Professional Documents
Culture Documents
GENERAL INFORMATION
MANUAL ORGANIZATION
CHAPTER ONE
SAFETY
FIRST
SERVICE
HINTS
GENERAL INFORMATION
CHAPTER ONE
23. Take your time and do the job right. Do not forget
that a newly rebuilt engine must be broken in just
like a new one.
TORQUE SPECIFICATIONS
FASTENERS
GENERAL INFORMATION
a. Diameter.
c. Thread pattern.
d. Thread direction.
Bolts
Slotted
Phillips
Allen
Internal Torx
External Torx
MACHINE SCREWS
Hex
Flat
Oval
Fillister
Round
CHAPTER ONE
Nuts
a. As spacers.
per inch.
Figure 7 shows several types of nuts. The com
mon nut is generally used with a lockwasher. Selflocking nuts have a nylon insert which prevents the
nut from loosening; no lockwasher is required. Wing
nuts are designed for fast removal by hand. Wing
nuts are used for convenience in non-critical loca
tions.
by the fastener.
c. To help distribute fastener load during torquing.
d. As seals.
opening.
Self-Locking Fasteners
Common nut
Self-locking nut
Wing nut
strength and better vibration resistance. Some selflocking fasteners can be reused if in good condition.
Others, like the nylon insert nut, form an initial
locking condition when the nut is first installed; the
nylon forms closely to the bolt thread pattern, thus
reducing any tendency for the nut to loosen. When
Folding
Washers
Internal tooth
External tooth
GENERAL INFORMATION
<&
Snap Rings
<&
Installation
of cotter pin
Full support
areas
Direction
of thrust
install them.
LUBRICANTS
Rounded edges
y% I 'Sharp edges
Direction of thrust
CHAPTER ONE
Engine Oil
Oil for motorcycle and automotive engines is clas
sified by the American Petroleum Institute (API) and
the Society of Automotive Engineers (SAE) in sev
eral categories. Oil containers display these classifi
cations on the top or label.
API oil grade is indicated by letters; oils for gaso
line engines are identified by an "S." The engines
covered in this manual require SE or SF graded oil.
Viscosity is an indication of the oil's thickness.
The SAF uses numbers to indicate viscosity; thin
oils have low numbers while thick oils have high
numbers. A "W" after the number indicates that ihe
1970-1984
stamped on a pad on the right-hand engine crankcase. The frame VIN number is stamped on the
right-hand side of the steering head. All 1978-1984
models have a VIN label attached to the right front
frame downtube.
Grease
SERIAL
describing the country of origin, manufacturer, Harley-Davidson code, model type, model introduction
date, factory check number, year of manufacture.
assembly plant and a 6-digit sequential serial num
ber. The full 17-digit code is stamped on the frame
steering head and printed on the VIN label. The
engine number is an abbreviated 10-digit code. It
lists the model code, model type, year of manufac
ture and sequential number. See Table 5.
NUMBERS
1966-1969
PARTS
REPLACEMENT
GENERAL INFORMATION
BASIC
HAND
TOOLS
Screwdrivers
CHAPTER ONE
10
Pliers
CORRECT
TAPER
AND SIZE
FRONT
SIDE
TAPER TOO
GENERAL INFORMATION
11
Adjustable Wrenches
An adjustable wrench can be adjusted to fit a
variety of nuts or bolt heads (Figure 18). However,
it can loosen and slip, causing damage to the nut and
injury to your knuckles. Use an adjustable wrench
only when other wrenches are not available.
Adjustable wrenches come in sizes ranging from
4-18 in. overall. A 6 or 8 in. wrench is recommended
as an all-purpose wrench.
Socket Wrenches
Torque Wrench
A torque wrench (Figure 20) is used with a socket
to measure how tightly a nut or boll is installed. They
come in a wide price range and with either 3/8 or 1/2
square drive. The drive size indicates the size of the
square drive which mates with the socket. Purchase
one that measures 0-150 ft.-lb, (0-207 N-m).
CHAPTER ONE
12
Impact Driver
currents.
Feeler Gauge
This tool has both flat and wire measuring gauges
and is used to measure spark plug gap. See Figure
22. Wire gauges are used to measure spark plug gap;
flat gauges are used for all other measurements.
Vernier Caliper
This tool is invaluable when reading inside, out
side and depth measurements to close precision. The
(23
TEST EQUIPMENT
GENERAL INFORMATION
13
Figure 24,
Compression Gauge
An engine with low compression cannot be prop
erly tuned and will not develop full power. A com
pression gauge measures the amount of pressure
present in the engine's combustion chambers during
the compression stroke. This indicates general en
gine condition.
The easiest type to use has screw-in adaptors that
fit into the spark plug holes (Figure 25). Press-in
rubber-tipped types (Figure 26) are also available.
Dial Indicator
Portable Tachometer
=tj i <-r i
-i
^^ffB^^B^BI
" n r i i i =^^y
^^^^^^^W^BB
fw *
CHAPTER ONE
14
Expendable Supplies
MECHANIC'S
TIPS
portion.
(D
GENERAL INFORMATION
15
Center punch
Drill hole
Tap extractor
Remove
into hole
screw
CHAFfER ONE
16
Table
GENERAL
SPECIFICATIONS
Wheelbase
1966-1969
1970-early 1978
FL/FLH
FX
FXS
Late 1978-1984
FLH/FLHS
FXB/FXSB/FXS
FXE/FXEF
FXWG
Overall length
1966-1969
1970-early 1978
FL/FLH
FX/FXS
Late 1978-1984
FLH/FLHS
FXB/FXSB/FXS
FXE/FXEF
FXWG
Overall width
1966-1969
1970-early 1978
FL/FLH
FX
FXS
Late 1978-1984
FLH
FLHS/FXE/FXEF
FXB/FXSB/FXS
FXWG
Overall height
1966-1969
1970-early 1978
FL/FLH
FX
FXS
Late 1978-1984
FLH
FLHS
FXB/FXSB/FXS
FXE/FXEF
FXWG
Vehicle weight
1966-early 1978
63,25
48.12
41.75
45,75
47.00
in.
In.
in.
in.
in.
(160.6 cm)
(122.2 cm)
(106 cm)
(116.2 cm)
(119.4 cm)
Late 1978-1984
FLHS
FX
FLH
Horsepower
1966-1969
FL
FLH
1970-early 1978
FL
FLH
Late 1978-1984
1200 cc
GENERAL INFORMATION
Table
17
1966-1969
Total
Reserve
1970-early 1978
FL/FLH
Total
Reserve
FX/FXE
1973-1974
Total
Reserve
1975-early1978
FX/FXE
Total
Reserve
FXS
Total
Reserve
Late 1978-1984
FLH/FLHS/FXWG
Total
Reserve
FXE
Total
Reserve
FXS/FXEF/FXB/FXSB
Total
Reserve
* Not specified.
Table
DECIMAL
AND
METRIC
EQUIVALENTS
Fractions
Decimal
in.
Metric
mm
Fractions
Decimal
in.
1/64
0.015625
0.39688
0.03125
0.79375
0.28125
0.296875
7.14375
1/32
9/32
19/64
3/64
0.046875
1.19062
5/16
0.3125
7.93750
1/16
5/64
0.0625
1.58750
21/64
0.328125
8.33437
0.078125
3/32
0.09375
11/32
23/64
0-34375
0.359375
8.73125
9.1289
7/64
0.109375
1.98437
2.38125
2.77812
3.1750
9/64
0.125
0.140625
0.375
0.390625
9.52500
1/8
3/8
25/64
0.15625
11/64
0.171875
3.96875
4.36562
0.40625
0.421875
10.31875
5/32
13/32
27/64
7/16
0.4375
11.11250
3/16
13/64
0.1875
4.76250
29/64
0.453125
11.50937
5.15937
0.234375
0.46875
0.484375
0.500
12.30312
15/64
15/32
31/64
1/2
11.90625
7/32
0.2033125
0.21875
1/4
0.250
33/64
0.515625
13.09687
17/64
0.265625
17/32
0.53125
13.49375
3.57187
5.556
5.95312
6.35000
6.74687
(contini Jed)
Metric
mm
7.54062
9.92187
10.71562
12.70000
CHAPTER ONE
18
Table
Decimal
Metric
Fractions
in.
mm
35/64
0.546875
0.5625
0.578125
13.89062
14.28750
14.68437
0.59375
15.08125
15.47812
9/16
37/64
19/32
39/64
EQUIVALENTS (continued)
Decimal
Metric
Fractions
in.
mm
25/32
0.78125
19.84375
51/64
0.796875
13/16
0.8125
20.24062
20.63750
53/64
0.828125
21.03437
27/32
0.84375
15.87500
55/64
0.859375
21.43125
21.82812
5/8
0.609375
0.625
41/64
0.640625
16.27187
7/8
0.875
22.22500
21/32
0.65625
16.66875
57/64
0.890625
22.62187
43/64
0.671875
17.06562
29/32
0.90625
23.01875
11/16
0.6875
17.46250
59/64
0.921875
45/64
0.703125
15/16
0.9375
23/32
0.71875
0.734375
17.85937
18.25625
61/64
0.953125
23.41562
23.81250
24.20937
18.65312
31 /32
0.96875
0.750
19.05000
0.765625
19.44687
63/64
1
0.984375
1.00
47/64
3/4
49/64
Table 3
24.60625
25.00312
25.40000
5/8
3/4
7/8
69
96
155
206
310
78
114
154
382
587
71
110
154
215
360
840
78
119
169
230
380
570
600
1/4
5/16
3/8
7/16
1/2
SAE2
12
20
32
47
SAE5
10
19
33
54
SAE7
13
25
44
SAE8
14
29
47
9/16
700
SAE 2
Table 4
VEHICLE
SAE 5
IDENTIFICATION
SAE 7
SAE 8
NUMBER CHART--1970-1980
VIN number:
3G
62152
Model code
Sequential number
Manufacturer code
Model year
MODEL CODE:
SEQUENTIAL NUMBER:
1A FL-1200
MODEL YEAR I:
1
1970*
1971
1976
1972
1977
1973
1978
1979
1980
2A FLH-1200
6H
FL-80
7E FLHS-1200
3G FLH-80
7H
8H
FLH-1200 Police
FLH-1200 Shrine
3G 1979 Classic
9H
FLH-80 Police
MANUFACTURER CODE:
1974
3H 1980 Classic
1K
FLH-80 Shrine
H: 1970-1979
1975
5H FLHS-80
2H
CLE
J:
* Unavailable
1980
GENERAL INFORMATION
Table
VEHICLE
19
IDENTIFICATION
VIN number:
NUMBER
1
HD
CHART--1981 -1984
AA
**
110000
Country of origin
Harley-Davidson
HD code
Model code
Engine displacement
Introduction date
ENGINE DISPLACEMENT
INTRODUCTION DATE
1: Heavyweight motorcycle
K: 80 cu. in.
MODEL YEAR
Can be 0-9 or X
MODEL CODE
AA FLH-80
AB FLH-Police-Std.
AC FLH-Shrine-Chain
AD FLH Classic
AG FLH Classic with sidecar
AH FLH-Police-Dlx.
B:
1981
C:
D:
1982
1983
AJ FLH-80 Heritage
E:
1984
AK
AL
SA
SD
FLHS-80
FLH-Shrlne-Belt
Sidecar not used with Classic
Sidecar sold with Classic
1 HD1AAK1 1 EY110000
CHAPTER TWO
TROUBLESHOOTING
complicated a machine is, the easier it is to troubleshoot because symptoms point to specific prob
lems.
OPERATING
REQUIREMENTS
21
TROUBLESHOOTING
WARNING
taminate the fuel with water. Drain the old fuel (fuel
TROUBLESHOOTING
INSTRUMENTS
EMERGENCY
TROUBLESHOOTING
FUEL VALVE
out.
ENGINE
STARTING
w *
Fuel tank
Gasoline strainer
Nut
Handle
Clamp
Fuel hose
CHAPTER TWO
22
ENGINE
PERFORMANCE
d. Seized piston(s).
e. Seized crankshaft bearings.
f. Broken connecting rod.
TROUBLESHOOTING
23
f. Dragging brakes(s).
Engine Lacks Acceleration
a. Carburetor mixture too lean.
d. Dragging brakes(s).
ENGINE
NOISES
ENGINE
LUBRICATION
CHAPTER TWO
24
TROUBLESHOOTING
25
CLUTCH
CHARGING
a. Clutch noise.
b. Clutch slipping.
c. Improper clutch disengagement or dragging.
All clutch troubles, except adjustments, require
partial clutch disassembly to identify and cure the
problem. The troubleshooting chart in Figure 2 lists
clutch troubles and checks to make. Refer to Chapter
Five for clutch service procedures.
SYSTEM
STARTING
SYSTEM
TRANSMISSION
The basic transmission troubles are:
\Z)
1
CLUTCH TROUBLESHOOTING
Clutch slipping
._ _,
Clutch dragging
7T.
Check:
Check:
Check:
CHAPTER TWO
26
in Chapter Seven.
^2)
TRANSMISSION TROUBLESHOOTING
Check:
* Worn gearings
* Worn or damaged gears
* Excessive gear backlash
Check:
Difficult shifting
* Damaged gears
* Damaged shift forks
engagement
Check:
Check:
* Bent shift lever
Check:
27
TROUBLESHOOTING
IGNITION
SYSTEM
NOTE
ELECTRICAL
PROBLEMS
BREAKER
POINT
IGNITION
TROUBLESHOOTING
STARTER TROUBLESHOOTING
Symptom
Probable Cause
Remedy
Low battery
Recharge battery
Worn brushes
Replace brushes
Defective relay
Defective switch
Repair or replace
Repair or replace
Worn brushes
Recharge battery
Clean or replace
Replace brushes
Defective connection
Short circuit in commutator
Stuck relay
Replace relay
Repair or replace
Low battery
Pitted relay contacts
28
CHAPTER TWO
Spark plug
wire and boot
b. Shorted condenser.
Spark plug
TROUBLESHOOTING
29
which is defective.
Ignition Coil
Ignition coil testing for 1970 and later models is
IGNITION
TROUBLESHOOTING
NOTE
Spark Test
Perform the following test to determine if the
ignition system is operating properly.
1. Remove one of the spark plugs.
2. Connect the spark plug wire and connector to the
spark plug and touch the spark plug base to a good
ground like the engine cylinder head. Position the
spark plug so you can see the electrodes.
WARNING
NOTE
NOTE
CHAPTER TWO
30
1. Cover screw
13.
3.
14.
4.
15.
16.
Flyweight (2)
Advance assembly base
Flyweight roll pin (2)
2.
5.
Washer (2)
6.
17.
7.
Trigger rotor
18.
8.
Advance assembly
19.
20.
21.
Ignition coil
Spark plug cable (2)
Ignition coil terminal (FL)
Ignition coil terminal (FX)
9. Sensor
10. Shield
11.
Timer plate
12.
22.
22A.
TROUBLESHOOTING
31
Front cylinder
results as follows:
wide lobe
<2>
^/,
D^
1.
Trigger rotor
7.
Transistor
2.
Sensor
8.
Ignition coil
3.
Control module
9.
Spark plug
4.
10.
5.
Ignition switch
Battery
11.
6.
12.
CHAPTER TWO
32
1.
2.
3. Ignition coil
9.
Gasket
Inner cover
11. Outer cover
10.
4.
Ignition module
12.
5.
Connector
6.
Sensor plate
14.
Rotor
7.
Washer (2)
15.
8.
16.
33
TROUBLESHOOTING
I980-on
NOTE
NOTE
faulty reading.
3.
4.
5.
Battery
Sensor plate
1.
2.
6.
Rotor
8. Computerized
control module
9. Ignition coil
10. Spark plug
tion (blue).
34
CHAPTER TWO
KXCFSSIVK
NOTE
VIBRATION
CAUTION
a. Broken frame.
Red
Green
Black
13. Turn the engine so that the rotor slots are not
aligned with the sensor (Figure 16). Measure the
voltage reading. It should be 4.5-5.5 volts.
14. Turn the engine so that the center of the sensor
is between the 2 rotor slots. The voltmeter should
read 0-1 volts.
Voltmeter
Sockets
Pins
Jl
Pin housing
Red
Socket
Green
housing
Black
Sensor
Module
Terminals
TROUBLESHOOTING
35
FRONT
AND
STEERING
CARBURETOR
SUSPENSION
TROUBLESHOOTING
b.
c.
d.
e.
Test adaptor
2S3CII3
Red
steering neck),
Stiff Steering
>:>>;:;;-;-; :>;->;
steering neck).
c. Loose or worn steering head bearings.
d. Steering damper loo right (FL models with
Voltmeter
adjustable fork).
Vertical
Rear
cylinder
(wide
lobe)
CHAPTER TWO
36
PROBLEMS
(J7)
BRAKE
HD CARBURETOR TROUBLESHOOTING
Check:
Check:
Check:
postion
* Nozzle check valve not sealing
Check:
* Carburetor flooding
(continu ed)
37
TROUBLESHOOTING
("17J (continued)
*
Check:
Check:
Check:
Check:
Check:
* Carburetor flooding
* Inlet control lever adjusted incorrectly
* Choke valve not staying open due to worn or
damaged choke friction spring and friction ball
Carburetor flooding
Check:
CHAPTER TWO
38
Hard starling
Check:
Fuel overflows
Poor idling
* Idle misadjusted
* Worn idle mixture screw
Poor acceleration
Check:
Check;
Check:
* Float level too low
* Loose jets
Check:
*
*
*
*
Carburetor dirty
Fuel tank strainers clogged or dirty
Accelerating pump not operating correctly
Fuel tank dirty
TROUBLESHOOTING
39
Check:
Brake overheating
Check:
Brake chatter
Brake locking
Check:
Insufficient brakes
Check:
* Air in brake lines
Brake squeal
( s>
Check:
CHAPTER TWO
40
\2y
Brakes do not hold
Check:
Brakes grab
Check:
Brakes chatter
Check:
*
*
*
*
*
*
CHAPTER THREE
PERIODIC
LUBRICATION,
MAINTENANCE
AND
TUNE-UP
ROUTINE
CHECKS
General Inspection
NOTE
Tire Pressure
CHAPTER THREE
42
MAINTENANCE
INTERVALS
TIRES
AND
WHEELS
Tire Pressure
NOTE
43
BATTERY
CAUTION
CHAPTER THREE
44
CA UTION
NOTE
45
WARNING
(TYPICAL)
21
iiCJr16
or
10 1
When replacing the old battery with a new one, be
sure to charge it completely (specific gravity, 1.2601.280) before installing it in the bike.
1. Lockwasher
2. Nut
9.
Lockwasher
3. 12-volt battery
10.
11.
Bolt
Rubber mount
4. Battery strap
5. Cover
13. Screw
14. Cover
6. Battery plug
7. Battery cover cushion
15. Damper
8. Bolt
PERIODIC
LUBRICATION
CHAPTER THREE
46
The engine oil runs cooler when the oil level is kept
high in the tank. Refer to Figure 9 for this procedure.
1. Have an assistant support the bike so that it
stands straight up. If the bike is supported on the
sidestand, an incorrect reading will be obtained.
