.

38.

Molorcycle

a.

of rear

(par. 98).

damper

to

If the steering head

the steering head bearings (par.

pressure. Adjust

If

the condition,

are

the fork springs are broken, replace (par.

wheel (par.

If trouble persists, refer

Molorcycle

I).

suit

to

correct

c.

the tire tread is unevenly worn,

pressure. Make sure rear wheel mounting screws

Motorcycle Shimmies at

replace

tight. If the rocker

f

assemblies (par.

or

Pulls l<(

60). If the

Weaves

One

Side. Inspect

front forks

from

to

speed and road conditions. If this fails,

bearings are too tight, weaving will result. Check

98).

Hi^h Speed. Inflate tires

steering damper

to

and shifting tires does not correct

the defective casings. Make sure

studs

plate

TM 9-879

37-38

cover

bearing.

97).

and correct

are bent or twisted, replace

higher authority.

Siile

and adjust

suit speed and road

Side. Adjust

lo

if necessary.

and bushings are badly worn,

98).

Replace

alinement

steering

inflate tires

are tight.

correct

to

conditions.

axle

the

nuts

or

I

rt

9-879

TM

39-40

MOTORCYCLE, SOLO

(HARLEY- DAVIDSON MODEL

Section XI

WLA)

ENGINE

Description

Tune-up

Replacement

Carbon removal 42

Valve tappet

Replacement

DESCRIPTION AND

39.

a.

L-head design

Of

connecting rod

and

ntted with

slotted

viewed from left side

counterclockwise.

is

b.

maintained in a tank away

is

supply

system

lubricating it.

c.

Type of

*'

Cylinder

Stroke

Piston

Compression ratio 5.0:1

Horsepower (N.A.CC. Rating) 6.05

Engine

and data

of head gasket

adjustment

of oil feed pump

DATA.

Description. This 2-cyIinder. V-type, air-cooled gasoline

operates on

assemblies

low-expansion

pistons and

with

of vehicle

Lubrication system is

feed pump and

plays a most important

Data.

engine

bore

displacement 45.12

number (serial), left

below front cylinder.

just

the 4-stroke, 4-cycle principle.

operate on roller bearings.

aluminum alloy, cam-ground, horizontally

deep-finned aluminum cylinder

(drive chain side), rotation

dry-sump type, in which

of

from engine. Oil is

a

scavenger, return pump. This oil

part in

2

-cylinder, V-type,

cooling the engine

L-head, air-cooled

heads. As

oil supply

circulated

circulating

as well as

2^

3i3/i6

cu in.

of engine base,

side

Flywheel

Engine is

of engine

Paragraph

39 40

41

43

44

engine

by a

in.

40. TUNE-UP.

Tune-up consists of

a.

:appets.

ing and

bowl;

servicing air cleaner, and adjusting

circuit breaker ignition

correcting ignition timing; draining

cleaning

Valve tappet adjustment

(1)

Circuit breaker

(2)

and

flushing

making

points,

gasoline

point adjustment

correct adjustment

soark plug electrodes: check-

and flushing

strainer: cleaning muffler

carburetor.

(par. 43).

(par. 84).

72

valve

to

carburetor

outlet,

Spark

(3)

(4)- Timing ignition (par.

Draining carburetor bowl

(5)

Cleaning

(6)

Cleaning

(7)

deposits,

suitable

(S)

(9)

caked

tool. Do not enlarge outlet

Servicing

Adjusting carburetor

FRAME

BRACKET

service (par.

plug

strainer

fuel

muffler outlet requires freeing outlet of carbon

dirt, oil,

cleaner (par, 7i5).

air

SPARK

^Bjg

ENGINE

83).

86).

(par.

73).

(par-

72).

etc.,

with blade of

when cleaning.

size

(par.

68).

PLUGJU^^OfL TANK

screwdriver,

TM 9-879

40-41

or other

uj ».-* ^m^va-t^., /^m^^

.INDER BRACKET

'SPACERS

CYLINDER

B—

CYLINDER UPPER

C—

SPARK CABLE CLIP

D—

E_CYLINDER BRACKET BOLTS

OIL

F—

HOLLOW

-11. REPLACEMENT OF

a.

_-:its

(1)

(2)

(3)

free

srtention

frame

-ead.

(4)

AND WASHERS

RETURN PIPE

BOLT

Figure 1

BRACKET AND FRAME

MOUNTING

CONNECTION

AND WASHERS

5—Disassembly far Head

BOLT

BRACKET

HEAD GASKET

Removal. Refer to figure

to be removed to perform this operation.

Remove Remove

Remove

clamp which

to shim

lug, as these

Remove

instrument panel cover (par. 119).

gasoline tank and

cylinder head bracket

secures front

washers placed between cylinder head bracket

washers must

spark plug, or plugs.

73

COVER

PANEL

FUEL TANK

PO 315711

TANK

WASHERS

INSTRUMENT

BOLTS,

AND

NUTS

Casket Reptacement

(fig.

15).

illustrating necessary

15,

oil tank

spark

replaced when installing cylinder

be

(par.

107).

frame

to

lug

plug cable. Pay particular

parts and

bolt: this will

and

9-879

TM

41-43

MOTORCYCU,

Remove

(5)

NOTE:

1525.

addition

thick),

were

oil to both

head on

plain

inch thick

bolt

use the

having bolt

thick washers.

(spool-shaped)

cylinder heads and frame bracket. A flat washer

of each

fiat washers between

joint. Use

just

are securely tightened. If

bolts to 60 foot-pounds minimum,

when engine is

in

used to

(6)

b.

(1)

(2)

prevent cylinder head

Perform

Installing

Clean top

sides

cylinder.