2. Remove oil tank cap (Figure 10) and dipstick.
Oil level should be above "Refill" mark. If not add
in too much
electrolyte
Do not suck
Hold
tube
vertical
Float must
be tree
*-V.
* m * *
1. Fllfc clip
Filter element
9.
10.
11.
5. Cup spring
6. Cup seal
7. Cup
12.
8. O-rl ng
15.
13.
14.
Valve assembly
Cap
Cap
Cap
Cap
Cap
Cap
gasket
cotter pin
screw
washer
nut
top
47
CHAPTER THREE
48
3. Place a drip pan under the oil tank and remove the
drain plug (Figure 12). Remove the oil tank cap and
dipstick (Figure 10); this will speed up the flow of
oil.
wrench.
b. Discard the oil filter.
49
CAUTION
CA UTION
change.
3. Reinstall the oil tank drain plug and plug all tank
hose openings.
tank.
CHAPTER THREE
50
NOTE
In order to measure the correct amount
CAUTION
Control Cables
The control cables should be lubricated at ihc
51
1. Steering damper
adjusting screw
2. Spring
3. Spider spring cover
4. Spider spring
5. Pressure disc
6. Friction washer
7. Anchor plate
8. Friction washer
9.
-JiWtbr
13h@>
Pressure disc
Dust shield
18
26. O-rlng
29. Cotter pin
30. Nut
34. Slider
CHAPTER THREE
52
NOTE
Lubricator method
Oil method
1. Bail
2. Filler can
3.
Funnel
4. Metal tubing
5. Flexible tubing
6. Metal tubing
7. Rubber plug
53
CHAPTER THREE
54
Chapter Nine.
2. Wipe away the old grease, being careful not to get
any on the brake shoes.
1966-on
55
(chain drive)
CHAPTER THREE
56
PERIODIC
MAINTENANCE
bolts.
57
CHAPTER THREE
58
<>
59
1. Sight along the top of the drive chain from the rear
sprocket to see that it is correctly aligned. It should
leave the top of the rear sprocket in a straight line. If
it is cocked to one side, the rear wheel must be
in this chapter.
Drive Chain Cleaning,
Inspection and Lubrication
The drive chain should be cleaned and inspected
every 3,000 miles or more frequently if ridden in
dusty conditions.
1. Remove the drive chain as described in Chapter
Nine.
b. Loose pins.
c. Damaged rollers.
d. Damaged plates.
e. Dry plates.
If any of these conditions are visible, replace the
chain.
CHAPTER THREE
60
CAUTION
Inspection/Adjustment
The final drive belt stretches very little after the
first 500 miles of operation, but it should be in
spected for tension and alignment according to the
maintenance schedule (Table 3).
1. Remove the belt guard bolts and remove the belt
guard.
2. On FLH models, remove the left-hand saddlebag.
3. Have a normal weight rider sit on the seat with the
wheels on the ground.
4. Apply 10 lb. (4.5 kg) of force to the middle of the
belt am. Deflection of the belt should be 5/8 to 3/4
WARNING
cotter pin
61
it.
WARNING
CA UTION
WARNING
cloth.
Disc Brake Lines and Seals
^\ Ul
*^
jf
m&miA L-
3
I
62
CHAPTER THREE
NOTE
WARNING
3.
4.
5.
6.
6. Loosen the brake shoe pivot stud (6) and the front
axle nut. Do not remove them.
63
turns freely.
6. Turn rear cam nut clockwise until wheel has
noticeable drag.
7. Turn the wheel forward and backward. This will
center the rear brake shoe.
8. Turn the rear cam nut counterclockwise until the
1966-1969
Brake pedal
Piston rod
Lock nut
Plunger
Rubber boot
CHAPTER THREE
64
197Q-on FL
tion.
Locknut
Stop bolt
1972-on FX
\'*
46
1.
Pedal
2.
3.
4.
5.
65
(1984 FXWG)
3 2 4 5
1.
Brake pedal
2.
Locknut
3.
1
1. Stop bolt
or brake rod
5. Grease fitting
1. Foot pedal
2. Foot pedal bearing cover
3. Clutch lever rod
Jam nut
Clevis
Locknut
CHAPTER THREE
66
1
3/8-5/8 in. clearance
Anchor pin
Hand lever
Bushing
Cable
ferrule
Bushing
Slot open end must face
toward inside of lever
1. Starter
2.
Release lever
67
1. Clutch pushrod
adjusting screw lock
CHAPTER THREE
68
NOTE
HAND CLUTCH
BOOSTER ADJUSTMENT
1. Control coil adjusting sleeve
2. Control coil adjusting
sleeve locknut
rubber pedal
69
WARNING
released position.
Throttle Cable(s)
1.
2.
3.
4.
5.
6.
7. Control elbow
10.
11.
12.
13.
14.
15.
9. Control wire
17.
Handlebar
CHAPTER THREE
70
WARNING
(1981-1984)
screw (11).
1.
2.
3.
4.
5.
6.
7. Friction adjuster
8. Ferrule
9. Open cable
10. Adjuster
11. Locknut
12. Close cable
71
Open cable
Close cable
1967-EARLY 1978
3. Screw
9. Rubber seal
4. Gasket
{late 1977-1978)
5. Housing
10. Cover
6. Screw
11. Plate
7. Bolt
12. Screw
CHAPTER THREE
72
4. Clean out the inside of the air box with a shop rag
and cleaning solvent. Remove any foreign matter
that may have passed through a broken cleaner ele
ment.
dure.
CAUTION
(LATE 1978-1984)
1. Gasket
2. Housing
3. Screw
4.
Lockwasher
5. Screw
6. Air filter
7. Baffle
8. Cover
9. Grill
10. Washer
11. Screw
12. Washer
Wheel Bearings
73
stop.
Steering Play
stop.
CHAPTER THREE
74
NOTE
d. Gearshift lever.
g. Exhaust system.
h. Lighting equipment.
SUSPENSION
ADJUSTMENT
TUNE-UP
a.
b.
c.
d.
2
3
4fc
5
7
Pressure disc
6.
Friction washer
7. Anchor plate
8.
Friction washer
9. Pressure disc
10. Fork stem nut
28. O-ring
75
76
CHAPTER THREE
Air Cleaner
The air cleaner element should be cleaned or
Pushrod Adjustment
complete failure.
The results, when properly interpreted, can indi
cate general cylinder, piston ring and valve condi
tion.
completely open.
NOTE
NOTE
77
CHAPTER THREE
78
NORMAL
,-.
OIL FOULED
GAP BRIDGED
can be cleaned.
CARBON FOULED
LEAD FOULED
WORN
Can be cleaned.
worn electrodes.
be replaced.
Can be cleaned.
OVERHEATING
PREIGNITION
^C
r^diPX""^
*^^^^^^^
dr
^S^^^^=^"
'i
&~^
*^*
79
-p.*
or fourth gear.
2. Turn off kill switch before closing throttle and
simultaneously pull in clutch. Coast and brake to a
stop. Do not downshift transmission while stopping.
3. Remove spark plugs and examine them. Compare
them to Figure 70.
If the insulator tip is white or burned, the plug is
too hot and should be replaced with a colder one.
A too-cold plug will have sooty deposits ranging
in color from dark brown to black. Replace with a
CHAPTER THREE
80
BREAKER
IGNITION
POINT
SERVICE
and grease.
Breaker Point Service
81
CA UTION
(AUTOMATIC ADVANCE)
1.
Breaker cam
5. Contact points
6.
Lock screw
7. Adjust screw
8. Timing marks
9.
Nut
10. Cover
11. Screw
12. Circuit breaker lever
13. Pivot stud
14. Support
15. Nut
82
CHAPTER THREE
BREAKERLESS
(LATE
IGNITION
SERVICE
1978-1979)
cover.
<)
83
NOTE
^&
-'""'
8 . : ii*
CA UTION
Rear cylinder
(wide
lobe)
CHAPTER THREE
84
BREAKERLESS
IGNITION
SERVICE (1980-ON)
86
Front cylinder
Rear cylinder
advance mark
advance mark
ment.
RETARD
ADVANCE
1. Ignition module
2. Timer plate screw (2)
3. Ignition module ground screw
4. Sensor screws
5. Sensor
6. Trigger rotor
7. Timer plate
8. Plate adjusting notch
85
hole plug.
7. Drill out the 2 pop rivets (12, Figure 87) with a
3/8 in. (9.5 mm) drill bit.
8. Referring to Figure 87, remove the outer cover
(11), inner cover (10) and gasket (9).
9. Loosen the timing plate sensor plate screws (8,
CARBURETOR
NOTE
<g>
ADJUSTMENTS
1.
2.
3.
4.
5. Connector
6. Sensor plate
7. Washer (2)
8. Sensor plate screw (2}
9.
10.
Gasket
Inner cover
13
14
15 \
16
CHAPTER THREE
86
MODEL HD CARBURETOR
off.
4. Throttle lever
5. Choke lever
89
6. Accelerating pump
7. Inlet fitting
8. Vent fitting
INCORRECT
fu\
NT
tJ
\2J
CORRECT
speed needle
87
BENDIX CARBURETOR
4. Turn the throttle stop screw (12) and set the idle
to 700-900 rpm.
5. Turn the idle mixture screw in or out as required,
to get the highest and smoothest idle speed. The best
performance will usually result if the mixture is
slightly rich (screw turned in a little).
6. Rev the engine a couple of times and see if the idle
speed is constant. Readjust the idle speed, if neces
sary, to 700-900 rpm by turning the throttle stop
screw (12).
5. Accelerating pump
6. Hose fitting
7. Drain plug
8. Carburetor ID number
CHAPTER THREE
88
3. Set the idle speed to 900 rpm with the throttle stop
CARBURETOR (1981-ON)
screw.
Throttle
stop screw
NOTE
Fast idle
adjusting screw
KEIHIN
CARBURETOR
ADJUSTMENT
(1976-EARLY 1978)
1. Throttle lever
7.
4.
8. Rocker arm
9. Screw
10. Mounting flange
5.
Choke lever
11.
2.
3.
5. Choke plate
6. Choke lever shaft
7. Mounting flange
NOTE
89
Grease
Grease
Grease
Grease
Grease
saddle post.
saddle bar bearing.
rear brake pedal bearing.
foot shift lever bearing.
hand clutch booster bearing.
Adjust clutch.
Adjust brakes.
Clean, inspect and adjust breaker points.
Every 5,000 miles or 1 year
90
CHAPTER THREE
Table 1
* This Harley-Davidson factory maintenance schedule should be considered as a guide to general main
tenance and lubrication intervals. Harder than normal use and exposure to mud, water, high humidity, etc.,
will naturally dictate more frequent attention to most maintenance items.
1.1966 models.
2.1966-1967 models.
3.1966-1969 models.
Table 2
1978)
Weekly
Table 2
Table 3
or 6 months
91
92
CHAPTER THREE
Table 3
Table
TIRE
PRESSURE
Front
Sidecar
Rear
PSI
kg/cm2
PSI
kg/cm2
5.10x16
20
1.41
24
1.69
5.00x16
12
.84
18
1.26
20
1.41
26
1.83
12
.84
20
1.41
5.10x16
22
1.55
26
5.00x16
14
.98
Solo
20
With passenger
PSI
kg/cm2
1.83
20
1.41
20
1.41
14
.98
1.41
24
20
1.41
26
1.69
1.83
Solo
24
26
1.83
With passenger
24
1.69
1.69
28
1.97
22
1.55
26
1.83
20
1.41
20
20
1.41
24
1.69
1.41
26
1.83
Solo
24
1.69
26
1.83
With passenger
26
1.83
28
1.97
Solo
30
2.11
26
With passenger
30
2.11
28
1.83
1.97
1966-1969
Solo
With passenger
5.10x16
5.00x16
Rider with sidecar
1970-early 1978
FL series
FX series
With passenter
FX series (except FXWG)
FXWG
(continued)
93
Front
Sidecar
PSI
kg/cm'
PSI
kg/cm'
PSI
kg/cm'
22
1.55
26
1.83
20
1.41
Table
Specific gravity
State of charge
1.110-1.130
Discharged
1.140-1.160
1.170-1.190
Almost discharged
One-quarter charged
One-half charged
Three-quarters charged
Fully charged
1.200-1.220
1.230-1.250
1.260-1.280
Table
RECOMMENDED
LUBRICANTS AND
FLUIDS
Brake fluid
DOT 3
DOT 5
Fork oil
1966-1969
1970-on
Battery lop up
Transmission
Distilled water
HD transmission lubricant
Primary chaincase
HD primary chaincase
Engine oil
HD special light
HD medium heavy
HD regular heavy
Below + 40 F
40-60 F
+ 60 F and up
Severe engine operating
conditions @+80 F
10-90 Fnormal and
Table
OIL CAPACITY
Quantity
Oil tank
Transmission
CHAPTER THREE
94
Table 8
Quantity
1966-1969
Wet
Dry
1970-early 1978
FX Series
1970-1972
Wet
Dry
1973-early1978
Wet
Dry
FL Series
1970-early 1977
Wet
Dry
Early 1977-early 1978
Wet
Dry
Late 1978-0n
FL Series
Wet
Dry
Wet
Dry
FXWG
Wet
Dry
TABLE 9
TUNE-UP SPECIFICATIONS
1966-1969
Ignition timing
Retarded
5 BTDC
Automatic
35 BTDC
1970-early 1978
Breaker point gap
Ignition timing
Retarded
Advance
Late 1978-on
34-36 BTDC
Ignition timing
Compression
Standard
1966-early 1978
Late 1978-1984
1966-early 1978
Late 1978-1984
Table
10 SPARK PLUG
Type
1966-1974
HD No. 3-4
1975-1976
HD No. 5-6
1977-1979
1980-on
Gap
1966-1969
1970-early 1978
Late 1978-on
Table
11
CARBURETOR
IDLE SPEED
Carburetor
Idle
HD
Bendix
900-1,100 rpm
700-900 rpm
Model DC
Keihin
900 rpm
95
CHAPTER FOUR
ENGINE
The engine is an air-cooled 4-cycle, overheadvalve V-twin design. The engine has three major
assemblies: top end, crankcase and gearcase.
Viewed from the engine's right side, engine rotation
e. Gearshift mechanism.
is clockwise.
f. Clutch.
g. Transmission,
b. Cylinder head.
c. Cylinder and pistons.
d. Camshaft.
h. Carburetor.
stroke.
ENGINE
ENGINE
Removal/Installation
PRINCIPLES
SERVICING
ENGINE
IN
FRAME
ENGINE
97
Carburetor
INTAKE
as piston begins
downward, drawing
air/fuel mixture into
EXHAUST
POWER
Exhaust valve
Spark plug
opens as piston
ignites
rises in cylinder,
pushing spent
gases out through
compressed
the valve.
mixture, driving
piston downward.
Force is applied
to crankshaft
causing it to
rotate.
CHAPTER FOUR
98
NOTE
Three.
ter Six.
gine.
13. Disconnect both spark plug wires.
14. Remove the cylinder heads as described in this
chapter.
15. Remove the cylinders as described in this chap
ter.
ENGINE
99
HEAD
Removal
CHAPTER FOUR
100
PUSHROD ASSEMBLY
m s
1. Oil fitting
2. Oil line sleeve
16. Washer
30.
Cap
31.
Spring
4. Oil line
32. Washer
5. Nut
19. Sleeve
33.
O-ring
6. Washer
20. Nut
21. Oil line
34.
36.
23. Gasket
37. Screw
3.
Fitting
35.
10.
Spacer
24. O-ring
38.
11.
Rocker arm
25. Pushrod
Bushing
15.
O-ring
26. Nut
Pushrod hydraulic
39.
43. Gasket
ENGINE
101
CYLINDER ASSEMBLY
1.
Nut
2. Washer
3. Engine brace
4. Bolt
5. Nut
6. Cotter pin
7. Helicoil insert
8. Stud
9. Cylinder head
10. Hose (1981-1982)
11.
12.
13.
14.
15.
Clamp (1981-1982)
Fitting (1981-1982)
Cylinder head gasket
Spacer (1981-1982)
O-ring (1981-1982)
16. Nut
17. Spacer
18. Cylinder
19. Piston
20. Washer
21. Bolt
22. Gasket
23. Stud
CHAPTER FOUR
102
Removal/Installation
(Figure 6).
2. Tap the rocker arm cover with a plastic mallet and
remove it from the cylinder head.
x.i" -L^.b^ .
- - - .
x x,^
...
: *'**sfts
^*
\
1 "
' l
'
^
XXL
-.-
-X* XL b ^L-
<< t. '"^
^^'L
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X . x" "^ *
3
. ^^
xf*
..-;'/f:ij;^i JJ
*"*** -.. .
Ol-^x V " " "l
rf^.l
x-
;, -j*
;;'-
'.
ENGINE
103
.:-
.:
7... :^^m^^mmm>mm
^L
.(
'li-X^liim
taV
T V\
a^ff^i$$8i$
;:.
'
'
J *
sBSfiis
104
CHAPTER FOUR
and spacer.
16. Install the rocker arm shaft washer and locknut
<>
n*x>Lull*M5UAfittxxmiJ~
gfttrs
stems.
CAUTION
SMI
ENGINE
105
4. The new bushings must be reamed with HarleyDavidson tool HD-94804-57 (Figure 30). Have a
Harley-Davidson dealer do this for you if you do not
have access to the reamer.
,^*tfai
m&mt
'
L C
29 ]
CHAPTER FOUR
106
PUSHRODS
NOTE
SMBKBmmUL
MKRN
d!!!iHl!
l&#Mii
"?'
"* -.."' i-
ENGINE
107
Disassembly/Inspection/'Assembly
1. Remove the pushrod from the pushrod cover
assembly.
2. Disassemble the pushrod cover as follows:
a. Remove the lower pushrod cover (Figure 42).
b. Remove the middle O-ring (Figure 43).
Pushrod
Locknut
Adjusting screw
CHAPTER FOUR
108
NOTE
NOTE
-"
*' -
L-, *
**>x**'Vl.
l b L
!!l.
..**"-
.
L' '
Lxf
"
| Lx
*..
El
^x.
!'M
.xxx
'
L L <^ H
t* t L 4 t .
..&*.*
'
.:
L1 *^'T " \ t t
-I,*-
KIM
Lxl I
.'
x.
Mm
L t
- - .
LX
...
IL--
-1' ' ii
...
i,,
.... .
L X X*
x.L.
.i.
L X X
;:
L L
L L
Ilk.
t
42
...
. (i i
L__
...
'
;;
.-^f 1l(
is:
;:: ; .
(*''"
:::: \ .::
' i
; i w r - * .
" .
.'
"\.
x,.
109
ENGINE
'
-:
-/
CHAPTER FOUR
110
TAPPETS
AND TAPPET
GUIDES
Disassembly/Inspection
CAUTION
ENGINE
111
1. Screw
Hydraulic unit
3. Cork washer (1966-early 1979);
O-ring (early 1980-1984)
4. Tappet guide
5. Tappet and roller assembly
2.
l j- '
. . "
l ."*# "
-^. .
"J, L . ^ ^ > x .
l^l1 -
"*^
6. Gasket
7.
=;;'"
'..
-;-..'.k'-3v.
......a;;
'
CHAPTER FOUR
112
changed
with other units. Store each
o
I
lj*
LL
si
^-
'"
::
L XL
' -
...
.;
:
Reassembly/Installation
Oil holes
ENGINE
113
gearcase.
VALVE ASSEMBLY
<m.
VALVES
AND VALVE
COMPONENTS
8
CAUTION
2. Split keepers
3. Inner spring
4. Outer spring
5. Lower valve collar
6. Valve stem seal
7. Valve guide
8. Gasket
9. Valve
CHAPTER FOUR
114
Deburr
Valve stem
ENGINE
115
measured.
Installation
cylinder head.
2. Install the bottom spring collar.
reused.
V" \
r\\
|0/
Valve Lapping
Valve lapping is a simple operation which can
restore the valve seal without machining if the
amount of wear or distortion is not too great.
-. \ ....
*^w,,^:
-*--"
-"
..:
-:-
::\*'-"'-zi'Zm'
;;K;;;r-^-
CHAPTER FOUR
116
73
2.
3.
4.
5.
Cylinder
Cylinder base gasket
Piston rings (2 compression)
Oil control piston ring and
expander spring
6. Piston pin lock ring
7. Piston pin
8. Piston
117
ENGINE
CYLINDER
Removal
*mm
!aIEi3%ttW
CHAPTER FOUR
118
NOTE
der's taper.
Installation
: t
:.
I.
L.
44
>*
. m < * T * * *
lilll 1
x_ b '
' .
I 4 A A.
ILL
I4A4AlA.Il
,. :-:-\
./
.111
xA
it
'
4444
II
1.44
.11.
Lx'
*1
i i i i i n i u
mm.
\'^V. *
tfi '
r ^
LI
. L I
*AA l , - I
t 1 \
r ' -^
"Wf1"^ ...t--^ii-TL
.....
L .
L . L L L
Liil"li
. *
r
..
- r * " \
--'->,*
- >.***+*
:;
~ *
r.
;.-
.::
\ A . t T ' *l i h J "
- L
:;;
.'V!;;
::' ;:
..: %
.
....
ENGINE
119
..
PISTONS
AND
PISTON
RINGS
Piston Removal/Installation
Threaded rod
CHAPTER FOUR
120
Piston Inspection
1. Carefully clean the carbon from the piston crown
with a soft scraper (Figure 88). Do not remove or
damage the carbon ridge around the circumference
of the piston above the top ring.
CAUTION
NOTE
gS^^
the bottom.
L-
[\V/
ENGINE
121
Piston Clearance
NOTE
, #^
fl
\
Taper on bottom
Dot on top
CHAPTER FOUR
122
NOTE
ENGINE
123
NOTE
or Table 4.
2(y
as
PUMP
The oil pump is installed at the rear of the gearcase. The pump consists of 2 sections: a feed pump
which supplies oil under pressure to the engine
components, and a scavenger pump which returns
oil to the oil tank from the engine.
The oil pump may be removed as a unit only with
the engine removed. However, the oil pump can be
disassembled with the engine mounted in the frame.
Three.
CAUTION
Removal/Disassembly
Refer to Figure 97 (1966-1967) or Figure 98
(1968-on) for this procedure.
24
OP*
25
5. Circlip
6. Drive gear
7. Woodruff key
8. Idler gear
9. Nuts and washers
11.
12.
13.
14.
15.
16.
17.
CHAPTER FOUR
124
Engine removed
CAUTION
shaft.
5. Circlip
6. Drive gear
7. Woodruff key
8. idler gear
9. Nuts and washers
12.
13.
14.
15.
16.
17.
Drive gear
Woodruff key
Idler gear
Bypass valve plug
Bypass valve spring
Bypass valve spring
plunger
18. Check valve spring
cover screw
23. Washer
24. Elbow
25.
26.
27.
28.
ENGINE
125
^--^'- i;-
. F * -c^l
'--"
"
-""
6. Pull the oil pump partway out. Then take the oil
pump drive gear (Figure 107) and its Woodruff key
off the end of the oil pump drive shaft.
7. Remove the oil pump body with the drive shaft as
shown in Figure 108.
8. If necessary, disassemble the oil pump as follows:
mmmsmm
w^mM^msmm^mmm
CHAPTER FOUR
126
Inspection
[1M
..
-:
..
...
...
'&:ii
:'.v.,.:'--..^-; ""
*mm
mm
^>ffl$$%iW3$>
;.,
iW**H*^pw^ ^;HliSM:
-1;* '
%Hii!l&*& ixi'i'.iiei'
: ;
ENGINE
127
CAUTION
lation.
Assembly/Installation
wore
: ......
::
".-
---
CAUTION
...
ft
mm
::.
....
:::
..:;;*
wma
. mum
: ItM
:
;:
:::;.;
:::
:l
. . .
..---...
1
I*^^Pf. '
--LL--xJ.
T,
Tr ,
- -
x^'-'LXXr-^_x-^'-
--.
-T.
....
::..;::::;
Ur'-jS...
J''
>:::: -
,.
i :'
.. i
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.....
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r : :: \
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it..
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:
:::.
.:::
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ii
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...
.:
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--
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...
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.;- s .--..-
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;-^
...r-\
;*
k8
..-.:^:r
CHAPTER FOUR
128
the other.
AND
GEARS
Removal/Disassembly (1966-1969)
ft/yv/i
NOTE
;;--^
K:,j-:%jH*!3i -
:.- jg-gSB
ma
::
.:.
_sv
129
ENGINE
13. Remove the pinion gear shaft nut (19). This nut
has a left-hand thread.
19. Remove the oiler drive gear (29) and key (30).
NOTE
Inspection
119
fii
Mi
i....
KIP: g;jj
Assembly
:
....
-,::-
..
;
-
.:
"
:::
:::* +
::
\.S
m
,.::
...
\\..-:--'r
|i
-,.-y
::
. .
---
:;::i
:-: : ii
..
.
;;;
.-.'
'
r~.
:
.
..
tit.
si
fcfi
sum
mmmm
;:
fek vwypE
^..gSSae*:^i;:
l*r**.<* v. j .
:
;
7-.'f
*
L . ' '
&
(1966-1969)
. .
JPKITQ
GEARCASE COMPONENTS
EN
1 O
Cam gear
Can gear spacing washer
Cam gear thrust washer
Breather valve and gear
11.
10.
9.
8. Gear cover
7.
5.
4. Oil screen
3.
Idler gear
22.
21.
1C.
16.
15.
14.
13.
Cap gasket
Spring
2.
Breather separator
Oiler drive gear shaft spring ring
Oiler drive gear
Oiler drive gear key
Needle roller cam shaft bearing
Circuit breaker gear stud
Idler gear stud
27.
28.
29.
30.
31.
32.
33.
50
>
fs#J
ENGINE
131
(1966-1969)
1. Pinion gear
2. Cam gear
3. Breather gear
4.
5.
6.
7.
3 2
132
CHAPTER FOUR
cover.
Removal (1970-on)
moval.
Seven.
CAUTION
GEARCASE ASSEMBLY
(1970-1984)
q>^@>
36 35 33 34 13
1.
2.
3.
4.
Plug
Plug
13.
14.
15.
16.
19. Gasket
20. Gearcase cover
10.
29.
30.
31.
32.
11.
Camshaft bushing
12.
Woodruff key
35. Dowel
36. Gearcase
5.
6. Oil screen
7.
8.
9.
ENGINE
133
l hup;;:
Sjgffi|g| i
:.
...
fef.S
Iff
Inspection
134
CHAPTER FOUR
ENGINE
135
Assembly
mm^m&mmm
ill;
*;;;
r;;
- ^t
"
. !.' j
' ?
: -;: -: ::l.
i
:;;;:;;:;:;-.. fe
i/?^:'^ '"
mm%
wsm
(MWUrn
139
y.
'
r.-:
... '-a*
. .:.
1.
-:
CHAPTER FOUR
136
ENGINE
137
NOTE
NOTE
nut.
'
CRANKCASE
::
&
p
;;
;"':
to;;
PS
If Screwdriver
138
CHAPTER FOUR
Disassembly
CRANKCASE ASSEMBLY
(1966-1968)
12
3 4
2.
3.
4.
5.
6.
7.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Bearing washer
Bearings and retainer
Bearing washer
Spiral lock ring
Pinion shaft bearing race
studs.
ENGINE
139
CRANKCASE BOLTS
(ii)
1.
2.
3.
4.
5.
6.
10. Flywheels
11. Connecting rods
12. Bearing washer
13. Bearings and retainer
CHAPTER FOUR
140
152
vyl s
141
ENGINE
149).
as is hard acceleration.
ENGINE
of the tank.
BREAK-IN
Number of cylinders
1200 CC
Displacement
73.66 CU. in. (1200 cc)
1200 cc
Compression ratio
FLH
8:1
7.25:1
FL
Lubrication
Table 2
mm.
0.004-0.006
0.10-0.15
0.0035-0.0055
0.089-0.140
Valves
Fit in guide
Exhaust
1966-1969
1970-early 1978
(continued)
CHAPTER FOUR
142
Table
ENGINE
SPECIFICATIONS (1966-EARLY
1978) (continued)
Specification
in.
mm
0.002-0.004
0.05-0.10
0.0018-0.0038
0.046-0.096
FL
1 13/16
46.04
FLH
1 31/32
49.99
1 31/32
49.99
FL
1 15/32
37.29
FLH
1 25/64
35.31
1 23/64
34.52
0.0005-0.002
0.004-0.025
0.013-0.051
0.10-0.63
Taper
0.002
0.05
Out-of-round
0.003
0.08
Clearance
0.001-0.002
0.03-0.05
Intake
1966-1969
1970-early 1978
Valve spring free length
Outer
1966-1969
1970-early 1978
Inner
1966-1969
1970-early 1978
Rocker arm
Fit in bushing-bearing
clearance
End clearance
Cylinder
Piston
Piston rings
End gap
0.010-0.020
0.25-0.51
0.004-0.005
0.10-0.13
0.003-0.005
0.08-0.13
0.0008-0.0012
0.020-0.030
0.006-0.010
0.005-0.025
0.15-0.25
0.13-0.63
1966-1969
0.0006-0.001
0.02-0.03
1970-early 1978
0.001-0.0015
0.03-0.04
0.002
0.05
0.0025
0.063
1966-1969
0.001-0.002
0.03-0.05
1970-early 1978
0.001-0.003
0.03-0.08
Roller fit
0.0005-0.001
0.013-0.03
0.008-0.010
0.20-0.25
0.003-0.007
0.08-0.18
0.003-0.020
0.001-0.005
0.08-0.51
0.03-0.13
1966-1969
0.001-0.0015
0.03-0.04
1970-early 1978
0.0008-0.0018
0.020-0.046
0.0005-0.003
0.013-0.08
0.001-0.005
0.03-0.13
Side clearance
Compression
Oil control ring
Connecting rod
Piston pin fit
Side play
1966-1969
1970-early 1978
Crankpin fit
Tappets
Crankcase guide fit
1966-1969
1970-early 1978
Fit in guide
Gearcase
Fit in bushing
Fit in bearing
Cam gear end play
(continued)
143
ENGINE
Table 2
mm
0.020-0.030
0.001-0.0015
0.03-0.04
0.003
0.08
0.001
0.03
1966-1969
0.0015-0.0035
0.04-0.09
1970-early 1978
0.0012-0.0032
0.030-0.081
0.0002-0.0015
0.005-0.038
0.0005-0.006
0.013-0.152
0.001-0.006
0.03-0.15
0.0004-0.0008
0.010-0.020
0.0005-0.0012
0.013-0.030
Flywheels
Runout (at rim)
End play
1966-1969
1970-early 1978
Pinion shaft bearings
Number of cylinders
1200 cc
1340cc
Displacement
1200 cc
1340 cc
Compression ratio
1200 cc
8:1
1340 cc
Late 1978-1980
1981-1984
8:1
7.4:1
Lubrication
Table
ENGINE
^h
SPECIFICATIONS
9 ^
(LATE
1978-1984)
&
Wear limit
in.
mm
in.
0.004-0.002
0.10-0.05
0.006-0.004
0.15-0.10
0.0035-0.0055
0.0075
0.004
0.190
0.0014-0.0031
0.089-0.140
0.035-0.079
0.0018-0.0038
0.046-0.096
0.0038
0.096
0.0021-0.0040
0.053-0.102
0.0060
0.152
0.0009-0.0026
0.023-0.066
0.0035
0.089
0.050-0.090
1.27-2.29
mm
Cylinder head
^
Valves
Fit in guide
Exhaust
0.102
Intake
Late 1978-1979
1980*early1981
without seals
(continued)
CHAPTER FOUR
144
Table 4
Wear limit
in.
in.
mm
1.900-1.960
48.3-49.78
Late 1982-on
1.720-1.780
43.69-45.21
1.36
34.52
Late 1982-on
1.50-1.56
38.1-39.6
0.050-0.090
1.27-2.29
1.600-1.645
40.64-41.78
Fit in bushing
0.0005-0.002
0.013-0.051
0.0035
0.089
End clearance
0.004-0.025
0.10-0.63
0.025
0.63
0.002
0.05
0.003
0.08
0.0020-0.0025
0.051-0.063
0.005
0.13
0.0008-0.001
0.00015-0.00065
0.020-0.025
mm
Inner
Seat width
Rocker arm
Cylinder
Taper
Out-of-round
Piston
Clearance
0.0038-0.0165
Piston rings
End gap
Compression rings
0.010-0.020
Late1983-on
0.008-0.015
0.25-0.51
0.20-0.38
0.25-1.14
0.031
0.015
0.79
0.045
1.14
0.10-0.13
0.08-0.13
0.006
0.15
0.006
0.15
0.0008-0.0010
0.020-0.025
0.00015-0.00065
0.0038-0.0165
0.030
0.76
0.001-0.0015
0.13-0.63
0.03-0.04
0.0017
0.04
0.0025
0.063
0.0025
0.001 -0.002
0.03-0.05
0.003
0.063
0.08
Roller fit
0.0005-0.001
0.013-0.030
0.0012
0.030
0.008-0.010
0.20-0.25
0.015
0.38
0.001-0.016
0.03-0.41
0.016
0.41
0.0008-0.0018
0.020-0.048
0.003
0.08
0.0005-0.003
0.01-0.08
0.003
0.08
0.001
0.03
0.016
0.41
0.0008
0.020
0.0025
0.063
0.000-0.006
0.00-0.15
0.006
0.15
0.000-0.002
0.00-0.05
0.002
0.05
0.0012-0.0032
0.030-0.081
0.0002-0.0015
0.005-0.038
0.0004-0.0008
0.010-0.020
0.0008
0.020
0.0005-0.0012
0.013-0.030
0.0025
0.063
0.010-0.045
0.38
Side clearance
Compression
Oil control ring
Connecting rod
0.004-0.005
0.003-0.005
Late 1983-on
Side play
Crankpin fit
0.005-0.025
Tappets
Gearcase
Fit in bearing
Cam gear end play
Oil pump drive shaft
crankcase bushing
Flywheels
145
ENGINE
ft.-lb.
N.m
15
20.7
Cylinder head
Oil pump
65
89.7
50 in.-lb.
5.7
100
138
100
138
175
241.5
Flywheel assembly
H.-lb.
N.m
15
20.7
Cylinder head
65
89.7
Oil pump
Cylinders
Flywheel assembly
45-50 in.-lb.
5.2-5.7
32-36
44.2-49.7
170
234.6
1970-1971
170
234.6
1972-earlyl978
400
552
175
241.5
35-40
48.3-55.2
30-35
41.4-48.3
18-22
24.8-30.4
35-40
48.3-55.2
10
20-24 in.-lb.
13.8
2.3-2.7
12-15
16.6-20.7
22-26
29.9-35.9
Stud nuts
Bolts
ft.-lb.
N.m
1980-early 1981
300-400
414-552
Late 1981-on
290-320
400.2-441.6
1980-early 1981
150-250
207-345
Late 1981-on
180-210
248.4-289.8
1980-early 1981
120-160
165.6-220.8
Late 1981-on
140-170
193.2-234.6
35-45
48.3-62.1
45-50 in.-lb.
5.2-5.7
90-120 in.-lb.
10.3-13.8
50-60 in.-lb.
65-105 in.-lb.
5.7-6.9
7.5-12.1
12-15
16.6-20.7
55-75
75.9-103.5
44.2-55.2
32-40
12-15
Crankcase bolt
22-26
6-11
30.4-35.9
8.3-15.2
90-120
124.2-165.6
(continued)
16.6-20.7
CHAPTER FOUR
146
ft.-lb.
N.m
8-12
11-16.6
16.6-24.8
12-18
Timer screws
Inner cover
15-30 in.-lb.
15-30 in.-lb.
1.7-3.4
1.7-3.4
43-48 in.-lb.
90-160 in.-lb.
4.9-5.5
10.3-18.4
Spark plug
18-28
35-40
24.8-38.6
Sensor plate
Table 8
INNER
48.3-55.2
BEARING SPACER
SIZE
Part No.
9120
0.0925-0.0915
9121
9122
0.0945-0.0935
0.0965-0.0955
9123
9124
9125
0.0985-0.0975
0.1005-0.0995
0.1025-0.1015
9126
9127
9128
0.1045-0.1035
0.1065-0.1055
9129
0.1085-0.1075
0.1101-0.1095
9130
9131
9132
0.1125-0.1115
0.1145-0.1135
0.1165-0.1155
9133
0.1185-0.1175
9134
0.1205-0.1195
CHAPTER FIVE
CLUTCH
Removal
KICKSTARTER
motor sprocket with Harley-Davidson tool 9455755 (Figure 7) or compensating sprocket cover with
a chain wrench. Wrap the compensating sprocket
cover with shim stock to prevent damage from the
chain wrench. If these tools are not available, an air
CHAPTER FIVE
148
CLUTCH (1966-1969)
1.
2.
3.
4.
5.
6.
7.
8. Steel disc
9. Friction disc
CLUTCH (1970-1984)
1 2 3
-twv>
@])dlEQID
1.
2.
3.
4.
5.
6.
7.
8.
14 15 17
9. Clutch shell
13.
14.
15.
16.
17.
18
10
11
12 13
16
149
m&s&z
Safety
wire
Compensating
sprocket nut
COMPENSATING SPROCKET
1. Nut
2. Cover
5. Compensating sprocket
6. Shaft extension
7. Spacer
CHAPTER FIVE
150
NOTE
NOTE
1. Foot pedal
2. Foot pedal bearing cover
3. Clutch lever rod
*
^
7. Clutch cover
5 6 .7 8
151
Figure 16).
20. Remove the clutch hub Woodruff key (Figure
18) from groove in main shaft.
Inspection
1A. Primary chain models: Clean all clutch parts in
a non-oil based solvent and thoroughly dry with
compressed air.
CHAPTER FIVE
152
spring tension.
e. After loosening the nuts, remove the washers
and 3 bolts. The separate the pressure plate
and remove the clutch springs.