Install

washers, if any were

washers

holes

(3)

cylinder

in

0-095-inch thick washers in

hole depth of

Install

long cylinder bolt,

Tighten

(4)

head bolt

snug,

then

SOLO

cylinder head bolts, using

On some

to

carbon

Gasket and Head (fig- 15).

of cylinder.

of

head bolts, using heavy

in

cylinder

spacers,

the

head

tightening each bolt

cold.

(HARLEY-DAVIDSON

head

42 WLA

regular

removal

gasket

removed). If in doubt

addition to regular

head.

Head

IW^

frame bracket with the two

and

above

spacers and the bracket.

bolts evenly to ensure

wrench

torque

models, plain

(heavy)

C^ead

Apply

before

cylinder bead bolt

bolts from bottoming.

only). Refer to

light

a

locating

on

washers (also

washers, measure depth

having hole

addition

inch does not

f^at washers.

the

bracket; some engines may have

41-W-1525.

Ys

wrench

65 foot-pounds maximum tension

to

The

first

to

Y^

is available, tighten head

turn at

MODEL WLA)

wrench 41-W-

bolt

washers

application

cylinder head.

as

depth

regular washers.

require

long bolts, special

spacers

goes

tight cylinder head

a

turning down

(O.OPS-inch

paragraph

of

0.095-inch

to use

"Vn^

the

'^^^'^

0.095-inch

of

go

under the head

a time,

washers,

grease

Place

rhick

0.095-

of

must

Head

between

bolts

until

42.

or

of

all

42. CARBON REMOV.^L.

a. At tirr\e cylinder head

must

bon

43. VALVE' TAPPET

a.

spring covers,

will facilitate raising

(1)

be removed from

ADJUSTMENT (fig.

.Adjust Tappets with

light

a

Loosen valve

application of oil around

cover

spring covers; use tappet and valve

wrench 41-W-3617.

(2)

valve

ahead

Before

is seated

until like tappet (inlet or exhaust, whichever

checking

aad that

or

tappet

removed for

is

only.

head

gasket

replacement,

16).

Engine Cold. Before loosening valve

edge of each

top

without damage to seal. packing.

adjusting

is

tappet clearance, make

at lowest position, by

turning engine

one is being

74

car-

cover

sure

ENGINE

TM 9-879

43

ING

ADJUST-

SCREW

7_TAPPET

2—ADJUSTING

SCREW

LOCK NUT

TAPPET BODY.

3—

4—

VALVE STEM.

figure 1 6~yalve

adjusted) in the other cylinder is at highest

open).

turning adjusting screw

inch

"4."

(correcting

tightened.

0.

thickness gage

sary) clearance after lock

between each cover and

gasket

spring covers.

Inlet valves are located nearest

Loosen adjusting screw lock nut

(4)

(fig.

Adjust inlet valve

(5)

maximum

fig.

Adjust

(6)

007-inch

Before

(7)

to prevent

clearance between

Use thickness

16).

if necessary) clearance

exhaust valve tappets to

maximum clearance

to determine clearance; recheck (correcting

nut has

turning down

tappet

oil leak.

tappets to 0.004-tnch

Tappet Adjustmenf

carburetor

the

("2,"

16).

stems and

valve

gage to determine

after lock nut

0.006-inch

between valve stems and

securely tightened.

been

valve spring covers, inspect paper gasket

guide. If

broken or

Turn down and securely tighten

75

position

fig. 16)

minimum,

tappet

clearance:

has been

mimmum,

damaged, fit

RAPD 310271

(valve fully

manifold.

slightly before

0.005-

and

("1"

and

recheck

securely

and

tappet. Use

neces-

if

a new

valve

9-879

TM

43

MOTORCYCLE,

SOLO

(HARLEY-DAVIDSON

MODEL WLA]

EXTENDED

WASHERS

NUTS

figure

^O

1 7—OH Pump Removed

76

RA PD

315712

ENGINE

REPLACEMENT OF OIL FEED

44.

Removal.

a.

Disconnect oil tank feed pipe at

(1)

tank nipple

on

connect

(2)

oil feed pipe from oil pump nipple.

Oil pump

to prevent

secured to engine gear case

is

from running out,

oil

head bolt and three nuts. Two of

wrench

put back

clearance,

where they belong when reinstalling pump. After removing

their location

and

screw and auts, remove pump. Unless a new pump

able, take care

special

channels.

out

and

lightly

line up with

three lock washers

gasket

of

commission.

b. Installing Oil Pump.

Clean

(1)

see that gasket is

Start

(2)

against pump

Insert hexagon-head bolt and lock washer, and

(3)

mounting studs. Make

studs from which they

Tighten mounting

(4)

Connect oil feed

(5)

from tank nipple and connect

nipple. Tighten nipple

not to damage or break

concerning

"homemade"

A

surface

pump

and

of pump body mounting on gear case

good

in

on mounting

until driving dogs

drop into driving

and nuts (two are long extension nuts) on pump

sure to replace the

were originally removed.

bolt and three nuts securely.

pipe to

nuts securely.

thickness and holes provided for oil

both

gasket may put oiling

condition. Clean face of

studs,

oil

upper end of oil feed pipe

PUMP

nuts are extra

the

should be

the old one,

turn

(ng. 17).

oil

tank.

or drain

cover

noted so they will be

engine

on end of

slot in oil pump

two

extra

pump nipple. Remove

9-879

TM

44

Install nipple cap

tank. Dis-

one hexagon

by

long

gasket is avail-

as this is

system

oil

slowly

cam

rotor.

long

provide

to

very

a

completely

cover

body.

pump

and press

gear shaft

install the

nuts on the

nipple

cap

this

to

77

9-879

TM

45-46

MOTORCYCLE,

SOLO

(HARLEY- DAVIDSON MODEL WLA)

Section

XM

ENGINE-REMOVAL AND INSTALLATION

Remove

Install

45.

a. A study of

steps necessary

methods, as this

to parts or unit assemblies.

(1)

right side of vehicle.

(2)

right side of rear support rod), remove cotter pin and plain washer.