3. Measure the free length of each clutch spring as
show in Figure 19. Replace any springs that are too
short (Table 1).
4. Inspect steel clutch plates (A, Figure 20) for
warping or wear grooves. Replace if necessary.
plate.
d. Secure with 2 new rivets.
sap
153
Installation
**
.;
;<*
NOTE
'
CHAPTER FIVE
154
PRIMARY
CHAIN
Removal/Installation
COMPENSATING SPROCKET
1.
Nut
2. Cover
5. Compensating sprocket
6. Shaft extension
4. Sliding cam
7. Spacer
155
Inspection
Alignment
Figure 27).
b. Add 0.200 in. (5.08 mm) to measurement A.
c. Measure the distance from the chain cover
spacer thickness.
e. Spacers are available in thicknesses of 0.516,
0.546, 0.576, 0.606, 0.636 and 0.666 in.
(13.11, 13.87, 14.63, 15.39, 16.15 and 16.92
mm).
Spacer
^
~*
Measurement B
Measurement B
Measurement A
(1966-1968)
(1969 only)
(AH 1966-1969)
J
156
CHAPTER FIVE
spacer thickness C.
e. Select the proper spacer thickness from Table
3.
PRIMARY
Inspection
BELT
Alignment
;__i_
TUJj^m^
i
Measurement A
Measurement B
i
Add spacer
<s>
1. Roller bearing
2. Spacer
30
16. Locknut
6. Axle
17.
18.
19.
20.
21.
22.
23.
9. Washer
3. Oil seal
4. Washer
5. Retaining ring
6. Wheel sprocket
7. Spacer
28. Lockwasher
29. Nut
15. Lockwasher
10. Bolt
157
CHAPTER FIVE
158
Table 4.
COMPENSATING
SPROCKET
Broken belt
Removal/Installation
lation .
Missing teeth
Inspection
Primary chain models
Cracked teeth
screw.
NOTE
Tooth wear
<>
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159
CHAPTER FIVE
160
CAUTION
mum).
Step 5.
161
CAUTION
TRANSMISSION
Removal/Installation
162
CHAPTER FIVE
ADJUSTMENT
1. Control coil adjusting sleeve
2. Control coil adjusting
sleeve locknut
rubber pedal
1. Foot pedal
in Chapter Nine.
NOTE
The transmission can be removed with
163
51).
frame bolts.
a. Transmission.
b. Shifter cover.
c. Side cover.
d. Shift forks.
164
CHAPTER FIVE
Inspection
61.
ure 63).
21 2019 18
14 15 16 17
ft
26 25
24 23
1. Countershaft nut
2. Lockwasher
3. Lock plate
23. Screw
24. Washer
4.
5.
6.
7.
8.
26. Gasket
9. Washer
10. Shifler clutch
30. Collar
165
case.
(Figure 58).
50.
12
1. Washer
First gear
3. Bushing
2.
4. Washer
5. Shifter clutch
6. Retaining ring
7. Washer
8.
9.
10.
11.
Second gear
Bushing
Bearing
Countershaft gear
13.
14.
Bushing
Bushing
16A.
16B.
Countershaft (1980-1984)
Transmission housing
17.
CHAPTER FIVE
166
$&$&&(?2:i<Su&*wUsuiS*t?3EGv'sjS'
NOTE
:'-
.;
I3A. 1966-1979:
mmm
IBP*3*
Itelfc
b. Install the lockwasher and countershaft nut
(Figure 68).
c. Tighten the nut to 55-60 ft.-lb. (75.9-82.8
N.m).
d. Bend the lockwasher arms over the nut to lock
it.
"
mm1
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167
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168
CHAPTER FIVE
'
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chapter.
.......
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chapter.
3.1966-early 1978: Referring to Figure 69, perform
the following:
.;.;:^x.:
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faS
em
NOTE
kMmm
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169
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CHAPTER FIVE
170
plate screw
2. Oil deflector
3. Retaining plate
4. Ball bearing nut
1. Nut
2. Lockwasher
3. Bearing
4. Bearing case
5. First/second
gear combination
6. MainshaH
7. Third gear
8. Bushing (hand shift
models only)
13. Bushing
14. Oil seal
9. Washer
16. Spacer
15. Bearing
171
\*-i%'ii-.
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\:
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CHAPTER FIVE
172
; \xM'
iaw-fflKflfflttBaB^ffn
:-::;';:,'::.;:u;;^^
the case.
:-:'0:^;>-:;>
1.. '
ter.
l r
.
.
8A. 1966-1979:
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"T.
;::
. f:-i:
"1l
-"
f^-'M.-'lllx^l
--f
' ',-.
:::'
Ll
.::;
W.n'llI'luC'M'lll.
"
* */, .
fl
.... -^
,.<
r* l
-.a $:
:-'
(Figure 68).
d. Tighten the nut to 55-60 ft.-lb. (75.9-82.8
N.m).
e. Bend the lockwasher arms over the nut to lock
it.
chapter.
t}
...
-'-tit*
":::;
...
.
, 1" , . :-j,;-'
::-r. :
:::..;;
:,.
....
..
;.
:.
. !
::
F;ii :j
;iii
173
NOTE
1. Sprocket locknut
2. Sprocket lockwasher
6. Thrust washer
7. Roller bearings
3. Oil deflector
4. Chain sprocket
5. Main drive gear
14. Gearbox
CHAPTER FIVE
174
'
"
'
;
.
lM
ill
^1
175
Transmission Housing
Figure 87.
3. Carefully install the new oil seal over the shaft
(Figure 88) and align it with the seal bore in the
transmission case.
HAND
transmission case.
SHIFTER
COVER
(1966-EARLY 1979)
Oil seal
ing.
3. Installation is the reverse of these steps. Note the
following.
4. Install the shifter cover with a new gasket. Coat
the gasket with Perfect Seal No. 4 or equivalent.
5. Install the shift cover screws. The 2 long screws
are installed in the holes next to the bulge in the
cover over the shift gear. Install the transmission
vent screw in its original position.
^
"*"**JWI
:.:
'-$$
r;.
::'**4
jggfe.w
''ASi1
i55"
k
~*;^P5
(\.ii
ffiSr
l/j *
Wtt
**
Wfrc&*&
%_,_
Isa&ssr
.,,...
'
EPSRttRw
ft* V ' ^ r
-^
' M
.4
"*
r r ftp j
j
y.^VtU
CHAPTER FIVE
176
Disassembly/Assembly
4. Insert a drift into the shaft hole. Then tap the shaft
cotter pin.
Inspection
1. Clean all parts in solvent, except the oil seal.
2. Inspect all parts for wear or damage. Replace parts
as required.
(1966-1969)
2. Shaft
3. Oil seal
4. Shifter cam
5. Cotter pin
6. Shifter lever
7. Leather washer
15 12
8. Shifter gear
9. Shifter gear spring
10. Cam plunger cap screw
11. Ball screw
FOOT
177
SHIFTER
(1966-EARLY
1979)
Removal/Installation
The shifter cover can be removed with the trans
Figure 92.
1. Remove the battery and battery carrier.
2. Drain the oil tank as described in Chapter Three.
Then remove the oil tank.
3. Disconnect the transmission shifter rod from the
CAUTION
(1970-EARLY 1979)
1. Neutral indicator switch
2. Washer
4.
4A.
5.
6.
6A.
9. Oil seal
10. Shifter cam
17. Bushing
9- Pawl carrier
8. Cover gasket
screw washer
Dust shield
3.
(right)
(left)
spring
carrier spring
Pawl
Pawl
Pawl
Pawl
10.
11.
12.
13.
25. O-ring
21. Spring
(1966-EARLY 1979)
30. Camshaft
31. Shifter cover
<
>
00
179
Disassembly
(Figure 96).
2. Remove the dust cover (Figure 97).
3. Remove the neutral switch (18, Figure 92).
4. Pry the lockwasher tab (20) away from the cam
installation.
WARNING
92) is removed.
- :
1. Foot pedal
2. Foot pedal bearing cover
3. Clutch lever rod
-.;.
. -.
CHAPTER FIVE
180
Assembly
NOTE
NOTE
10. Remove the shifter shaft cotter pin (27). Then tap
the shifter shaft (30) out of the cover.
Inspection
1. Thoroughly clean all parts (except neutral switch)
in solvent, then blow dry.
NOTE
<
*>
'
tun*
181
Z2 FL timing mark
FX timing mark
Shifter gear
Shifter shaft
First slot
///A
10 C\
FL timing mark
FX timing mark
CHAPTER FIVE
182
reassemble.
20. Install the dust shield. Then align the shift lever
with the dust shield and install it. Coat the mounting
machine oil.
15. Install the pawl springs (12) and pawls (10 and
11) into the pawl carrier (9). Make sure to align the
pawl grooves with pawl carrier pins.
16. Align the pawl carrier tab with the 2 pawl earner
springs and install the pawl carrier.
17. Lubricate the back of the pawl carrier with
grease.
COVER
(LATE 1979-1984)
183
washers.
Disassembly
Inspection
Refer to Figure 106 for this procedure.
1. Thoroughly clean all parts (except neutral switch)
in solvent, then blow dry.
NOTE
184
CHAPTER FIVE
FX MODELS
10 35 15 16
FL MODELS
1. Bolt (5)
2. Washer (5)
16. Washer
3. Shift cover
17. Plug
4. Gasket
18. Lockplate
7. Bolt (2)
8. Lockwasher (2)
9. Bolt
20.
21.
22.
23.
Plunger body
Plunger
Spring
Retaining ring
15. Nut
35.
36.
37.
38.
39.
Bushing
Shift lever arm (FX)
Shift lever (FX)
Shift linkage arm (FX)
Retaining ring (2) (FX)
40.
41.
42.
43.
Assembly
185
15 4 3 2
1. Cam follower
2. Spring
6. Screw
3. Lock plate
7. Pawl stop
4. Bolt
8. Spring
FORKS
Removal/Disassembly
Refer to Figure 109 for this procedure.
1. Remove the shift cover as described in this chap
ter.
Pawl carrier
NOTE
Shift cam
CHAPTER FIVE
186
Hi*
i|
: iSi
Inspection
. . .
Ik-
LATE 1979-ON
LATE 1979-ON
@$ foV@a^
1. Nut (2)
2. Lockwasher (2)
3. Shifter fork (counterfork)
9. Lock ring
10. Shifter fork (main shaft)
187
Assembly
CAUTION
^jsk;
ftXXjr*
iiiw.i,i if if fit ii s-Ilk.1
KICKSTARTER
AND
STARTER CLUTCH
Removal/Installation
.....
(1971-1984).
wmmm
M
mm
Three.
IB'
wm.. #
C113v
#
Lift
',.<.
'bL(
*
|B 11*1 .1
.lllllfl
fellS
I.,,
.i.r\.
:..
r w ^ 4 v r r n i < t - .-\-*^t.
W(^B^
**
*.
itui
x l
--
unVfttV:3>* J ' j \ . . c i - .
..i
"**'*
s.jfifr-tt
x
ifft
^Tl^
a;;a
ii...
Ii
<b Itkl
v::: ;
mm !&&
Tl.llfl
....
t
L
i- ;- ".':":
I **
_T
.:?:n:
:. :
....
CHAPTER FIVE
188
NOTE
in Figure 128.
it
-::-:^;--; ..v:K-.
. [i
"">zr-v'y--irrx.
V*K
'-"tf*ii
VfVtV&S
*'
(116
;
...
j;:
t .
Ii :: .
::
iflii .' .. ..
...
...
m -
;;':;.;;.
Mm
'n*r ':
Hi _
...
wmm
.',:;::;,:
mm
;:
::
ailiiil
,'U
rSRB EKKiTO
ilflsii :.
- >
!*3SS
******* "
ss&w
Disassembly
Refer to Figure 120 or Figure 121 for this proce
189
dure.
27
28
1. Bolt
3. Bushing
4. Pedal
16. Cap
28. Lockwasher
29. Nut
30. Screw
31. Lockwasher
19. Washer
20. Starter clutch
9. Stud
33. Seal
22.
23.
24.
25.
34. Nut
2. Lockwasher
7. Bolt
10. Spring
11. Thrust washer
12. O-ring
13. Bushings
27. Rivet
32. Cover
35. Washer
36. Cover
37. Gasket
CHAPTER FIVE
190
KICKSTARTER (1970-ON)
12
1971-1976 FX MODELS
16
17
18
KICKSTARTER (1971-ON)
1. Starter crank
13. Bushing
2. Pivot pin
3. Spring
14. Lockwasher
36. Key
15. Bolt
25. Cap
26. Spring
4. Ball
27. Washer
5. Bracket
17. Bolt
28. Nut
6. Circlip
18. Lockwasher
7. Lockwasher
19. Cover
41. Rivet
8. Bolt
31. Gasket
9. Starter pedal
21. Washer
32. Bushing
33. O-ring
11. Bolt
23. Stud
24. Plug
34. Nut
35. Washer
44. Pin
45. Lockwasher
46. Nut
191
Inspection
mm
Hi-- ---
PUSHROD ADJUSTMENT
: #n
.:-.
mm
..
Releasing disc
Pressure plate
:. :
t Locknut
, Adjusting screw
Spring adjusting
nuts (3)
ii 111 ^.:
It
i
. :
' .: ":,;:
.: --:-
MmmF
'ds
TK.-sii
.;. -
mi
***
Bferi - ,'
my. i v
-J*: ^;;-:''--;;.:.:;.;
3M
^.l^KS-<\'\'.Z^--~:
'
~.
..:
CHAPTER FIVE
192
.:
.r i
sasf"'
::,.;;
Disassembly.
b. Lift the outer spring hook off of the shaft
spring stop.
c. Tap the spring off the kickstarter shaft with a
punch and hammer.
d. Install the new springs so that the outer spring
hook faces to the left-hand side when looking
at the kickstarter crank end. See Figure 131.
! :
\ .
LJ21;.\
& [\,Tv].r.
#\^-
ir'\. f
SijtiLJj :*
LP
;aix;::K%'^iE |
FTC35
U:;:
^:
ig&iill
.i;-:
tlI t
'
~f '
L .
:iSi.2UWtf
1 t u n 1 *vi
:::::
*^ -
* ^ - "*^
\ / -^*
;;i.5
:;;;--.
.-;'.:sf:!:ji:;s
Assembly
. , jj
;..
;-,-.. ::!:;;;::;
*
'
<)
01
193
12 o'clock position
7 o'clock position
Starter crank gear
CHAPTER FIVE
194
SIDE
COVER
(ELECTRIC START)
Removal/Disassembly
1. Refer to Figure 135 for this procedure. Discon
nect the negative battery cable.
2. Drain the transmission oil as described in Chapter
Three.
in Figure 128.
15. Install the side cover mounting bolts and tighten
them to 13-16 ft.-lb. (17.9-22.1 N.m).
16. Refill the transmission with the correct type and
quantity of oil as described in Chapter Three.
17. Adjust the clutch as described in Chapter Three.
Disassembly/Inspection/Assembly
Refer to Figure 135 for this procedure.
1. Remove the release lever nut and washer.
cover.
(HD-95650-42)
195
NOTE
ELECTRIC
STARTER
DRIVE
Removal (Type I)
The Type I electric starter drive (Figure 136) is
used on the following models:
a. 1966-1982 FL.
Inspection
SIDE COVER
Nut
Lockwasher
Release lever
Shaft
\
M
r Upper bushing
/ Cover
i
Gasket
Finger
Washer
Cover nut
Washer
^ /- Lower bushing
Q^Clip
CHAPTER FIVE
196
15 19 14
16
17
18
22 21
20
1. Bolt
3. Oil defector
4. Gasket
7. Shifter lever
(left-hand thread)
8. Drive gear
9. Thrust washer
21. Spacer
10.
11.
12.
13.
O-ring
Bearing (in drive gear housing)
Drive gear housing
Locating pin
22. Circlip
23. Nut
24. Lockwasher
25. Stud
NOTE
197
Installation
Chapter Seven.
CHAPTER FIVE
198
Seven.
Inspection
1. Check the drive gear (5) for worn, chipped or
14
1.
18 13 15
Bolt
2. Bolt
3. Outer drive
gear housing
8. Gasket
9. Screw
10. Shifter lever
4. Gasket
11. Bearing
5. Drive gear
12. Seal
6. Bolt
7. Inner drive
14. Bearing
gear housing
threads)
199
perature grease.
Installation
NOTE
4.
threads,
CHAPTER FIVE
200
SHIFTER ADJUSTMENT
been removed.
1978)
Retaining clip
Locknut
Locknut
201
in.
mm
0.002-0.003
0.051-0.076
1966-1967
1 31/64
37.70
1968-on
1 45/64
43.26
31/32
11/32
24.61
26.19
1/32
0.80
Lining thickness
ft.-lb.
N.m
80-100
110.4
See text
1970-early 1978
50-60
69-82.8
105-120
80-90
144.9-165.6
18-22
24.8-30.4
Late 1986-on
110.4-124.2
Spacer thickness
0.060
0.090
0.120
0.150
0.180
0.210
0.3125-0.3427
0.3427-0.3750
0.3750-0.4063
0.4063-0.4375
in.
in.
in.
in.
(7.94-8.70 mm)
(8.70-9.52 mm)
(9.52-10.32 mm)
(10.32-11.11 mm)
in. (1.52
in. (2.28
in. (3.05
in. (3.81
in. (4.57
in. (5.33
mm)
mm)
mm)
mm)
mm)
mm)
Spacer thickness
0.324-0.304
0.304-0.284
0.284-0.264
0.264-0.254
0.254-0.244
0.060
0.040
0.020
0.010
in (8.23-7.72 mm)
in. (7.72-7.21 mm)
in. (7.21-6.71 mm)
in. (6.71-6.45 mm)
in. (6.45-6.20 mm)
in. (1.52
in. (1.02
in. (0.51
in. (0.25
mm)
mm)
mm)
mm)
None
mm
0.005-0.002
0.013-0.051
0.002-0.003
0.051-0.076
1966-1969
0.003-0.013
0.076-0.330
1970-early 1978
0.0025-0.0135
0.063-0.343
0.000-0.017
0.00-0.43
Item
Roller bearing
Inner bearing
Drive gear end play
Main shaft
(continued)
CHAPTER FIVE
202
Table
TRANSMISSION
Specification
Item
in.
mm
1966-1969
0.008-0.012
0.20-0.30
1970-early 1978
0.007-0.012
0.18-0.30
0.075
1.90
0.080-0.090
2.03-2.29
0.100
2.54
0.100-0.110
2.54-2.79
1966-1969
0.055
1.40
1970-early 1978
0.060-0.070
1.52-1.78
0.003-0.006
0.08-0.15
0.0005-0.0065
0.013-0.165
Countershaft
1970-early 1978 .
Third and fourth gear
1966-1969
1970-early 1978
Sliding reverse gear
Gear backlash
Wear limit
in.
mm
in.
mm
Late 1978-1981
0.0025-0.0135
0.063-0.343
0.025
0.63
1982-on
0.010-0.025
0.254-0.635
0.025
0.63
0.0018-0.0032
0.046-0.081
0.004
0.10
0.000-0,017
0.00-0.43
0.020
0.51
Fit on shaft
0.0012-0.0023
0.030-0.058
0.003
0.08
2.54-2.79
0.110
2.79
Item
Mainshaft bushing
Mainshaft
0.0013
0.033
0.0020
0.051
Press
0.0001
0.003
0.0005
0.013
0.001
0.025
0.0015
0.038
0.0007
0.018
0.001
0.025
Loose
0.0005
0.013
0.0009
0.023
Press
0.0010
0.025
0.0015
0.038
0.003
0.076
0.0025-0.020
0.063-0.51
0.002
0.051
0.0005-0.0019
0.013-0.048
0.002
0.051
0.004-0.012
0.102-0.305
0.015
0.381
0.003-0.017
0.076-0.432
0.020
0.51
0.000-0.0015
0.000-0.038
0.002
0.051
0.0005-0.0025
0.013-0.063
0.002
0.051
0.000-0.0015
0.000-0.038
0.002
0.051
0.0005-0.0025
0.013-0.063
0.002
0.051
Shifter clutch
0.080-0.090
0.090
2.29
Gear backlash
0.003-0.006
2.032-2.286
0.076-0.152
0.010
0.25
0.127-0.165
0.007
0.178
Fit on shaft
Loose
Press
Housing in case
Countershaft
Runout
End play
0.005-0.0065
CHAPTER SIX
FUEL AND
EXHAUST
CLEANER
SYSTEMS
Chapter Three.
Removal/Installation
CARBURETORS
NOTE
Service
concerning emissions.
so equipped).
CHAPTER SIX
204
NOTE
DC CARBURETOR-1966
1.
2.
3.
4.
5.
6.
15.
16.
17. Bowl
18.
Bowl gasket
19.
Float nut
20. Float
23.
24.
25.
36.
Vent clamp
39.
Vent housing
Vent gasket
40.
Throttle body
43.
Main housing
205
QSJ
CHAPTER SIX
206
25. Clean the idle jet hole with a No. 57 (0.043 in.,
1.092 mm) drill, and the angular hole it meets with
a No. 52 (0.0635 in., 1.613 mm) drill.
26. Clean nozzle bleed holes with a No. 54 (0.055
in., 1.397 mm) drill. Clean the main passage with a
No. 17 (0.173 in., 4.394 mm) drill.
207
11. Remove the main jet plug screw (44) from the
CAUTION
Disassembly/Assembly
(HD Carburetor, 1967-1970)
CHAPTER SIX
208
HD CARBURETOR (1967-1970)
1. Accelerating pump
2. Accelerating pump lever
19.
20.
5. Channel plug
6. Welch plug
7. Welch plug
8. Welch plug
9. Choke shaft friction ball
10.
11.
12.
13.
Choke
Choke
Choke
Choke
retainer
21.
screw
22.
38.
39.
23.
24. Economizer check ball
40.
41.
26.
washer
spring
Intermediate adjusting
Intermediate adjusting
packing
Intermediate adjusting
spring
Intermediate adjusting
screw
33.
17. Diaphragm
18. Cover
36.
screw
washer
screw
screw
209
Disassembly/Assembly
(Bendix Carburetor, 1971-1975)
&&&&
i^A^^V
ft
j*^V*t*'**
.ft1
210
CHAPTER SIX
211
BENDIX MODEL
16P12 CARBURETOR
Disassembly/Assembly
(Keihin Carburetor, 1976-early 1978)
(1971-1975)
1. Accelerating pump lever screw
2. Accelerating pump lever
3. Accelerating pump
Refer to Figure 9.
1. Disassemble the accelerating pump as follows:
a. Remove accelerating pump housing (33) at
the bottom of the float bowl (29).
4. Idle tube
8. O-ring
9. Bowl
wall.
6. Remove the rod (7) and boot (8) from the float
22A. Plunger
22B. Spring
23. Choke shaft seal retainer
24. Choke shaft seal
bowl.
spring (16).
11. If necessary, remove the 2 brackets (2 and 15) at
the top of the carburetor housing.
12. The throttle and choke valve assemblies (40) are
212
CHAPTER SIX
213
(1976-EARLY 1978)
1. Screw and washer
2. Bracket
3. Screw
chapter.
15. Adjust the carburetor as described in Chapter
Three.
Disassembly/Assembly
(Keihin Carburetor, Late 1978-on)
4. Screw
5. Float pin
6. Screw
7. Rod
8.
Boot
9. O-rlng
10. Throttle stop screw
11. Spring
12. Low speed mixture screw
13. Spring
14. Screw and washer
15. Bracket
16. Spring
17. Throttle lever
18. Washer
19. Nut
20. O-ring
21. Fuel valve
22. Clip
23. Float assembly
24. Main nozzle
25.
26.
27.
28.
Slow jet
Main jet
Plug
O-ring
30. O-ring
31. Diaphragm
32. Spring
33. Housing
34. Screw and washer
35. Screw and washer
36. Clip
37. Hose
38. Fitting
chapter.
14. Adjust the carburetor as described in Chapter
Three,
tive or motorcycle supply stores, in a small, resealable tank with a dip basket (Figure 12). If it is tightly
CHAPTER SIX
214
:-: :;-
2. Bracket
18. Washer
4. Screw
19. Nut
34. Clip
5. Float pin
35. Hose
6. Screw
36. Fitting
7. Rod
21. Clip
22. Float assembly
37. O-ring
8. Boot
38. Washer
9. Limiter cap
26. Gasket
27. Float bowl
13. Spring
15. Bracket
16. Spring
31. Housing
215
KEIHIN CARBURETOR
-19
16. Nut
5. Float pin
18.
19.
20.
21.
8. Rubber boot
22.
23.
Clip
Float assembly
Low speed jet
Main jet
Plug
Rubber gasket
24.
Float bowl
25.
13. Spring
14. Fast idle cam assembly
15. Lockwasher
25A.
26.
27.
39. Washer
CHAPTER SIX
216
Model DC Carburetor
Float level
3/16 inch
*s^*
14
*
otsThs
ft
j-fl
^m ^C fflk t[.j
?" ?SSW"
&.
fc ^ *fclft & *
E*
217
tang to adjust.
Rejetting Carburetors
Valve fully
closed
Lip
15
(16-17 mm)
Lip
1976-1977:
9/16-5/8 in.
VALVE
FULLY CLOSED
(14-16 mm)
1978-on:
0.63-0.67 in.
(16-17 mm)
T
1-3/32-1-3/16 in
(28-30 mm)
Stopper
VALVE
FULLY OPEN
CHAPTER SIX
218
NOTE
THROTTLE
CABLE
REPLACEMENT
10. Remove the tape and untie the string from the
cable and the frame.
11. Lubricate the new cable as described under Con
Open cable
Close cable
219
18. Start the engine and turn the handlebar from side
to side. Do not operate the throttle. If the engine
speed increases as the handlebar assembly is turned,
the throttle cable is routed incorrectly. Remove the
seat and fuel tank and recheck the cable routing.
FUEL TANK
Removal/Installation
ets.
dure.
WARNING
-.
1. Fuel cap
2. Gasket
3. Left-hand tank
8. Nut
9. Flat washer
4. Right-hand tank
5. Bolt
11. T-connector
6. Flat washer
7. Lockwasher
CHAPTER SIX
220
fuel tanks.
FUEL SUPPLY
VALVE
NOTE
...i.
1. Fuel cap
2. Gasket
3. Fuel tank
4. Bolt
5. Flat washer
6. Spacer
7. Rubber bushing
8. Front rubber tank mount
9. Flat washer
10. Nut
11.
12.
13.
14.
9 10 11 12
13 15
221
10. Pour a small amount of fuel into the fuel tank and
SYSTEM
Removal/Installation
Nut
Handle
, ** * *
1
rrf^i
(
u-
JJ
Nut
Handle
required.
Fuel tank
Gasoline strainer
Clamp
Fuel hose
222
exhaust system. Special chemical cleaners and preservatives compounded for exhaust systems are
available at most motorcycle shops.
Severe dents which cause gas flow restrictions
require the replacement of the damaged part.
CHAPTER SIX
CHAPTER SEVEN
ELECTRICAL SYSTEM
CHARGING
SYSTEM
(1966-1969)
Preliminary Tests
The following tests and inspection should be per
formed before checking the generator charging. The
following check can be performed with the gener
ator installed in the frame.
CHAPTER SEVEN
224
1. Mounting gasket
2. Gear shaft nut
3. Gear shaft washer
36.
4. Drive gear
Brush
33. Frame
14. Armature
225
ELECTRICAL SYSTEM
20 21 22
23 24 25 32 33 34
35 37
54 48
17
36] L
M* ^-3816 15 14 28 29 30 13 12
3. Fan housing
1110
24. Clutch
7. Fan
31. Armature
36. Lockwasher
CHAPTER SEVEN
226
GENERATOR TERMINALS
mm
\\
1
minal.
Field
fo Gen.
Bat.
Ammeter
CAUTION
Regulator
ELECTRICAL SYSTEM
227
Generator Removal/Installation
ii*r?tt
terminal wires.
Polarizing Generator
Standard generator
NOTE
5).
Air-cooled generators
Regulator
Field
Gen.
Bat.
=J
"""^
Jumper
cable
(if so equipped).
CHAPTER SEVEN
228
NOTE
Generator Testing
iimHi.
VOLTAGE
REGULATOR
(1966-1969)
Testing
ELECTRICAL SYSTEM
229
NOTE
rpm.
Connect to
ground
if
Field
control
rheostat
Regulator
QJ
Ammeter
Voltmeter
CHAPTER SEVEN
230
CHARGING
SYSTEM
(1970-1984)
load.
cedure.
FIELD CONTROL
Rheostat
Field
3-
Gen.
Y^l
A
Generator
'
To battery
Voltmeter
ELECTRICAL SYSTEM
231
Service Precautions
Connect to
fj ground
3
GEN
Additional load
BAT
Regulator
Voltmeter
Ammeter
To battery
Motorcycle load
Rectifier
regulator
module
CHARGING SYSTEM
Alternator
stator
1. Diode
2. Diode
3. Diode
4. Silicon controlled rectifier
5. Capacitor
6. Resistor
7. Thermistor
8. Zener diode
9. Zener diode
White
/^rRed
V3^-Blue
Male
Wjre
connector
Red
/--.
1 0-7
Blue (BE) ^M_J
wire
wires
Female
connector
232
CHAPTER SEVEN
o
o
Voltmeter
Ammeter
Regulator
0-20
0-20
rectifier module
_L
o
o
Battery
Rheostat
250 watt
To alternator
i/
ELECTRICAL SYSTEM
233
at another location.
Preliminary Testing
manufacturer's instructions.
_1
15.0
J2
Upper limits
14.0
TO
ffl
Lower limits
13.0
^^
12.0
*
<S>
>5
+25
+50
Air temperature F
+75
+100
+1 25
CHAPTER SEVEN
234
Testing (1976-on)
Refer to Figure 14 for this procedure.
1. Connect a tachometer to the engine following the
manufacturer's instructions.
To ground
"NT
-
V oltmel:er
Ammeter
Regulator
0-20
0-20
rectifier module
0
o
< Battery
Rheostat
(15ohm,
250 watt)
To alternator
ELECTRICAL SYSTEM
NOTE
Alternator Test
235
Regulator/Rectifier Test
There is no test for the regulator alone. The regu
lator can be checked by substituting a known good
regulator.
NOTE
ALTERNATOR
(TYPICAL)
5
1. Screw
2. Screw
3. Lockwasher
4. Rotor assembly
5. Stator
CHAPTER SEVEN
236
CA UTION
rotor.
CAUTION
i&rm!&ft"7&
HMMVHPG
ma
WW---
rc;:
: \
::;
r.
.;::
. . . .
ELECTRICAL SYSTEM
237
CIRCUIT BREAKER
mmmmmmm
Removal (1966-1969)
......
f.
ii
sui",..;
^h-IHiw1
mkmmm
BASp*
-ill::! ! tf ;" '<;\:\. \n\ia:-S\
mmfM^as
mzms
mm
'<
^S!?rfc''"V*i-'i:::V.:
L..:-*=
!!1 "-*
MM
Mr
5a : ;:: Vf\
CHAPTER SEVEN
238
1. Cover
2. Screw and lockwasher
3. Lock screw
14. Base
15. Fiber washer
16. Washer
17. E-clip
18. Flyweight spring
19. Flyweight
20. Washer
21. Cam
22. Camshaft
23. Screw and washer
24. Stem
25. Gasket
26. Shaft washer
27. Gear
30. Clamp
29
\
3D
ELECTRICAL SYSTEM
239
<>
1_
D)
C
a. a
i'
^^
D.
CO
**
i_
"iS
^_
0)
(A
or
to
cu
(0
(0
05
<o
o
->-*
*w
D> O) O)
a>
O
CO
0)
<d
ii E
>
^5
CD
U- U- U- O
u-
5> E
0
CO
CO
<L>
COO
lfl(DN CO O O i - CM
t- i- CM CM CM
00
IS
>.
o
0)
"It
a>
co
to
2: .c c
</>
o
CO
CO
E Z
t?
O -
CU
0)
*-
co
to
co
fl) 3 N
co
CO
CO p
CO
ttSrao
<
W "5* 111
A3 CO CO
ircuit
oC CO
S tCU
E >
E
ircuit
co
ii
a> cu
.* j c
CO CO
a> ai
w
*-
SITCQCQ<CDC0CD
<
ircuit
00 O) O t- CM CO
iince
bly
kercscrew
crew
11
to
a. cu
*-
u.
CU
CU
0)
>
>
>
888
>
^-
CU CU cu
X .* J
CO
CO
CO
cu
cu
cu
^3 ^
o
A
E
CO
c
CO
u
1M
cu
"co
c
4)
i2 J2
5 a>
u
MB
I- CM CO t
CU
BBB
(0
w
a . a . T3
C
E
5
JW4
CD
CU
'5
JOO
CO
CO
CO
CO
> a)
CD CD c
uj CO <
CD
CHAPTER SEVEN
240
Installation
(1966-1969)
Advance
front piston
(AUTOMATIC ADVANCE)
NOTE
1. Breaker cam
2. Fiber cam follower
9. Nut
10. Cover
11. Screw
4. Condenser
5.
6. Lock screw
14. Support
Adjust screw
8. Timing marks
15. Nut
7.
tSftftj.
Contact points
ELECTRICAL SYSTEM
241
ing.
1. Clean all metal parts in solvent and allow to dry
thoroughly.
2. Make sure the base plate is cleaned of all dirt or
grease before installing the contact breakers.
3. Check the gear (27, Figure 25) for worn, chipped
or broken teeth. Replace the gear if it shows these
conditions.
CHAPTER SEVEN
242
Three.
Disassembly/Inspection/Reassembly
IGNITION
SYSTEM (LATE
1978-1979)
SBj&afc
1
Mmw
ELECTRICAL SYSTEM
243
: ..
v.
: .
::
r
..
..
..
..
' - i*
Jim
]
:,:
: ---mm
'<
*tt!
.. .
<-::-'
^.
- m;
;.:
ii
, \%
..
::
..
)
(^
s*^^
. . w
. .. .
'
.,
NOTE
.:
1
::
...
..
. .
..
;.
"...
i
"
. '
..
...
...
;.!...
. .. ;
-
CHAPTER SEVEN
244
1.
2.
3.
4.
5.
6.
7.
8.
9. Sensor
10. Shield
14.
15.
16.
17.
18.
Flyweight (2)
Advance assembly base
Flyweight roll pin (2)
Cam stop roll pin
Register roll pin
20.
21.
22.
22A.
Ignition coil
Spark plug cable (2)
Ignition coil terminal (FL)
Ignition coil terminal (FX)
ELECTRICAL SYSTEM
245
IGNITION
(1980-ON)
in place.
6. To disassemble the advance mechanism, perform
the procedures as described under Disassembly!In
spection!Reassembly.
7. Installation is the reverse of these steps. Note the
following,
SYSTEM
1.
Trigger rotor
7. Transistor
2. Sensor
8.
3. Control module
9.
4.
5.
6.
Ignition coil
Spark plug
12.
<>
CHAPTER SEVEN
246
started.
to the crankcase.
Rear cylinder
(Wide lobe)
RETARD
ADVANCE
1. Ignition module
2. Timer plate screw (2)
3. Ignition module ground screw
4. Sensor screws
5. Sensor
6. Trigger rotor
7. Timer plate
8. Plate adjusting notch
ELECTRICAL SYSTEM
247
:-B
16
/
./
/
.'
3. Ignition coil
4. Ignition module
5. Connector
6. Sensor plate
7. Washer (2)
14. Rotor
15. Rotor screw and star washer
9. Gasket
CHAPTER SEVEN
248
NOTE
Installation
Three.
1.
2.
3.
7. Rotor
8. Computerized
control module
IGNITION COIL
5.
Battery
6.
Sensor piate
9. Ignition coil
10. Sparkplug
Testing (1966-1969)
No test specifications are available for these mod
els. If a coil is suspected to be faulty, replace it with
a new one. Refer to Ignition Troubleshooting in
Chapter Two.
Testing (1970-On)
If the coil (Figure 50) condition is doubtful, there
are several checks which can be made. Disconnect
tu; : ; 7 ; ; - :
k..
w'.i~r
mmm:
ELECTRICAL SYSTEM
249
Removal/Installation
1. Sparkplug cable
CHAPTER SEVEN
250
STARTER
tery.
caution.
Disassembly/Assembly
Removal/Installation
Prestolite starters
NOTE
starter removal.
NOTE
TYPICAL STARTER
ELECTRICAL SYSTEM
251
1.
Through-bolt washer
7. Nut
2.
Lockwasher
8. Starter motor
9. Starter motor bracket
3. Lockwasher
10.
5.
Through-bolt lockwasher
Through-bolt nut
6.
Nut
12.
4.
11.
CHAPTER SEVEN
252
NOTE
Hitachi starters
Frame
Brushes
ure 55).
Brush
holder
Notch
Terminal
Drive end
cover
Frame
Terminal
Wire clips
Alignment
ridges
Brush holder
Notch
Commutator
end cover
<>
ELECTRICAL SYSTEM
253
14
8 7 9v 5
11. Armature
7. Negative brush
8.
and washer
lockwashers
Positive brush
14. Frame
CHAPTER SEVEN
254
NOTE
STARTER
SOLENOID
6. Bolt
7. Lockwasher
8. Solenoid
9. Spacer
1. Cover
2. Nut
3- Lockwasher
4. Nut
5. Lockwasher
15. O-ring
17.
11. Plunger
12. Spring
Washer (1970-1971)
Drive gear
Shaft housing
21. Nut
20. Lockwasher
19.
18. Bearing
16.
10. Gasket
Spacer
Pinion gear and
shaft assembly
34.
Bearing
32.
31.
30. Circlip
27. Pin
25. Spring
H
H
>
m
o
CHAPTER SEVEN
256
(Figure 65).
5. Depress the retainer cap (26, Figure 63) at the
front of the starter shaft housing and remove the pin
(27) and spring (25).