(3)

board front stud nut.

end of safety guard. Disconnect

bolt

support rod. freeing

move nut

assembly

(A)

skid plate

(5)

(6)

tank feed

Disconnect

(7)

free control

(8)

(9)

also green

(10)

(11)

bracket

clamp. Pay

cylinder head

in the

(12)

shifter

engine

REMOVE ENGINE (figs.

figures

for

would

engine

and

18

removal. Do

consume more

and

18. 19,

will provide a good picture of the

19

time

203-

attempt

not

possibly cause damage

and

any

Disconnect battery ground wire at frame lug connection on

To disconnect brake front rod from bell crank (located on

Loosen footboard

then

which secures front exhaust

stop light switch and

front

from

for removal.

support

Remove the two

(fig. 37).

Remove muffler

Disconnect

pipe nipple

pipe from

Disconnect

housing clamp

Disconnect brake

Disconnect

wire

from generator

Remove

spark

Remove

to

frame !ug

particular

bracket

original position.

Remove lever

rod.

(par.

oil pipe from

prevent

to

oil pump

spark control

rear rod

red

wire and

plugs.

engine

bolt: this

attention

and

bottom

support stud nut

rear

pull footboard

outward to free

and

remove

brake front rod at bell crank.

clamp. Remove

pipe

end of side bar.

rear

freeing footboard and brake

rod,

rear mounting bolts and drop rear

81).

nut

tank and install nipple cap on oil

oil from running out,

remove

and

wire at circuit breaker lever,

at cylinder base.

oil pipe.

or

drain

from bell crank.

wire

black

terminal.

top mounting

also frees front

shim

to

frame lug; these

bolt, freeing

from front end of

(cylinder

washers

will have to be installed

gear shifter lever

head bracket)

spark

plug

(if any) between

78

45

46

short cut

foot-

right front

Remove

from rear

Re-

end

tank.

and

relay,

cable

from

of

ENGINE-REMOVAL

AND

INSTALLATION

TM

9-879

45

FOOTBOARD, CLUTCH PEDAL

LEFT

A—

MOUNTING NUTS AND WASHERS

8

SPARK CONTROL WIRE AND HOUSING

—

ENGINE SPROCKET, KEY, NUT AND

C—

D—ENGINE

E—REAR SUPPORT

SPROCKET SHAFT

ROD

F_|NNER CHAIN GUARD

AIR CLEANER AND BRACKET ASSEMBLY

G—

CHAIN

H—

OUTER

NUT

AND COTTER

GUARD

j_SPARK COIL REAR TERMINAL NUT,

K—OUTER

CHAIN GUARD

L—AIR CLEANER BRACKET UPPER

AIR CLEANER HOSE AND CARBURETOR

M—

MOUNTING SCREWS

ENGINE LEFT REAR BASE MOUNTING

N—

P—INNER

Q—

R—ENGINE

AND

—REAR

FUEL

COTTER PIN

SUPPORT

CHAIN

PIPE AND STRAINER

ROD EXTENDED

GUARD MOUNTING

LEFT

FRONT

NUT AND COTTER PIN

GEAR SHIFTER

S—

AND ROD ATTACHING

T^TANK. LOWER FRONT MOUNTING

U—ENGINE SPROCKET NUT WRENCH

Figure

8—Disassetnbiy

1

REAR

MOUNTING

MOUNTING BOLT

NUT

ASSEMBLY

BASE

MOUNTING

for Engine

79

H J

K

RA PD

31S713

AND SIDEBAR ASSEMBLY

DRIVE CHAIN

FRONT

WASHER, SPRING,

BOLT,

WASHER AND

BOLT CASTLE

SCREWS AND LOCKS

BOLT,

BOLT, WASHERS AND NUT

Removal—Left

SCREW

NUTS AND WASHERS

FITTING

BOLT,

ASSEMBLY AND

NUT, WASHERS

WASHERS, CASTLE

WASHER AND

RA PD

Side

AND

NUT

31S713B

9-879

TM

45

MOTORCYCLE, SOLO

C

fHARLEY-

E

TSRQPON

A—MUFFLER ASSEMBLY AND

8

SKID PLATE

—

STOP LIGHT SWITCH

C—

—

D

E—CYLINDER

—ENGINE RIGHT FRONT

F

BRAKE

REAR

WASHERS, SPARK

WASHERS AND COTTER

ROD FRONT

BRACKET

CABLE CLIP AND NUT

G—REU\Y TERMINAL

SAFETY GUARD

H—

J—RIGHT FOOTBOARD,

MOUNTING

END

NUTS AND WASHERS

K~FRONT EXHAUST PIPE CLAMP, BOLT,

EXHAUST PIPE

L—

SPARK

—

M

—REAR SUPPORT

N

PLUGS AND GASKETS

ASSEMBLY

ROD, WASHER

—BRAKE ROD BELLCRANK

P—ENGINE REAR

COTTER PIN

Q

R—VENT PIPE

—OIL

FEED PIPE

S—VENT PIPE

OIL RETURN

T—

Figure

BASE

HOLLOW

PIPE

1 9—

Disassembly for Engine Removal—Right Side

MOUNTING

END

AND

FRAME

BASE MOUNTING

SCREWS AND WASHERS

BRAKE PEDAL AND

AND NUT

MOUNTING BOLTS. WASHERS,

AND

BOLT

DAVIDSON MODEL

F

M

WASHER

80

H J

C

L

BOLTS AND NUTS

MOUNTING BOLT, SPACING

BOLT CASTLS

SIDEBAR

WASHER AND

ASSEMBLY AND

NUT

CASTLE

^* ^^

RA PD

I-

K

NUT AND

315714B

WLA)

315714

NUT,

ENGINE-REMOVAL

Close fuel

(13)

nipple

(14)

(15)

(four screws) and leave attached

mounting

fuel

and

filter nipple.