6. Remove the solenoid (Figure 66) boot, gasket,
2 3
7 4
4. Pinion gear
7. Housing
ELECTRICAL SYSTEM
257
LIGHTING
SYSTEM
Headlight Replacement
These models are equipped with a sealed beam
4. Bolt
5. Spacer
20 21 22 23
25 26 27 8.
SEXZ
1. Nut
2. Screw
3. Washer
8. Solenoid
9.
10.
11.
12.
Felt gasket
Spring
Spacer
Outer plunger
13. Pin
15. Spring
21. Collar
16. Collar
17. Pin
18. Spacer
24. Seat
25. Spring
terminal stud
20. Spring
26. Collar
27. Plunger
CHAPTER SEVEN
258
:^3-21 ?2 23 24 25
3 4
8. Mounting ring
15. Gasket
2. Hole plug
3. Housing
4. Adapter ring
9. Screw
16. Ring
7. Adjusting nut
27
1. Screw
5. Screw
6. Screw
26
17. Screw
11.
12.
13.
14.
18. Connector
Ring
Clip
Clip
Clip
22.
23.
24.
25.
26.
27.
Nut (1966-1969)
Bulb (1966-1969)
Lockwasher (late 1966-1969)
Washer (1966-1969)
Holder (1966-1969)
Lens (1966-1969)
5. Lockwasher
8.
9.
10.
11.
12.
6. Washer
13. Lockwasher
7. Bracket
14. Screw
1. Bolt
2. Lockwasher
3. Plug
4. Nut
<&**<*) <n$
10
'< 16
Cap
Clip
Terminal plate assembly
Housing
Clip
ELECTRICAL SYSTEM
259
Late 1978-on FX
1. Shell
2. Bulb
3. Ring
4. Trim ring
5. Connector
6. Lockwasher
9. Brace
10. Lockwasher
7. Bolt
11. Nut
13. Screw
14. Bolt
15. Screw
8. Flat washer
12. Plate
16. Nut
CHAPTER SEVEN
260
dure.
Headlight Adjustment
headlight lens.
CAUTION
Bulb
1, Screw
2. Cover
3. Retaining rings
4. Screw
5. Sealed beam
6. Connector
7. Rubber boot
8.
ELECTRICAL SYSTEM
261
r^ adjustment
Horizontal
adjustment
Trim plate
CHAPTER SEVEN
262
procedure.
electrical connector.
TYPE 2
1. Gasket
2. Nut
3. Lockwasher
4.
Lens
TYPE 1
5. Gasket
t. Socket
6. Lens
2. Dampers
7. Screw
3. Screw
8. Nut
4. Gasket
5. Lens
6. Mount
7. Screw
TYPE 3
1. Screw
2. Lens
3. Bulb
4. Gasket
5. Lens
6. Gasket
7. Nut
ELECTRICAL SYSTEM
263
SWITCHES
Early type
PASSING LIGHTS
BUTTON SWITCHES
,*
EARLY STYLE
Turn signal
screw
::*;-
.. tf;:; :
.;; :.:;...::-::
..
LATE STYLE
1. Screw
EARLY STYLE
* * '*"
2. Housing
1. Screw
3. Button
2. Terminal
4. Upper contact
3. Housing
5. Spring
4. Spring
5. Contact plate
6. Plastic washer
6. Button
7. Lower contact
CHAPTER SEVEN
264
switch.
nection.
3A. 1972-1981:
Late type
HORN
Removal/Installation
A-6
3 5
1. Screw
4. Base
2. Cover
5. Wires
3. Switch
6. Terminal screws
ELECTRICAL SYSTEM
265
FUSES
Adjustment
The horn on these models cannot be disassembled.
CAUTION
tone is obtained.
fuse.
(1972-1981)
LEFT SIDE
1. Screw
2. Switch cover
5. RUN-OFF switch
11. Washer
3. Screw
6. Screw
9. Rubber cap
4.
HI-LO switch
7. Retainer
CHAPTER SEVEN
266
WARNING
(1982-ON)
1. Screw
2. Switch housing
3. Switch
4. Screw
267
ELECTRICAL SYSTEM
White-to-white connection
Blue-to-red connection
Stator resistance check
75-125 volts
0.3-1.0 ohms*
White-to-white connection
White-to-blue connection
See text
Blue-to-red connection
1.5-2.0 ohms*
See text
4.7-5.7 ohms
16,000-20,000 ohms
Prestolite
Hitachi
AC voltage output
2-4 ohms
Primary
4,7-5.7 ohms
Secondary
16,500-20,000 ohms
1980-on
Primary
3-3-3.7 ohms
Secondary
16,500-19,500 ohms
Regulator
13.8-15 volts
1981
16 amps
17.8 amps
1982-on
22 amps
Late 1978-1980
Hitachi
Table 3
Delco-Remy
Voltage Regulator
Part No.
Setting
1118 388
11119 187C
11119187D
7.5
1118 307
7.01
1118 307
7.4
1118 794
1118 794
7.01
7.42
1118 995
7.0-7.3
1118 989
6.5-6.8
7.2-7.5
7.2-7.5
CHAPTER SEVEN
268
Table
CURRENT
REGULATOR SPECIFICATIONS
Delco-Remy
Part No.
Current Regulator
Setting
1118 388
18 amperes
1119 187C
13.5-16.5 amperes
1119 187D
13.5-16.5 amperes
9.0-11.0 amperes
11119 614
Table
MODULE
RESISTANCE CHECKS
Positive
Negative
Connection
Connection
Indication
Module base
Infinity
Module base
3-15 ohms
Module base
Infinity
Module base
3-15 ohms
Blue
Black
3-15 ohms
Black
Blue
Red
Module base
Module Base
Red
Infinity
Infinity
Infinity
Table 6
White-White
1st and 2nd White-Blue
Red-Blue
1.5-2.0 ohms
Any lead-Ground
Infinity
CHAPTER EIGHT
FRONT
SUSPENSION AND
STEERING
FRONT
WHEEL
Removal/Installation (1966-1971 FL
Models With Drum Brake)
NOTE
1. Cotter pin
2. Axle nut
3. Flat washer
4. Front axle
5. Wheel mounting
screws
CHAPTER EIGHT
270
1.
11. With the front wheel still clear of the ground, spin
the front wheel to make sure the wheel spins true.
12. Adjust the front brake as described in Chapter
Three.
271
assembly.
Three.
the wheel.
CAUTION
3).
CHAPTER EIGHT
272
CAUTION
the wheel.
FL FRONT WHEEL
1.
2.
3.
4.
Axle cap
Slider cap nuts
Speedometer cable
Hubcap
5. Spacer
6. Washer
7. Lockwasher
8. Axle nut
9. Axle
273
NOTE
CAUTION
1. Axle
6. Washer
7. Speedometer cable
CHAPTER EIGHT
274
wheel.
the wheel.
CAUTION
3).
4.
2. Axle
5. Axle nut
3. Caliper mounting
6. Lockwasher
bolts
7.
Axle
Speedometer cable
3. The standard end play is 0.004-0.018 in. (0.100.46 mm). If the end play does not fall within this
range, replace the axle spacer with a longer or shorter
one. Spacers of various lengths are available from
Harley-Davidson dealers.
275
chapter.
3. Remove the thrust bearing cover screws and lock
washers.
FRONT
HUB
Disassembly/Inspection/Assembly
(1966 Roller Bearing Hubs)
Refer to Figure 9 for this procedure.
NOTE
CHAPTER EIGHT
276
8. Thrust washer
washer
WARNING
277
Disassembly/Inspection/Assembly
chapter.
(1967-1972 FL Models)
ELECTRA-GLIDE HUB
(1967-1972 FL)
4. Bearing locknut
5. Seal
6. Spacer
7. Ball bearing
8. Ball bearing (1 front) (2 rear)
CHAPTER EIGHT
278
13. Install the snap ring (2) with its flat side against
the bearing. Make sure the snap ring seats in the
groove completely.
14. Working from the opposite side, install the bear
ing spacer. Then install the bearing (3) using the
same procedure as for the opposite bearing. Drive
the bearing in until it seats against the hub shoulder.
15. Install a new grease seal by driving it in with a
suitable size socket.
Disassembly/Inspection/Assembly
(1970-1972 FX)
(,
* ft
\ II
* 1/
r\Lr
l"
\) \f\\ K
\
ljr
*
/J / f
II
im
Disassembly/Inspection/Assembly
(1973-early 1978 Interchangeable
16 in. Cast and Spoked Hubs)
NOTE
SUPER GLIDE
FRONT HUB
(1970-1972 FX)
279
chapter.
2. Remove both oil seals (Figure 12).
3. Remove the spacer and both bearing cones.
4. Check the roller bearing cones and cups for wear,
pitting or excessive heat (bluish tint). Replace the
bearing cones and cups as a complete set. Replace
CHAPTER EIGHT
280
(1973-EARLY1978)
5 4_JJ
1. Circlip
6. Bearing race
2. Washer
7. Spacer
12. Spacer
3. Oil seal
8. Hub
13. Bolt
4. Spacer
9.
14. Nut
5. Bearing
Bolt
10. Nut
(1973-EARLY 1978)
1. Circlip
6. Bearing race
2. Washer
7. Spacer
12. Spacer
3. Oil seal
8. Wheel assembly
4. Spacer
5. Bearing
9. Bolt
13. Stud
14. Washer and nut
10. Lockwasher
281
1. Oil seal
2. Spacer
3. Bearing cone
4. Bearing cup
7.
5. Spacer
8.
FX FRONT WHEEL
(LATE 1978-ON
EXCEPT FXE AND FXWG)
4 6 3 2 5 1
1. Seal
2. Bearing
3. Bearing race
4. Hub
5. Spacer
6. Spacer
7. Screw
8. Brake disc
9. Wheel assembly
10. Spacer
11. Brake disc
282
CHAPTER EIGHT
c. Tap the oil seals in until they are flush with the
hub.
Disassembiy/Inspection/Reassembly
(Late 1978-1982 FL Models)
dure.
NOTE
1.
Brake disc
5. Bearing
2.
Bolt
6. Bearing race
3. Oil seal
4.
Spacer
7. Spacer
8. Hub
283
7 6 10 5
1. Bolt
2. Brake disc
7. Bearing race
3. Nut
8. Hub
4. Wheel assembly
5. Oil seal
6. Bearing
6(p
7
9 10 11 12 13
12 11
10
1. Bolt
2. Brake disc
8. Washer
3. Spacer
9. Spacer
4. Nut
5. Wheel assembly
11. Bearing
6. Spacer
7. Circlip
CHAPTER EIGHT
284
(D
@f)(3)6)
7 8 9 10 11 12
12 11 10 9 8 7
1. Bolt
2. Lockwasher
7. Circlip
3. Brake disc
9. Spacer
4. Spacer
5. Wheel assembly
6. Spacer
8. Washer
11. Bearing
2 3 4
7 8
1. Spacer
2. Circlip
3. Washer
8. Hub
9. Spacer (1983)
4. Spacer
10. Nut
11. Brake disc
5. Oil seal
12. Bolt
6. Bearing
7. Bearing race
285
Disassembly/Inspection/Reassembly (Late
c. Tap the oil seals in until they are flush with the
hub.
NOTE
ter.
WHEEL
BALANCE
CHAPTER EIGHT
286
Spoke Adjustment
287
(2.03 mm).
ment, rotate the rim and make sure another area has
Rim Replacement
5. Lift the hub and spokes out of the old rim, making
sure not to knock the spokes out of alignment.
Rim
Hub
: ..
Loosen
nipples until they just seat against the rim. True the
CHAPTER EIGHT
288
NOTE
Seating Spokes
When spokes loosen or when installing new
spokes, the head of the spoke should be checked for
proper seating in the hub. If it is not seated correctly,
it can loosen further and may cause severe damage
to the hub. If one or more spokes require reseating,
hit the head of each spoke with a punch. True the
wheel as described under Spoke Adjustment in this
chapter.
TIRE CHANGING
The stock cast wheel is aluminum and the exterior
Removal
NOTE
A head breaker machine will be re
the first tool prying the bead over the rim (Figure
g^TIWi.^B
289
first bead was pried over (Figure 33). Force the bead
on the side opposite the tool into the center of the
rim. Pry the second bead off the rim, working around
valve from its hole in the rim to the inside of the tire.
Carefully pull the tube out of the tire and lay it aside.
NOTE
Installation
Cap
Second nut
First nut
Stem
Metal washer
Rubber grommet
rim and insert the valve stem through the stem hole
in the wheel. The lower bead should go into the
center of the rim and the upper bead outside. Work
around the tire in both directions (Figure 36). Use a
tire iron for the last few inches of bead (Figure 37).
6. Press the upper bead into the rim opposite the
valve. Pry the bead into the rim on both sides of the
CHAPTER EIGHT
290
WARNING
TIRE
REPAIRS
(TUBE-TYPE TIRES)
sary.
NOTE
291
HANDLEBAR AND
THROTTLE CONTROL
turer's instructions.
TIRE
REPAIRS
(TUBELESS TYPE)
CAUTION
kit.
;:
-**"
Spiral grip
CHAPTER EIGHT
292
1. End screw
2. Spring
3. Grip
4. Roller pin
8. Control wire
5. Roller
10. Coil
6. Plunger
11. Handlebar
293
(1975-1980)
7. Control elbow
2. Upper clamp
13.
3. Lower clamp
9. Control wire
14.
15.
Handlebar
294
CHAPTER EIGHT
Open cable
Close cable
ure 43).
STEERING
HEAD
(1981-1984)
1. Throttle clamp screw
2. Upper clamp
3. Throttle friction spring
4. Lower clamp
5. Throttle grip
6. Friction adjuster spring
7. Friction adjuster
8. Ferrule
9. Open cable
10. Adjuster
11. Locknut
12. Close cable
295
STEERING ASSEMBLY
1. Fork cap
2. Oil seal
3. Fork stem nut
4.
Lockwasher
5. Upper bracket
6. Pinch bolt
8. Bearing seat
9. Dust shield
10. Bearing
15
CHAPTER EIGHT
296
STEERING ASSEMBLY
1. Steering damper
adjusting screw
2. Spring
3. Spider spring cover
4. Spider spring
5. Pressure disc
6. Friction washer
7. Anchor plate
8. Friction washer
9. Pressure disc
10. Fork stem nut
28. O-ring
29. Cotter pin
30. Nut
22 29 23
297
STEERING ASSEMBLY
1. Bolt
2. Washer
5. Spring
6. Spring
7. Upper pressure disc
8. Friction washer
9. Plate
15. Bearing
298
CHAPTER EIGHT
chapter.
2. Remove the fuel tank as described in Chapter Six.
471
STEERING ASSEMBLY
(1984 FX EXCEPT FXWG)
chapter.
4. Remove the handlebar as described in this
chapter.
NO CALIPER
MOUNTING
ON 1984
13. Install the bearing seat onto the fork stem and
tighten it until the steering bearings have no notice
able free play.
MODELS
1. Screw
2. Cover
9. Bolt
3. Bolt
4. Screw
11. Bearing
5. Screw insert
6.
7.
Fork teg
Upper bracket
8. Nut
FORK BRACKET
(1984 FXWG)
299
chapter.
2. Remove the fuel tank as described in Chapter Six.
3. Remove the fork tubes as described in this
chapter.
4. Remove the handlebar as described in this
chapter.
5. On models so equipped, bend the lockwasher tab
down and remove the fork stem nut. On other mod
NO CALIPER
MOUNTING
ON 1984
MODELS
Inspection
1. Clean the bearing races in the steering head and all
bearings and bearing cones with solvent.
2. Check for broken welds on the frame around the
1. Bolt
2. Lockwasher
3.
Fork cap
4. Washer
12. Bearing
5. Oil seal
6.
Cap
7. Nut
8. Lockwasher
9.
Upper bracket
CHAPTER EIGHT
300
1. Wooden drift
into the head tube and carefully tap the race out from
the inside (Figure 49). Tap all around the race so that
2. Bearing race
3. Head pipe
FRONT FORK
<s>
301
CHAPTER EIGHT
302
f-"3
-4
*i
'J 3hi
!J3
ri
E_1
V i
Drain plug
FRONT FORK
303
15.
16.
17.
18.
19.
Disassembly/Reassembly
(Late 1977-on FL and 1976-1983 FX)
CHAPTER EIGHT
304
15. Refill the fork tube with the correct type and
quantity of fork oil as described in Chapter Three.
FRONT FORK
10B
1. Bolt
11
2. Washer
3. Fork tube
6. Retaining ring
7. Oil seal
8. Washer
12
9. Sleeve
17. Bushing
15
3
I
i
305
1. Fork cap
2. O-ring
11. Washer
3. Spring
13. Slider
4. Piston rings
14. Bushing
5. Damper rod
15. Washer
6. Spring
16. Bolt
7. Fork tube
8. Dust boot
9. Retaining ring
19. Lockwasher
12. Sleeve
20. Nut
1. Fork cap
2. Washer
12. Slider
3. O-ring
13. Bushing
4. Spring
5. Piston rings
6. Damper rod
16. Washer
7. Fork tube
17. Bolt
8.
Dust boot
9. Retaining ring
10. ON seal
20. Lockwasher
11. Sleeve
21. Nut
CHAPTER EIGHT
306
NOTE
(1971-1975 FX)
Tube cap
Cap washer (1973 and later)
4. Pinch bolt
5. Fork boot
5A.
5B.
5C. Seal
6. Fork slide
7.
Spring retainer
(1972 and earlier)
9.
absorber assembly
Fork spring
Spring guide (1973 and later)
9A.
10. Fork slider
11.
13.
r~ Fork tube
Damper rod
16.
17.
18.
19.
22.
11
\n^-^^ 1
307
CHAPTER EIGHT
308
4. Pour the oil out of the fork and discard it. Pump
the fork several times by hand to expel most of the
remaining oil.
5A, 1971-1972: Insert a long screwdriver through
the top of the fork tube and engage it with the slot in
the top of the damper rod (10, Figure 65). This will
prevent the damper rod from turning when removing
Allen bolt.
1. Snap ring
7. Piston
5. Spring
6. Snap ring
8. Damper rod
3. Valve washer
9. Fork tube
309
1.
2.
3.
Retaining ring
Lower piston
Lower stop
4. Orifice washer
5. Valve
6. Spring washer
7. Valve body
8. Retaining ring
9. Upper piston
CHAPTER EIGHT
310
3. Pour the oil out of the fork and discard it. Pump
the fork several times by hand to expel most of the
remaining oil
4. Slip the dust seal off of the lower fork tube and
(S)
FRONT FORK
(1984 FX EXCEPT FXWG)
remove it.
1. Fork cap
2. Washer
3. O-ring
4. Spring
5. Wear rings
6. Damper rod
7. Spring
16. Slider
8. Fork tube
17. Bolt
18. Washer
9. Bushing
19. Washer
10, Sleeve
311
14. Install the spring into the fork tube so that the
FRONT FORK (1984 FXWG)
damper rod.
16. Install the fork tube assembly into the slider. Use
NOTE
tube.