Disconnect throttle control Disconnect

bracket

(par. 78).

valve.

tank

air intake hose connection

INSTALLATION

AND

Remove gasoline pipe

wire at carburetor lever.

fitting from carburetor

to hose. Remove

air

TM 9-8/9

45

from

cleaner

tank

from

(16)

(17)

(18)

to

crankcase.

(19)

board

support

rod from

Figure

20—Removing Bngine

Remove front chain guard

Remove

With

right side of vehicle.

engine

two screws and

'^',i;-inch

rod stud,

sprocket

deep socket wrench slipped over rear

remove

extended

102).

(par.

(par. 65).

locks securing inner

nut, and withdraw

81

RAPD

310215

chain guard

support

foot-

9-879

TM

45-46

MOTORCYCLE,

To disconnect rhe circuit breaker to

(20)

ground from

wire from oil pressure switch terminal. It will

air cleaner mounting bracket and swing it outward, to gain access

coil

to

nuts. Remove all engine

ator: this bolt cannot

merely push it

is removed from frame.

rear shielding ground terminal.

Engine mounting

(21)

Lift and remove

(22)

SOLO {HARLEY-DAVIDSON MODEL WLA}

coil wire and shielding

coil rear terminals, disconnect oil pressure signal light

far enough

up

necessary

be

are secured

bolts

mounting bolts,

removed without removing generator;

be

clear frame engine

to

by

except

cotter

the one

pins

under

when engine

lug

engine from right side of frame.

free

to

and castle

gener-

46. INSTALL ENGINE

a. Installing

followed

cedure

necessary

is

(1)

that

lug.

(2)

side of frame lugs through castle

generator.

pins.

(3)

terminal

(4)

(5)

side of

(6)

locks mounting

into screw

(7)

that engine

in engine removal.

because checking

Lift engine

mounting bolt under

Pass remaining

nuts.

Connect circuit

and ground shielding

Connect

Pass

vehicle and

Secure inner

slots for

Install

place before

the engine

to satisfactory

into frame from right side

Fit

plain washer and castle nut

Securely

rear footboard

tighten

oil pressure

install the

chain

inner

chain

security,

engine

shaft

tightening

is

sprocket

clean,

on wrench.

(S)

Install

Connect

(9)

washers,

four screws

frame

terminals,

bracket

outer front

and nuts

securing

was

securely

hose and

securing

hose

loosened

mount

assembly.

(figs. 18.

generally the

is

Pay close attention to the

19,

and

20).

reverse of

the procedure

following

and adjustment of controls and other items

vehicle operation.

vehicle. Make sure

of

generator

three

crankcase

all

breaker

engine mounting bolts

four

to coil wire. Connect

raised to clear frame engine

is

from under

up

lugs: install plain washers and

wire to

bolt

with

coil

on mounting

castle nuts and lock

on coil case terminal.

switch

support

guard guard to engine

sprocket

chain guard

fitting

air

fitting to carburetor.

and shifted

bracket

wire to switch terminal.

extended

rod through frame

'-'lu-inch-nut.

lug from right

by attaching the two screws and

base. Drift edge of

and

front drive chain together.

taper clean, and

nut.

Drift

nut

(par.

102).

assembly

cleaner to frame

by installing two

that key is in

tight,

using hammer

bracket; then

NOTE:

to gain

before

access to coif

installing air

bolts.

install

// cleaner

cleaner

32

pro-

under

cotter

rear

locks

See

rear

ENGINE-REMOVAL AND INSTALLATION

Connect

(10)

that throttle closes

throttle opens fully when grip is turned inward.

Install fuel

(11)

fuel strainer nipples.

for leaks.

Connect gear

(12)

ing bolt and

Attach engine top mounting bracket (cylinder

(13)

bracket)

of thin shims, together with clamp for front spark

space

to

between

NOTE; Frame

"e/ecfrica/" connection

adequate radio

Before installing spark

(14)

correct electrode

gaskets to ensure tight joints.

Connect red and black wires

(15)

to generator terminal

(fig.

73).

Attach rear brake rod

(16)

secure

secure control

sure

handle

control

wire

used)

tank

with

Connect spark control

(17)

spark advances

that

bar)

grip

lever connection.

and

Remove nipple

(18)

and connect oil feed pipe, securely tightening union nuts at

and oil pump.

Position exhaust

(19)

throttle

nut.

frame

bracket and frame lug before tightening

lug must be free irom

bonding.

adjustment. Service if necessary (par. 83).

cotter

pin.

wire housing clamp

is turned inward,

is turned

hanger frame bolt,

bracket

located

(20)

and muffier

Attach

bracket

(21)

sembly.

placing

clamp

but

bolt,

this bolt.

on

Lift rear

front

plate

skid

bolt and nut.

Install right

Install

lock washer

to

stop light switch

sidebar.

do

end of

left side bracket, tightening support rod nut

control wire

when right

fully

Securely

pipe.

fuel supply valve and check connections

Open

shifter

lug. exercising care

with

lever

plated

plugs,

carburetor lever.

to

is turned outward;

grip

tighten union nuts

end to

gear shifter rod

installing required number

in

paint or

shims

inspect

to

grease

and

mounting

relay; connect green wire

marked "SWITCH." Refer to

to bell crank. Install plain

wire

fully (lever inward) when control grip (left

and that

outward. Make needed

from tank oil pipe nipple (if

cap

and muffler

pipe

washer, and nut. Secure muffier

tighten nut

not

skid

plate, secure rear mounting

mounting bracket

side footboard, sidebar, and brake

bracket on rear support rod

and

tightening nut.

Install lock washer,

circuit

to

under

cylinder

spark retards fully when

adjustment at control

assembly

until skid

with

plate rear bracket is

bolt, washer, and nut.

Attach

and tighten

83

TM 9-879

Make sure

on

by

cable, to

plug

make clean

to

bracket for

cleanliness and

for

wiring diagram

washer

breaker

nut. Make

base

and attach rear

front mounting

exhaust

front

sidebar

46

and that

tank

and

tighten-

head

bolt

nut.

Replace

and

lever

and

one was

bracket

and

pedal as-

before

pipe

front

fill

9-879

TM

46

MOTORCYCLE,

support rod nut-

with footboard

Also

nut.

switch control to brake foot pedal,

(22)

secure with cotter pin.

(23)

vehicle.

b.

and

tighten

Attach

Connect battery ground wire to frame

Check

see that oil is in tank before starting

SOLO

Attach right

front support stud. Replace iock washer,

footboard rear support stud nut. Connect stop light

brake front rod to bell crank:

instrument panel signal lights for

[HARLEY-DAVIDSON

end of

front safet>'

fit plain washer

lug on right side of

engine.

MODEL WLA)

guard to sidebar

tighten

and

normal indications,

84

Description

Maintenance and

adjustment

Removal of disks

Inspection of disks and springs

Installation of disks

Replacement of clutch release

TM

Section

Xlll

CLUTCH

bearing 52

9-879

47-48

Parograph

47

48

49

50

51

47. DESCRIPTION (fig.

a.

Clutch is of

disks and

disk pack

three

to "cushion"

simple multiple-dry-disk type, having two steel

lined disks,

48. M.4INTENANCE

a. If clutch adjustment is correctly maintained, clutch will

very little trouble. Ease of gear shifting

mission-

ment

control linkage

sion before

control

hollow

Correct

before

position

the

clutch release

movement

of control cable

lever

shorten

from

ward

ing cable

lease of notch.

cable adjustable cable end

gear shifter

of the clutch. Clutch adjustment is in two parts; namely,

correcting

b.

Clutch Control Linkage (fig.

cable,

transmission shaft, disengaging

adjustment

push rod

0.

Clutch Control

Adjusting

(1)

(foot pedal heel down) the clutch release

countershaft sprocket

is

restricted,

and sprocket cover stud and/or

clutch control cable, cable

foot

pedal stud

(roe down) position,

end. Release other

lever

by pressing release lever

Rock

to right (clockwise)

clutch

spring

and

clutch

and

to

adjustment

Cable Length. With clutch

lever strike sprocket

must be

foot

the

end

21).

which provides spring

one of

clutch

operation.

.4ND ADJUSTMENT

(figs. 22,

and service

dogs depend

tension. Do not adjust clutch spring

control adjustment.

release

control cable

lever actuates

is made.

largely upon full disengage-

Operation

22).

the push rod through

engaging clutch

or

release lever

and

Adjustment (figs. 23, 24. 25, and

in fully disengaged

cover stud and/or nut

cover and nut,

clutch

and

adjusted

cannot be fully disengaged. Length

to obtain

adjustable end must

(figs.

23 and

remove

end

cotter pin and

of cable

inward and

pedal

to rear (heel down)

off

foot

pedal

stud.

to

shorten cable; turn

nut

24).

by

Yn^-inch

clearance.

With foot

from

notch

lifting cable

Loosen

position

lock nut

23. 24,

of foot

must be

lever must

Y-^q

clutch push

clutch

To lengthen

pedal

washer retain-

to left

action within

and

25).

cause

life of

trans-

pedal,

at

ten-

will.

made

26).

clear

Should

inch.

rod

release

removed

be

for-

in

in clutch re-

out

end

work

and

turn

and

(counter-

or

9-879

TM

48

MOTORCYCLE,

SOLO

(HARUy-DAVlDSON

MODEL

V/IAJ

a

a.

<

a

3

«

mi:

8

14

5

86

«

CLUTCH

TM 9-879

48

RA

PD 310219

AND

CLEARANCE

LEVER

1/16-INCH

BETWEEN NUT,

STUD,

Figure 22—

C/u*e/i Controf Linkage

Figure

23—Clufch Lever

and Stud

87

Nut Clearance

9-879

48

MOTORCYCLE,

SOLO (HARLEY-DAVIDSON

MODEL WLA]

Figure 24—Confro/ Cable Length Adjusfment

clockwise) to

foot pedal stud:

oi' cable

Adjusting

(2)

P'.'SH Rod (fig- 25).

s::ud clearance correctly adjusted

lever must

PUSH

mtoeiNO

lengthen

install washer

clutch release lever

in

Clearance

With

between

have

ano

aurai

Figure

LEVts ru

boo

cable. Tighten

notch.

clutch release

J^-inch and J^-inch

25—Clutch Adjustments

lock

nut. install cable end on

cotter pin,

and

Clutch

of

lever

(1)

ADJUSTINa

above),

free

(step

PUSH ROO ADJUStMEN'7 SCiFA'

S8

RAPO 3

and install

other

0221

J

end

Release Lever akd

sprocket cover

and

clutch release

play at end where

(OC

RA PP 31S71S

tcuw

PUM

CLUTCH

engages lever

control

fully

cable

engaged clutch without pressure on clutch release

justment is made by means

clutch

cover

i/^-inch

lock

clockwise) to increase amount

has

to

lock

cover.

explained

much

quently,

become

outer disk.

to chain guard

free

nut and turn push rod

more than ^-inch free

the right

nut after correct adjustment

CAUTION; //

above, clutch

free play is allowed,

transmission

damaged.

Remove

at end of

play

(clockwise)

notch (fig.

push rod adjusting

of

two screws

(fi.g. 25). If clutch release

cable, loosen push rod adjusting

adjusting screw to the left (counter-

of free play. If

play at end of

to decrease

ena

dutch release lever

of

will

not hold

clutch will drag

gears

will

25).

which

cable, turn adjusting

amount of

is obtained. Replace inspection hole

when

shift hard, clash,

TM

This free play

screw

secure inspection

lever

clutch

free

has no free play as

fully engaged. If too

when

disengaged; conse-

ensures a

bearing. Ad-

located

has less than

release lever

play. Tighten

and eventually

9-879

48

in

hole

screw

Adjusting Clutch

d.