NOTE
19. Lightly tap the hollow tube and install the bush
ing, seal spacer and oi! seal. Install the parts until the
retaining ring groove in the slider is exposed. Re
6
22. Refill the fork tube with the correct quantity and
weight of fork oil as described in Chapter Three.
Inspection (All Models)
3. Spring
4. Wear rings
5. Damper rod
6. Spring
15. Slider
7. Fork tube
16. Screw
8. Bushing
17. Washer
9. Sleeve
10. Dust seal
18. Screw
19. Washer
312
CHAPTER EIGHT
Table 1
N.m
50
34-42
69
46.9-57.9
22-26
30.4-35.9
22-26
30.4-35.9
11
15.2
20
27.6
FL models
40-45
55.2-62.1
FX models
55-70
75.9-96.6
Handlebar
Clamp screws
Riser mount bolts
Table 2
50
11
69
15.2
CHAPTER NINE
REAR
SUSPENSION
REAR
WHEEL
Removal/Installation (1966-1972)
Refer to Figure 1.
1. Support the bike so that the rear wheel clears the
ground.
2. Remove the rear fender support screws and raise
the fender.
CHAPTER NINE
314
Removal/Installation (1973-On)
Inspection
Refer to Figure 2 and Figure 3 (typical) for this
procedure,
1. Support the bike so that the rear wheel clears the
ground.
2. Loosen the drive chain or drive belt adjusting
locknuts and adjuster bolts.
3. Loosen and remove the axle nut and washer.
4. Slide the axle out of the wheel and allow the wheel
REAR SUSPENSION
315
Disassembly/Inspection/Assembly
(1966-early 1978)
REAR
HUB
iced.
WARNING
Disassembly/Inspection/Assembly
(Late 1978-on)
NOTE
CHAPTER NINE
316
lation.
13. Tap the oil seals (Figure 7) into the hub to the
following specifications:
a. Laced wheels (except FXWG and FXE):
13/64-7/32 in. (5.16-5.56 mm).
b. Laced wheels (only FXWG and FXE): 3/161/4 in. (4.76-6.35 mm).
c. Cast wheels (except 1983 FXDG and 1984
FXSB): 13/64-7/32 in. (5.16-5.56 mm).
d. Cast wheels (only 1983 FXDG and 1984
FXSB): 5/16-21/64 in. (7.94-8.33 mm).
14. If the brake disc was removed, refer to Chapter
Ten for correct procedures and tightening torques.
15. After the wheel is installed, the bearing end play
should be checked as described in this chapter.
16. If the hub on spoke wheels is damaged, the hub
can be replaced by removing the spokes and having
Removal/Installation (1966-1972)
Refer to Figure 8 for this procedure.
1. Remove the rear wheel as described in this chap
ter.
Chapter Ten.
3. Place the rear brake drum in a vise.
11 12
spring (1982-1983)
2. Grooved brake disc
(1982-1983)
16
13 14 15 1.6
7. Wheel assembly
8. Nut
9. Driven sprocket
15. Bearing
15A. Bearing (FXWG/FXE)
10. Bolt
11. Circlip
3. Bolt
4. Brake disc
12. Washer
5. Spacer
13. Spacer
6. Nul
15 14 13 12 11
18. Spacer
REAR SUSPENSION
317
1. Retaining ring
5. Bearing
6. Bearing race
7. Spacer
8. Screw
9. Brake disc
10- Spacer
11. Sprocket mounting
hardware (FL models)
12. Sprocket mounting
hardware (FX models)
13. Sprocket mounting
hardware (belt drive)
(1982-on FLH)
Brake drum
Power pin
L
JSB
Screw
REAR SPROCKET
CHAPTER NINE
318
30
1.
Roller bearing
Spacer
5.
Retaining ring
16. Locknut
6.
Wheel sprocket
Spacer
22.
23.
24.
25.
26.
27.
28. Lockwasher
29. Nut
20. Spacer
21. Bearing disc
30. Compensating
sprocket assembly
2.
3. Oil seal
4. Washer
15. Lockwasher
7.
8. Axle
9. Washer
10. Bolt
11. Rear belt
Small damper
Large damper
Primary belt
Compensator drive hub
Compensating sprocket
Flange bearing
REAR SUSPENSION
319
NOTE
side.
7. Check the brake drum rivet holes. If the holes are
drill.
NOTE
2.
to
3.
4.
GOOD
Bent teeth
Bent teeth
Worn area
Worn area
WORN
CHAPTER NINE
320
DRIVE
CHAIN
Removal/Installation
**
Broken belt
the chain.
NOTE
Missing teeth
Cracked teeth
Severe wear or
Three.
^^ <2>^0A, //\\
Tooth wear
1. Master link
2. Clip opening
321
REAR SUSPENSION
CAUTION
Three.
Lubrication
Three,
Inspection
DRIVE
BELT
Removal/Installation
ter.
CAUTION
WHEEL
ter.
BALANCING
TIRE
CHANGING
REAR
SWING
ARM
Removal/Installation
1. Pivot shaft
3. Rear fork
5. Bearing seal
6. Bearing
7. Grease fitting
chain guard.
6. Remove the rear brake drum or caliper as de
scribed in Chapter Ten.
CHAPTER NINE
322
NOTE
323
REAR SUSPENSION
SHOCK
ABSORBERS
The rear shocks are spring controlled and hydraulically damped. Spring preload can be adjusted on
all models. Refer to Chapter Three.
Removal/Installation
Removal and installation of the rear shocks is eas
CHAPTER NINE
324
REAR SHOCK
ABSORBER
(1966)
3
1. Cover clamp with
screw and nut
2. Top cover
3. Mounting stud nut
4. Cup washer
5. Stud rubber bushing
6. Cam support
7. Bumper
8. Cover
9. Spring
10. Lower cam
11 A. Rotating cam
12. Cam sleeve
13. Seal washer
--i
325
REAR SUSPENSION
Disassembly/Assembly (1966)
Refer to Figure 19 for this procedure.
1. Remove the shock absorber as described in this
chapter.
2. Loosen the cover clamp, then slip off the top cover
(2, Figure 19).
3. Remove the upper and lower rubber bushings.
WARNING
Do not attempt to disassemble the shock
Disassembly/Assembly (1967-on)
Refer to Figure 21 (FL) or Figure 22 (FX) for this
procedure.
1. Remove the shock absorber as described in this
chapter.
2. Remove the upper and lower rubber bushings.
3. Remove the retaining ring (5, Figure 21) if so
equipped.
WARNING
Washer (8).
Spring (9).
Washer (8).
Seal washer (10).
d. Spring (7).
CHAPTER NINE
326
REAR SHOCK
ABSORBER
(1967-ON FL)
1. Mounting stud nut
2. Stud cover
3.
4.
5.
6.
Cup washer
Stud rubber bushing
Retaining ring
Split key
7. Cover (long)
7A. Cover (short)
8. Washer
9. Spring
10. Seal washer
<o
12. Cam
Assemble cams
REAR SUSPENSION
327
e. 2 washers (6).
f. Spring guide (8).
SHOCK ABSORBER
(ALL FX TYPICAL)
1. Cover
2. Plain washer
7.
8.
9.
10.
Spring
Lower spring guide (late 1984)
Spring adjuster (late 1984)
Adjuster cup
11. Cam
12. Cam
13. Nut
14. Plain washer
15. Outer washer
18. Bushing
19. Outer washer
12 16 17
27. Bushing
28.
18 19
Lower stud
(1971-early 1972)
28
ma* ifblP
CHAPTER NINE
328
34-42
46.9-57.9
35
48.3
45-50
62.1-69
Late 1978-on
Laced wheels
Cast wheels
CHAPTER TEN
BRAKES
NOTE
BRAKES
ter.
"L" or "R." These markings represent left- and righthand brake shoes. If the brake shoes on your bike are
not identified, mark the casting with a felt-tipped pen
to represent alignment. The brake shoes must be
returned to their original positions during installa
tion.
Leading
Trailing
shoe
shoe
TURNING DIRECTION
washer.
CHAPTER TEN
330
Install the top brake shoe pivot in the pivot stud and
the lower brake shoe pivot on the cam lever.
12. Install the lower brake shoe return spring.
NOTE
1.
Cotter pin
2.
Axle nut
3. Flat washer
4.
7.
Front axle
Slider cap
8. Brake drum
20
1. Bolt
28
9. Clamp
2. Brake drum
3. Axle sleeve
11.
25. Lockwasher
4. Cup
5. Axle sleeve
27. Nut
6. Brake shoes
7. Springs
8. Nut
30. Plug
Plain washer
BRAKES
331
13. Slide the brake drum (2, Figure 2) over the brake
shoes. See Figure 3.
14. Install the brake drum bolts (1, Figure 2) and
tighten securely.
15. Adjust the front brake as described in Chapter
CAUTION
Three.
NOTE
Eight.
lation.
2.
3.
4.
5.
Operating
Operating
Operating
Operating
shaft nut
lever
shaft
shaft washer
CHAPTER TEN
332
shoes.
information.
this chapter.
10. Installation is the reverse of these steps. Note the
following.
11. Slide the shoe pivot stud (6) into the brake side
plate (7).
12. Install the washer onto the operating shaft (4).
Then slide the operating shaft into the brake side
plate. Install the operating lever (3) and secure with
CAUTION
the nut.
Install the top brake shoe pivot in the shoe pivot stud
(6) and the lower brake shoe pivot on the operating
shaft cam (4).
NOTE
NOTE
Inspection
WARNING
Do not inhale brake dust. It contains
due.
BRAKES
333
NOTE
NOTE
models.
in sets of two.
CAUTION
anchor pin
Enlarged
rim out
of round
surface thoroughly.
c. Rivet the new linings to the brake shoes. It is
important to start riveting from one end of the
lining and work toward the other end to pre
vent buckling.
d. Bevel the ends of both brake shoes with a file
Rusting or pitting
Welds at rib to
rim broken
(Figure 9).
7. On early style brakes, check the cam lever stud
play on the cam lever. If excessive play is detected,
have a Harley-Davidson dealer install a new cam
lever bushing.
8. Inspect the brake shoe return springs for wear. If
DRUM
BRAKE
(1966-1972)
CHAPTER TEN
334
1. Screw
2. Dowel pin
(1966-1972)
9. Wheel cylinder
17. Lockwashers
18. Plate
25. Nut
19. Block
4. Axle sleeve
5. Collar
20. Plate
13. Rivets
6. Spacer
14. Springs
22. Screws
7. Nut
30. Lockwasher
8. Piston assembly
16. Screws
3. Brake drum
31. Nut
BRAKES
335
NOTE
tion.
ter.
linings.
CAUTION
NOTE
Make sure to check the brake drum
WARNING
Do not inhale brake dust. It contains
NOTE
CHAPTER TEN
336
CAUTION
(Figure 9).
5B. Bonded brake linings: Measure the brake linings
with vernier calipers (Figure 11). They should be
replaced as a set if worn to 0.100 in. (2.54 mm) or
less.
DISC
BRAKES
337
BRAKES
not used.
date.
WARNING
BRAKE
PAD
REPLACEMENT
Service Notes
13).
CHAPTER TEN
338
cr;;n
1.
2.
3.
4.
5.
11 12 13 1415 16 1718
8.
Bolt
30. Bolt
31. Brake disc
33. Bolt
34. Nut
20. Bolt
35. Lockwasher
9. Cotter pin
10. Insulator (late
1978-early 1980 FL, FLH,
FLH-80 and Classic)
11. Piston
24. Nut
12. Seal
(early models)
27. Nut
28. Plain washer
29. Lockwasher
339
BRAKES
27 28
g<n=OTzf(3P
2 3
29
4 5 6 8
2. Anti-vibration disc
3. Brake pad
4.
5.
6.
7.
8. Bolt
26
26. Bolt
27. Plain washer
28. Bolt
11. Bushing
16. Piston"
17. Seal
25
10. Bushing
39. Bolt
**
CHAPTER TEN
340
mm) or less.
used).
NOTE
24 25 26
1.
2.
3.
4.
3 4 5 9 10
1113 14 15 16 17
18 23
12. Washer
21. Bolt
13. Nut
22.
23.
24.
25.
26.
27.
5. Shim
14. Insulator
6. Bushing
15. Piston
7. Bushing
8. Caliper mounting bracket
16. Seal
9. Bolt
18. Nut
20
21
Mounting pin
Outer caliper half
Spring (late 1984 FLH-80)
Washer (late 1984 FLH-80)
Bolt (late 1984 FLH-80)
Bushing (late 1984 FLH-80)
341
BRAKES
rivets.
NOTE
2 3
5 6 8
1214 15 16
17
22
23. Bolt
3. Brake pad
4. Brake pad mounting pins
14. Nut
15. Insulator
5. Brake pad
16. Piston
6. Shim
17. Seal
7. Cotter pin
29. Nut
32. Lockwasher
8.
Bolt
10. Bushing
11. Bushing
33. Bolt
23
342
CHAPTER TEN
9. Torque arm
3. Washer
10. Piston
6. Pressure plate
7. Brake pad
14. Seal
8. Rivet
washer locknut
BRAKES
343
rivets.
brush.
NOTE
CAUTION
9. Outer plate
7. Piston boot
8. Piston
344
CHAPTER TEN
Upper
.55 in.
mounting hole
(14 mm)
Outer
mm) or less.
caliper body
NOTE
.10 in.
(2.5 mm)
(1984 FX)
n-%,
13 12
1. Bolt
2. Pin
3. Washer
4. Bushing
5. Pin boot
6. O-ring
13.
7. Pad holder
8.
Foam tape
Spring holder
9. Pads
Retaining ring
Caliper
11
10
16
345
BRAKES
NOTE
12. Install the caliper over the brake disc. Make sure
a brake pad is positioned on both sides of the disc.
13. Install the caliper bolts and secure with new
locknuts. Tighten the bolts to 115-120 in.-lb. (13.213.8 N.m).
NOTE
Spring clip
Pad holder
Pad
CHAPTER TEN
346
(1981-1984 FLH)
12
13
14
10
1. Bolt (2)
2. Washer (2)
5. Seal (4)
fcfcn
6. Caliper
9. Brake hose
10. Brake hose seat
3. Pin (2)
7. Plate (2)
347
BRAKES
WARNING
seals.
bracket.
hose.
CAUTION
CHAPTER TEN
348
16. Coat the mounting screws with Loctite Antiseize and install them with their lockwashers.
frame.
CAUTION
11. Install the brake pad pins, plate and brake pads
into the right side caliper housing.
12. Install the anti-rattle spring with its arc to the top
and the prongs to the right side of the caliper.
13. Install the damper and sleeve onto the mounting
bracket.
1.
Bolt (4)
2.
10.
3.
Washer (4)
Inner caliper
4.
Outer caliper
12.
5.
13.
6.
Mounting bracket
Brake pad (2)
Dust boot
Piston
Square seal
Bleeder nipple
14.
Brake hose
7.
15.
16.
Anti-rattle spring
8. Plate
9. Insulator
11.
I
I
BRAKES
349
mm) or less.
follows:
NOTE
Abutment seats
Abutment shim
10. Refer to Figure 25. Install the pad spring into the
top of the caliper so that the spring's long tab extends
above the piston. Hook the spring's short tab above
the ridge on the caliper casting opposite the piston.
1. Screw
2. Bracket
3. Pads
8.
Pad spring
Retaining ring
9.
10. Piston boot
11. Piston
4.
Caliper body
5.
6.
Lower pin
Upper pin
12. Seal
7.
Pin boot
350
CHAFfER TEN
BRAKE
CALIPER
Removal/Installation
NOTE
b.
c.
d.
e.
Retaining ring.
Backing plate.
Spring washers (1972-1974).
Friction ring.
f. Seal.
II. Install the piston boot into the caliper bore so that
the small hole in the boot faces downward when the
WARNING
Pad spring
Short tab
order:
Long tab
a. Backing plate.
b. Wave spring (1972-1974).
c. Friction ring.
d. O-ring.
6. Check the mounting bracket bushings for wear
and damage. Replace them if necessary.
Caliper body
BRAKES
351
15. Align the piston with the caliper bore and install
it. Press the piston in all the way.
16. Install the brake pads as described in this chapter.
ter.
bore.
2. Rag
4. Air hose
3. Piston
5. Caliper
CHAPTER TEN
352
Inspection
a compressor.
FRONT MASTER
CYLINDER
Removal/Installation (1972-1981)
a. Piston.
b. Piston boot.
c. O-ring.
BRAKE
DISC
Removal/Installation
V Si \ f
M/
*"^^^
8888
4J*J^JU
pcjJVi
^
|.
i l
flVntr^nr.
l r l' l'* A
J^dr++T+T^V^1mJ\*I*"vl-!vi'l*>!'!*'*! Xvl'Av
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t^^^^^^^^^^^i }
yf
Vw m w \ >
j-^^
"1
i
*
1.
BRAKES
353
<>
11
1. Master cylinder
2. Cover
6. Brake lever
14. Circlip
3. Gasket
9. Pin
15. Piston
4. Screw
10. Plunger
11. Spring
12. Washer
16.
17.
18.
19.
O-ring
Piston cup
Spring cup
Return spring
CHAPTER TEN
354
e. Circlip (14).
12. Referring to Figure 29, install the plunger as
sembly as follows:
a. Washer (12).
b.
c.
d.
e.
f. Pin (9).
13. Lightly grease the pivot pin (7). Then install the
hand lever and pivot pin (7). Secure the pivot pin
with a new circlip (6).
Removal/Installation (1982-on)
Overhaul (1972-1981)
brake fluid.
brake fluid.
CAUTION
lever.
plugged.
9. Coat all internal parts with specified brake fluid
before assembly.
10. Install a new O-ring (16) on the piston.
11. Referring to Figure 29, assemble the piston
assembly in the following order:
a. Piston return spring (19).
Overhaul
BRAKES
355
f. Stop (16).
g. Spring (15).
WARNING
All 1984 FL and FX models do not use
son dealer.
8. Check to see that the vent hole in the cover is not
e. Cup (17).
<>
plugged.
1.
2.
Master cylinder
Master cylinder cover
3. Gasket
4.
5.
Screws (2)
Banjo bolt
6. Washers (2)
7. Hydraulic line
8.
Circlip
9. Pivot pin
10. Brake lever
17. Cup
12. Grommet
19. Piston
20. O-ring
15. Spring
16. Stop
CHAPTER TEN
356
4. Cotter pin
5. Nut
8. Lockwasher
9. Plain washer
14. Cap
15. Washer
Plain washer
20. Spacers
21. Bolt
22. Lockwasher
Nut
Junction block
Brake hose
Brake hose
33. Spring
34. Nut
36. Lockwasher
37.
Bolt
40. Strap
REAR
MASTER
CYLINDER
BRAKES
357
358
CHAPTER TEN
BRAKES
359
1. Bolt
2. Insulator
29.
3. Clamp
30.
4. Master cylinder*
(1973-earlyl979)
5. Cap
31.
32.
1972-early 1979)
Grease fitting
6. Washer
7. Spacer
34.
8. Plate
1972-early 1979)
10. Nut
11. Rubber washer
36.