(does not

controls

after

figure

hold when starting engine

26~Ad'njsting

have been

above), spring tension

spring tension any

Remove front outer

(1)

Bend

(2)

Turning nuts to right

(3)

tension. Tighten

at a time,

turn

more than

down

lock lips

(turn to

until clutch

SPRING TENSION

ADJUSTING

Clutch

Spring

correctly adjusted (step

must

Tension

be increased. NOTE:

actually required to

chain guard

to free the

(clockwise)

right) all three adjusting nuts, one-half

holds.

Test

NUTS

RA

PD

Spring

with vehicle in operation)

or

Tension

(fig. 26).

If clutch slips

c

) and

(

1

Do

not

maice clutch hold.

(par. 102).

three clutch adjusting nuts.

increases

clutch

after each half-turn

89

310223

(3)

increase

spring

9-879

TM

48-49

MOTORCYCLE,

of the

that holds

also

lock

three

holds on the

After

(4)

lips to secure

without

SOLO [HARLEY- DAVIDSON MODEL WLA)

adjusting

road.

clutch

any

spring tension

adjusting nuts.

by cranking engine. Usually a clutch

nuts

noticeable slippage when cranking engine,

adjustment

Replace

made, bend up nut

is

any

broken or badly

damaged locks.

When

(5)

distance

outer (releasing) disk

tighten the three adjusting nuts to the point where inner

shoulder of spring collar is

leasing) disk.

disengaged.

from

new

a

clutch is originally assembled

the inner

compressed

If

edge of

is

1%^

shoulder

inches (fig.

closer

than

more,

and adjusted, the

on spring collar

27). In any case, do not

inch

^

clutch probably cannot

face of outer

to

to face of

edge of

(re-

be fully

Figure

tension

be replaced (par.

outer front chain guard

49.

replacing.

27—MeasijHn^

If cli,itch still

(7)

adjustmenb?

After

(8)

REMOVAL

Clutch disks can be removed

a.

Springs

have

4'i).

making clutch

OF DISKS

can

KArD 310224

Distance Between Spring Collar and Disk

does not hold, after correct

been made,

spring tension

(par. 102).

(figs. 28, 29. and

removed for

be

clutch "pack"

for inspection, cleaning, and/or

checking and/ or

control and spring

assembly

adjustment, replace

30).

replacing

90

must

CLUTCH

ADJUSTING

LOCK NUT

Figure 2S—Remov/ng Spring and

SCRPA'

,*5

NUT LOCKS

LARGE

WASHER

ADJuIVVn^NUTS

TM

49-50

OUTER DISK

ASSEMBLY

RA PD

Outer Disk Assembly

315716

9-879

without

advisable

assembly

reassemble

and appear

replaced

washer, approximately

3/^-inch center

adjusting

disturbing sprocket, which

to remove releasing

because

springs

necessary (par.

if

Remove

(1)

Remove push rod adjusting screw lock nut.

(2)

screw

it

in this unit. If

to

be "set,"

outer front chain guard (par. 102).

hole,

lock nut just

(outer) disk, springs,

is difficult to

they should

50).

J^-inch

over push rod adjusting screw, and

removed

integitel \vith

is

correctly aline,

springs show signs of

be

thick.

1^-inch

(fig. 28).

screw lock nut against large washer until

adjusting

justing

one

as

from

30).

observe

50.

a.

nearly flush) with

replaced.

nuts are

nuts, and

unit. Remaining

sprocket and

NOTE; Ac time

relative

position of each disk

INSPECTION

Worn

Disk Liners. When disk

free. Bend nut lock

withdraw releasing (outer) disk and

and plain

lined

clutch shell unit

and plain

Vmed

OF DISKS AND SPRINGS.

rivet heads, disk

down, remove the three

steel disks

without

disks are

order of

in

liners are worn

and liner assembly

91

clutch

and collar as an

hold

in place,

Place

diameter

in

measured,

removed,

Tighten

three clutch

the

spring assembly

can now be removed

further

disassembly

removed

carreer

assembly.

down flush (or

shell. It

and

overheating,

and

flat

large

a

with a

replace

adjusting

spring

ad-

(fig.

shell,

from

must be

is

I

9-879

TM

50

MOTORCYCLE,

SOLO (HARLEY- DAVIDSON

MODEL WLA;

RELEASING

Figure 29—Outer Assembly

DISK

AND SPRING ASSEMBLY

NUT

LOCKS ADJUSTING

Removed,

SPRUNG DISK

LONG

NUTS

Exposing

STUDS

^^ ^^

Clutch Disks

315717

LOCKS

OUTER

ADJUSTING NUTS

Figure 30—Clutch

DISK

ASSEMBLY

Disks, Removed

92

LINED

STEEL DISK

SPRUNG

ON ONE

RA PD

DISK

DISK LINED

SIDE

315718

Loose Liner

b.

liner assembly with

and

Oil-soaked Disk Liners. If lined

c.

oil-soaked, wash them thoroughly

are

heat.

or

sir

Shrunken

d.

heated as a result

Rivets.

like assembly

^ eak Springs.

or

of

slippage, springs

weakened condition. Assuming

weakened springs

been tightened

havG

between

or weak

nut.

(outer) disk assembly.

springs

32

of

spring collar and releasing

springs

To

(1)

(2)

inch). Old

spring is

remove springs, remove

freeing spring collar

Measure springs

is approximately

NOTE: Before replacing

more than \'>2 inch to make

Assembling Releasing

(3)

the 10 springs upright

Place

stud

the 10

of

springs, locating the

|of

[Springs.

tighten

^

Place

adjusting screw

are

indicated when

to make the

are suspected, remove

for

I^ inches

springs found to be shrunk

inch

ly^

holes.

the

or less) must

springs, select

up

Place

spring collar (flanged

collar plate "dimples"

large

washer over push

nut, and compress springs lightly. Turn

ssembly over and observe

iecessary, insert a 3/^-inch

adjusting

down

screw nut;

rod

assembly is now

assembly.

TM 9-879

50-51

CLUTCH

disk liner rivets are loose, replace disk

If

new or

in

disks are

clean

in

If clutch has been

gasoline and dry

may be found

disk liners are not badly worn,

the three spring tension nuts

clutch

(outer) disk is

push

the

and

free

10 springs from the

length.

(they

be

the assembly.

Disk,

releasing disk

on

alJnement of springs and

through holes to

hold

for

them

rod

adjusting screw

Free

length of new

may vary plus

inch (total free length

^

replaced with new springs.

10

springs that do not

Springs,

to

edge

rod

aline

ready

order.

good

badly worn, but

not

badly

in

shrunken

until the

inch. If shrunken

"//s

inspection.

Spring

and

centrally

locate each

down) over ends

ends

in

for

of7of the

adjusting screw;

disk

springs. Tighten

complete clutch

distance

releasing

or

Collar.

holes. If

with

over-

or

lock

clutch

minus

vary

INST.\LLATION OF DISKS

fl.

It is important

a.

Install

tisk.

staggered

is the last

side)

installing disks,

are

21)

plate. This is to prevent

(1)

(2)

within the clutch shell, with

(3)

the two steel disks

on

splines in the shell, and the "sprung" disk (lined

placeonthe

in

Install

Ne.xt,

Install

one of the two lined

engage one of the two steel disks with

the remaining lined

when assembling a

of the pack,

that

see

short studs, and

noise

(figs. 30. 29, and 28).

clutch

so that

lined side facing

its

the antirattle devices are

bearing retaining plate

tight against the retaining

are

the clutch.

in

on clutch hub studs

disks

stamped "OUT"

side

disk on the clutch hub studs.

93

start with a lined

to

steel disk. Before

the

rings

lock

facing

("R."

the

outward.

one

on

fig.

first.

splines

9-879

TM

51

MOTORCYCLE, SOLO

Engage remaining

(4)

facing

side

(5)

clutch hub studs.

on

(6)

studs

that the three holes (keyhole shaped) in the spring collar

spaced equidistantly. Therefore,

spring assembly on clutch hub studs, the three threaded

holes

place the three

tighten all three

collar and face

(7)

screw lock nut.

and push rod adjusting screw until outer front chain

board

outward.

Install

It

are not spaced an equal distance apart. It will also

in

"siDrung" (one side lined)

will

spring collar must be alined. Install assembly

noted that the three long, threaded-end, clutch hub

be

nut locks,

evenly

of releasing

Remove the large washer and replace push

Do

not attempt adjustment of clutch

have

been

installed.

[HARLEY-DAVIDSON MODEL WLA]

steel disk

replace the three adjusting

until the distance between shoulder

disk is

with shell spHnes

steel

disk, lined side inward,

when installing

i^ich (fig.

IV32

with "OUT"

releasing

on studs, re-

27).

rod adjusting

release lever

guard and foot-

noted

be

not

are

and

disk

and

studs

nuts, and

spring

of

BOLT

WASHER

Figure

AND

31 —Removing

NUTS

WASHERS

AND

Clutch Releasing

94

315719

PD

RA

SPROCKET

CLUTCH LEVER ASSEMBLY

Bearing

COVER AND

Assembly

CLUTCH

Install outer front chain

(8)

Check controls

(9)

according to

REPLACEMENT OF CLUTCH RELEASE

52.

(fig.

a. Clutch

paragraph 48.

31).

release lever acts against a

and

assembly which actuates clutch releasing disk.

Remove Cluich Release Bearing.

b.

toe down) and

pedal

end of

rear chain oil

to

mission.

may

release bearing is exposed.

transmission shaft.

clutch

(1)

release

Loosen rear

pipe and secures

tr.ansmission countershaft sprocket cover.

Remove the four nuts which

(2)

Remove

(3)

down

Hold

(4)

Remove sprocket cover

(5)

be

necessary to pry cover off studs.

Withdraw clutch

(6)

disengage clutch

lever.

chain guard by

filler plug.

starter crank with screwdriver.

release

guard (par.

clutch

front end

and

bearing and

adjustment.

thrust

Engage

control

removing

of rear drive chain

secure

clutch

release lever assembly.

With cover removed,

TM 9-879

102).

necessary, correct

If

BEARING

bearing and push rod

clutch fully

cable end

cap screw

sprocket cover to

push rod assembly

from slotted

which retains

51-52

(foot

guard-

trans-

It

clutch

from

Install Clutch Release Bearing.

c.

Insert push rod with

(1)

transmission shaft hole, as far as rod will

clutch release

and well greased.

Install sprocket cover. Securely

(2)

Install cap screw which secures

(3)

chain oiler pipe clamp to sprocket cover.

Engage clutch control cable end

(4)

release lever.

Check

(5)

clutch release lever for free

95

bearing assembly

go. See that

tighten

rear chain guard

slotted end of clutch,

in

bearing is clean

four nuts.

the

play at end of cable.

end

into

and

9-879

TM

53-54

MOTORCYCLE, SOLO (HARLEY-DAVIDSON MODEL

Section XIV

WLA)

TRANSMISSION

Paragraph

Description , 53

Control linkage 54

Replacement of foot starter crank 55 Replacement of starter crsnk spring

Remove transmission 57

Install transmission

56

58

53. DESCRIPTION.

a. Transmission has

of the constant-mesh, non-selective

Since

"dogs" on

gears,

it is

justed.

vent

Clutch must be fully disengaged

clashing of gears, and possible

"dogs" and

control linkage be kept in

gear

shifter clutches

of

great importance

transmission

speeds: low.

three

that vehicle clutch is correctly ad-

gears. It

correct adjustment to ensure full

second, and high, and is

High gear is direct dr:ve.

type.

are used to engage transmission

when shifting

damage

is also important that gear shifter

to the shifter

•

gears, to

engage-

pre-

clutch

ment of shifter clutch driving dogs in all positions, thus pre%'enr.ng

possible damage caused by dogs jumping out

driving load. Close fitting

mission,

case

necessitate use of engine oil (seasonal

for adequate lubrication.

54. CONTROL LINKAGE

a. Transmission Shifted

and needle

(fig. 32).

lo .\djust Front

roller bearings,

transmission is located to receive power from front (engine) drive

chain and transmit power

and is movable

drive chain. When

mission

front drive cham

shifter control

gear

mounting

on its

front (engine)

adjustment, gear

through

linkage is affected.

rear drive

adjustment

for

drive

shifter

checked, and. if necessary, correctly adjusted

shifting with full engagement of the gear

"dogs" as

well

as prevent transmission from jumping out of gear

under load.

b. Checking Gear Shifter Control Linkage.

adjustment to gear shifter

checks; See that all linkage

lever

to gear

Check

is binding or interference with

range: this

hand

shifter

lever pivot

sometimes

hand lever are well

results

control linkage, make the

points from transmission gear shifter

boit

for

nut

tightness. Observe

shifter rod at

from a bent shifter

of engagem.ent

within

under

the trans-

grade) in transmission

Drive

Chain. The

chain to rear wheel.

of the front (engine)

chain is adjusted, trans-

Therefore,

control linkage must be

to ensure proper gear

shifter

after each

clutch driving

Before making

following

oiled and

any point

free-working.

whether

in the shifting

Check whether

rod.

there

96

TRANSMISSrON

or not shifter rod is correctly adjusted,

moved to any gear position

moves to

shifter cam

mission).

the

proper

spring plunger

position

tank

in

to

in

shifter

fully

cam-locsting notch (inside

so that when

guide, transmission

engage

shifter clutch dogs

TM

hand

9-879

54

lever

and

trans-

is

Adjusting

c.

Set hand lever in

(1)

Remove nut and

(2)

lever.

With

(3)

carefully

cam spring

notch.

Next,

(4)

tank

in

shifter guide.

310229'

RAPD

figure

32~Adjustlng Gear

Gear Shifter Control Linkage (fig.

(neutral) position in shifter

"N"

to disconnect shifter rod

bolt

slight backward and forward movement of shifter rod,

"feel"

transmission lever

plunger (inside transmission)

see

that

hand

lever is

into

Shifter

Rod

32).

from hand

position where shifter

exact

fully in

seats

in exact "N" (neutral)

cam-locating

97

guide.

position

9-879

TM

54-56

MOTORCYCLE, SOLO (HARLEY- DAVIDSON

Readjust length of shifter rod by loosening rod

(5)

turning rod

and

hole lines up with bolt hole in hand lever.

Replace bolt

(6)

Check Adjustment.

(7)

(low)

"L"

adjustment

(8)

of jumping out of

shifter control linkage is

and "S"

to be sure of

When

shifter

removed and referred to higher

(onto or

end

and

tighten

off rod as necessary)

nut.

It is advisable

(second) gear positions

having best all-round adjustment.

clutches become worn

engagement

correctly

under

authorit>' for service.

adjusted,

or

driving

MODEL WLA)

to shift

and

damaged to the extent

transmission must be

hand

check shifter rod

load,

55. REPL.\CEMENT OF FOOT STARTER CRA.NK.

Remove.

a.

(1)

crank.

(2)

b. Install.

clearance)

spring

tension on crank.

Use a 5^-inch, open-end wrench

)

(

1

Remove

Pull

starter

starter crank

In

must be in

counterclockwise

and

tion

inserted.

(2)

in upward position)

operated.

(3)

press starter crank onto shaft

Insert clamp bolt

Fit lock washer and nut and tighten nut securely.

crank clamp bolt nut

off

squared shaft.

installing foot starter crank, notch

upward position

in squared shaft

and

and turn

until bolt slot is upward. Hold

until clamping

with

bolt

head toward rear

provide clearance

to

when

remove bolt from

(for clamp-bolt

shaft

starter crank is

end lock nut,

until its bolt

lever into

even

though

'

~

to put return

square shaft

in this posi-

bolt

can be

wheel

(crank

56. REPLACEMENT

Starter

a.

crank spring fits rather snugly behind

OF STARTER CRAMC SPRING (Bg. 33).

countershaft sprocket cover; however,

without

end of spring

not be

of sprocket cover

position.

spring

removing

b. Remove.

Remove foot

(1)

With

(2)

necessary.

c. Install.

Turn

(1)

Engage

end

to rear, in

starter

cover.

crank

spring

end, at same time

spring off square shaft.

sprocket

the blade of a screwdriver or with

off stud. NOTE; // spring is

Pull on

so'as to pull

squared shaft so that clamp bolt

square

hole

in spring on shaft

with starter spring

line

98

it can be removed

(par.

55).

broken, this

stud. Work spring onto

pliers,

prying

notch

with

rear

edge

and installed

hooked

pry

operation will

spring free

is in bottom

the hooked

of

TRANSMISSION

TM

9-879

56-57

STARTER

shaft,

squared shaft.

(2)

(3)

57. RE.MOVE TRANSMISSION

a.

removed and installed together.

be

CRANK

Figure

prying

Transmission

it

Hook end of

Install foot

ASSEMBLY BOLT,

33—Removing Sfarfer

to rear

starter crank (par.

clear

to

spring in place on spring stud.

and clutch

I

WASHER

Crank Spring

sprocket cover. Press

55).

34

(figs.

assembled in one unit and

are

To make

99

and 35).

sure trouble is

AND

all

RA

315720

NUT

the way

trans-

in

PD

on

must