Spring
15. Bolt
16. Boot
Brake pedal
(1971-early 1979)
Plunger (early style)
42.
43. Plain washer
44.
(1971-early 1972)
45. Nut
21. Nut
46. Bolt
47. Lockwasher
22. Bolt
23. Lockwasher
(1971-early 1972)
53.
Stop plate
(1971-early 1972)
1972)
CHAPTER TEN
360
1. Spacer
15. Nut
2. Pad kit
29. Screw
3. Pedal rubber
17. Bracket
30. Diaphragm
4. Pedal plate
31. Bolt
5. Brake pedal
18. Nut
19. Lockwasher
6. Plain washer
20. Cover
7. Nut
21. Spring
22. Clevis pin
23. Plunger
8. Bolt
9. Bolt
10. Lockwasher
24. Nut
35. Bolt
36. Plain washer
12. Bolt
38. Nut
27. Bracket
39. Hose
14. Lockwasher
28. Cover
40. Strap
361
BRAKES
Three.
plugged.
9. Check the plunger assembly for wear, bending or
damage. Replace it if necessary.
10. Coat all internal parts in specified brake fluid
before assembly.
II. Referring to Figure 32 or Figure 33, install the
piston assembly into the master cylinder bore.
NOTE
On 1972 and earlier models with drum
brake, make sure to order parts 4177358 (valve and seat) and install them in
plugged.
8. Check the plunger assembly for wear, bending or
damage. Replace it if necessary.
9. Coat all internal parts in specified brake fluid
before assembly.
10A. Referring to Figure 34, install the following
parts in order:
a. Spring (37G).
362
CHAPTER TEN
r**f ^ ,
(LATE 1979-1983
EXCEPT FXWG AND FXSB)
46
39
(1983-0N FXSB)
(1984 FXE)
42
43
44
45
BRAKES
363
Bolt
3. Lockwasher
4. Plate
5. Screw
6. Cover
7. Diaphragm
8. Master cylinder
housing
9. Rubber boot
10. Brake rod
14. Diaphragm
15. Master cylinder
housing
16. Plate
17. Bolt
18. Brake hose
19. Bolt
20. Clip
21. Brake hose
22. Junction block
(all models)
23.
Plate
24. Lockwasher
25. Nut
30. Bracket
31. Spacer
32. Mounting plate
33. Brake hose
34. Bolt
35. Washer
42. Bushing
43. Brake pedal
44. Spring
45. Plain washer
46. Bracket
WARNING
47. Washer
CHAPTER TEN
364
(1980-1982 FXWG)
10
11
14
12
13
3. Bolt
17. Nut
4. Spring washer
18. Spring
32. Washer
5. Nut
6. Bolt
20. Bolt
34. Bolt
7. Plate
8. Lockwasher
21. Bolt
36. Screw
24. Screw
38. Diaphragm
11. Bolt
39. Nut
26. Cover
40. Spacer
9. Nut
37. Cover
365
BRAKES
(1983-ON FXWG)
20 21 22
24
16
23
x^
^^f%],8
37 3
39
1. Screw
2. Cover
14. Bracket
15. Lockwasher
3. Diaphragm
27. Nut
16. Nut
4. Reservoir
17. Hose
30. Bolt
5. Bracket
31. Nut
42. Nut
43. Brake rod clevis
6. Bolt
32. Nut
7. Clamp
45. Bolt
8. Hose
21. Lockwasher
46. Washer
9. Hose fitting
22. Bolt
35. Bolt
10. Bolt
24. Bolt
36. Lockwasher
37. Washer
12. Hose
25. Nut
38. Washer
39. Spring
41. Plunger
49. Nut
CHAPTER TEN
366
a.
b.
c.
d.
plugged.
8. Check the plunger (41) on the end of the brake rod
clevis (43) for wear, bending or damage. Replace it
if necessary.
9. Coat all internal parts in specified brake fluid
before assembly.
10. Referring to Figure 37, install the following
parts in order:
a. Spring (33G).
b. Spring seat (33F).
c. Piston cup (33E).
d. Washer (33D).
NOTE
BRAKE
HOSE
REPLACEMENT
CAUTION
BRAKES
367
CAUTION
BLEEDING
THE
SYSTEM
WARNING
CHAPTER TEN
368
clean.
NOTE
settle out.
WARNING
line.
N.m
50-55
69-75.9
1972-1973
35
48.3
1974-1977
10
13.8
16 In. wheel
21-27
29-37.3
19 in. wheel
16-19
22-26.2
23-27
31.7-37.3
16-19
22-26.2
23-27
31.7-37.3
14-16
19.3-22
50
69
FL models
30-34
41.4-46.9
115-120 in.-lb.
13.2-13.8
FX 1970-1977
30-34
41.4-46.9
115-120 In.-lb.
13.2-13.8
15-20
20.7-27.6
1970-early 1978
Brake disc screws
1970-early 1978
Early 1978
Late 1978-on
1970-early 1978
Brake caliper
1970-early 1978
Late 1978-on
Union bolts
369
INDEX
INDEX
HD, 1967-1971
207-209
Keihin
Air cleaner
71-72, 203
1976-early 1978
211-213
late 1978-on
213
model DC
Battery
Brake caliper
caliper overhaul
all except type I and type II
type I
type II
Brake disc
43-45
350-352
351 -352
350-351
351
352
366-367
36
1980-on
33-34
29-33
service
1980-on
84-85
late 1978-1979
82-84
troubleshooting
Breaker point ignition
80-82
troubleshooting
27-29
Bendix 16P12
223-228
1970-1984
230-237
testing
1970-1975
233-234
1976-on
234-235
Circuit breaker
237-242
1966-1969
237-241
1970-early 1978
241-242
Clutch
158-159
Crankcase
137-141
Cylinder
117-119
337-350
337-340
340-343
343-345
345-347
87
87
Disc brakes
Drive belt
model DC
86-87
Drive chain
model HD
85-86
Carburetors
203-218
disassembly/assembly
Bendix, 1971-1975
25, 147-154
Compensating sprocket
87-89
late 1978-on
213-216
35
25
1966-1969
type V
type VI
type VH
85-89
Keihin
1976-early 1978
29-34
service
Carburetor adjustments
204-207
347
347-348
348-350
61-62, 336-337
321
57-60. 320-321
lubrication
209-211
54-55
56
316-319
370
INDEX
Electrical problems
Electric starter drive
removal/inspection/installation
type I
type II
27
195-199
195-197
197-199
Emergency troubleshooting
Engine
21
96-98
crankcase
137-141
cylinder
gearcase cover and timing gears
117-119
128-137
lubrication
23-24
noises
oil pump
performance
pistons and piston rings
principles
pushrods
rocker arm cover/cylinder head
starting
tappets and tappet guides
valves and valve components
Exhaust system
23
123-128
22-23
119-123
96
106-110
99-106
21-22
110-113
113-117
221-222
Fasteners
4-7
285
352-356
removal/installation/overhaul
1972-1981
352-354
1982-on
354-356
35-36
269-275
removal/installation
1966-1971 FL models
with drum brake
269-270
1970-1972 FX models
270-271
270
1973-early 1978 FX
271
273-274
271-272
except FXE/FXWG
Fuel supply valve
272-273
220-221
Fuel tank
219-220
265-266
128-137
177-182
1966-1969
128-129
329-333
1970-on
132-133
removal/installation
1966-1971 FL
329-331
1971-1972 FX
331-332
Front fork
disassembly/reassembly
1966-early 1977 FL models
301-303
1971-1975 FX
304-309
1984 FX
309-311
1976-1983 FX
Front hub
disassembly/inspection/assembly
1966 roller bearing hubs
1967-1972 FL models
291 -294
252-253
Horn
264-265
275-285
275-277
277-278
278
303-304
1970-1972 FX
300-312
279
279-282
282
Ignition coil
Ignition system
248-249
1980-on
245-248
late 1978-1979
242-245
troubleshooting
Insti-uments, troubleshooting
27
21
INDEX
371
throttle
adjustment
Kickstarter and starter clutch
187-193
cable
69-70
69
Master cylinder
front
352-356
rear
356-366
Mechanic's tips
Lighting system
14-15
257-263
Lubricants
7-8
Lubrication
54-55
56
Oil pump
Operating requirements
123-128
20-21
periodic
45-56
primary chain lubrication
54
speedometer/tachometer cable lubrication ... 54
Parts replacement
M
Maintenance
intervals
42
periodic
56-74
disc brake
inspection
61
61
61-62
Periodic lubrication
45-56
Periodic maintenance
56-74
119-123
Prestolite starters
250-252
Primary
Primary
Primary
Primary
156-158
154-156
159161
54
belt
chain
chain/belt case
chain lubrication
Pushrods
106-110
333-336
Rearhub
315-316
356-366
change
62
level
61
drive chain
cleaning, inspection
and lubrication
59-60
inspection/adjustment
57-59
drum brake lining (front and rear)
62
final drive belt inspection/adjustment.. 60-61
foot clutch control adjustment
(1966-early 1978)
65-66
62-63
66-67
67-69
56
56
63-65
63
overhaul
1966-early 1979
361
1983-on FXWG
363-366
356-361
321-323
Rear wheel
313-315
removal/installation
1966-1972
1973-on
313-314
314
99-106
41-42
372
INDEX
S
Safety first
Serial numbers
Service hints
2-4
96
200
Troubleshooting
brake problems
breakerless ignition
36
1980-on
33-34
29-33
27-29
carburetor
35
183-185
charging system
25
Shift forks
185-187
clutch
25
electrical problems
emergency
engine
27
21
Shock absorbers
323-327
194-195
54
250-254
lubrication
Hitachi starters
252-253
noises
Prestolite starters
250-252
solenoid
254-257
performance
starting
Starting system
25-27
23-24
23
22-23
21-22
excessive vibration
34-35
294-300
35-36
27
FL models
294-298
instruments
FX models
299
Steering head
disassembly/reassembly
Suspension adjustment
74
Switches
263-264
21
starting system
25-27
transmission
25
Tune-up
74-80
Tools, basic
Torque specifications
Transmission
110-113
12-14
218-219
288-290, 321
290-291
291
113-117
34-35
228-230
w
Wheel balance
Wheel balancing
285-288
321
42-43
Wheels
9-12
front
269-275
rear
313-315
4
25, 161-175
2-43
WIRING DIAGRAMS
374
or
LJJ
CO <
UJ
cc
UJ
<
QC
O
LU
LU
Red
CD
Gre
Blac
CD
CD
Yel c
Blac
0)
o
Red
i- *>
a> o
*-*
(0
^2
UJ
4-*
c* *
0)
cc
O
o
o
ii
cc o
ii
ii
co >
II
a> =
>
1 :=
.* 5
0)
or
ii
ii
ir
cc >-
Q CC
WIRING DIAGRAMS
375
1966-1967 ELECTRA-GLIDE
A. Conduit (4 wires)red, green, black
and yellow
B. Conduit (1 wire)green
19.
Horn switch
wiring
21. Terminal
22. Terminal
23. Terminalnot used with
2 black wires
N. Conduit (1 wire)black
0. Conduit (1 wire)black
P. Conduit (2 wires)2 black wires
Q. Conduit (1 wire)red
standard wiring
24. Terminal
25. Terminal
standard wiring
30. Terminalnot used with
standard wiring
31. Terminal
standard wiring
4. Switch terminaltaillight
5. Switch terminalignition coil
6. Ignitionlight switchsee
terminals 1 through 5
40. Terminal
7. Junction terminal
42. Terminal
8. Junction terminal
43. Terminal
9. Terminal
10. Terminal
wiring
12. Terminalnot used with standard
wiring
39 through 43)
39. Terminal
41. Terminal
screw (ground)
46. Headlight
47. Neutral indicator light
48. Neutral switch
49. Starter button
13. Regulator
14. Tail-and stoplight
51. Horn
376
WIRING DIAGRAMS
1968-1969 ELECTRA-GLIDE
COLOR CODE
B = Black
BN = Brown
G = Green
R
W
Y
Red
= White
=
Yellow
O = Orange
BR = Black with red tracer
RB = Red with black tracer
1
1
-J
EL>-
377
WIRING DIAGRAMS
1968-1969 ELECTRA-GLIDE
A. Conduit (4 wires)red, greeen, black and yellow
B. Conduit (1 wire)green
24. Terminal
25. Terminal
2 black wires
standard wiring
30. Terminalnot used with
F. Conduit (1 wire)red
G. Conduit (1 wire)yellow
31. Terminal
M. Conduit (1 wire)black
N.
0.
P.
Q.
R.
Conduit (1 wire)black
Conduit (1 wire)black
Conduit (2 wires)2 black wires
Conduit (1 wire)red
Conduit (1 wire)red
S. Conduit (1 wire)green
standard wiring
39 through 43
39. Terminal
40. Terminal
41. Terminal
42. Terminal
43. Terminal
2. Switch terminalheadlight
4. Switch terminaltaillight
5. Switch terminalignition coil
6. Ignitionlight switchsee terminals 1 through 5
screw (ground)
46. Headlight
7. Junction terminal
8. Junction terminal
9. Terminal
10. Terminal
11. Terminal
14.
15.
16.
17.
18.
55.
56.
57.
58.
51.
Horn
20. Terminal
21. Terminal
22. Terminal
23. Terminal
64. Connector
WIRING DIAGRAMS
378
1970 ELECTRA-GLIDE
COLOR CODE
B = Black
BN = Brown
G = Green
R = Red
W
= White
= Yellow
BE = Blue
V
= Violet
O = Orange
GY = Gray
T = Tan
379
WIRING DIAGRAMS
1970 ELECTRA-GLIDE
standard wiring)
17. Headlight switch terminal
51.
52.
53.
54.
55.
39. Headlight
44. Horn
57. Connector
61. Handlebar
WIRING DIAGRAMS
380
1971 ELECTRA-GLIDE
g x47 59
60 24
COLOR CODE
57 K
B = Black
BN = Brown
G = Green
R
W
Y
= Red
= White
= Yellow
BE =
Blue
= Violet
O = Orange
GY = Gray
T = Tan
381
WIRING DIAGRAMS
1971 ELECTRA-GLIDE
1. Front terminal board terminals
32.
4.
Ignition coil
39.
40.
Headlight
Neutral indicator light
41.
Neutral switch
43.
14.
35.
44. Horn
45.
standard wiring)
Headlight switch terminal
Supply switch terminal
Regulator-rectifier module
Alternator to module connector plug
47.
48.
Starter relay
Direction signal switch
49.
50.
51.
52.
23.
5354.
24.
55.
25.
26.
56.
57. Connector
17.
18.
19.
20.
22.
58.
28.
29.
Stoplight switchrear
382
WIRING DIAGRAMS
COLOR CODE
B = Black
BN = Brown
GN = Green
R
= Red
= White
= Yellow
BE = Blue
V
= Violet
O = Orange
GY = Gray
T
= Tan
WIRING DIAGRAMS
383
26.
27.
28.
29.
30.
7. Horn switch
31.
32.
9. Wire connector
33.
12.
13.
14.
15.
16.
39.
Speedometer light
Oil pressure signal switch
44.
45.
46.
22. Horn
23. Headlight
50.
WIRING DIAGRAMS
384
1972 ELECTRA-GLIDE
\-
COLOR CODE
B = Black
BN = Brown
GN = Green
R
W
Y
s Red
= White
= Yellow
BE =
Blue
= Violet
O = Orange
GY = Gray
T
= Tan
385
WIRING DIAGRAMS
1972 ELECTRA-GLIDE
Front terminal board terminal
2. Front terminal board terminal
32.
33.
1.
4.
6.
36.
Ignition coil
Rear terminal board terminaltop
9.
39.
40.
Headlight
Neutral Indicator light
41.
Neutral switch
OH signal light
44.
Horn
45.
46.
standard wiring)
Headlight switch terminal
Supply switch terminal
Regulator-rectifier module
Alternator to module connector plug
47.
Starter relay
14.
16.
17.
18.
19.
20.
26.
27. Horn switch
50.
53.
54.
55.
56.
57. Connector
28.
29.
Stoplight switchrear
60.
61.
Handlebar
62.
WIRING DIAGRAMS
386
1973 FX 1200
L-4
COLOR CODE
BK = Black
BN = Brown
GN = Green
R
= Red
= White
= Yellow
BE =
Blue
= Violet
O = Orange
GY = Gray
T = Tan
387
WIRING DIAGRAMS
1973 FX 1200
1. Fork terminal board terminal
2. Fork terminal board terminal
26.
7. Horn
9. Wire connector
32.
33.
34.
35.
36.
37.
20. Horn
21. Headlight
42. Switch
WIRING DIAGRAMS
388
COLOR CODE
BK = Black
BN = Brown
GN = Green
R
= Red
= White
= Yellow
BE s
Blue
V = Violet
O = Orange
GY = Gray
T = Tan
WIRING DIAGRAMS
389
3. Regulator-rectifier module
4. Alternator to module connector plug
5. Alternator stator
34.
35.
36.
37.
38.
39.
40. Connector
50.
51.
51.
52.
53.
Emergency flasher
Emergency flasher
Emergency flasher switch
Passing light switch
Passing light
28.
29.
30.
31.
32.
33.
SWITCH CONNECTIONS
Position
Contacts
Accessory
1-4
Off
Ignition and
accessory
Ignition, light
and accessory
1-2-5
2-3-5-6
WIRING DIAGRAMS
390
M~^r ,>^16
ii<r-r-
"J
III
,.
VW
'
-lOMl
>
50
-*.,
*0\
I.
SiI <>
5-ji
i
COLOR CODE
i?
BK = Black
BN = Brown
GN = Green
R
= Red
= White
= Yellow
BE = Blue
V = Violet
O = Orange
GY = Gray
T = Tan
PK = Pink
391
WIRING DIAGRAMS
2.
3.
4.
5.
Fork
Fork
Fork
Fork
terminal
terminal
terminal
terminal
board
board
board
board
terminal
terminal
terminal
terminal
32.
33.
34.
35.
9. Wire connector
36. Tachometer
10.
11.
12.
13.
14.
42. Switch
45.
46.
47.
48.
21. Headlight
22.
23.
24.
25.
WIRING DIAGRAMS
392
"l
/ /
40 35
COLOR CODE
BK =
Black
BN = Brown
GN = Green
R = Red
W = White
Y = Yellow
BE = Blue
V
Violet
O = Orange
GY = Gray
T
= Tan
WIRING DIAGRAMS
393
2. Switch (terminals 1 to 6)
3. Regulator-rectifier module
5. Alternator stator
6.
7.
8.
9.
10.
Tail/stoplight
Battery positive terminal
Battery negative terminal
Oil pressure signal switch
Headlight beam switch
40. Connector
30.
31.
32.
33.
Starter relay
Right turn signal switch
Direction signal flasher
Left front turn signal light
SWITCH CONNECTIONS
Position
Contacts
Accessory
1-4
Off
Ignition, light
and accessory
Ignition, light
and accessory
2-4-5-6
2-3-4-5-6
WIRING DIAGRAMS
394
PUSlflUE WIRE F*
q fusible 'IH;
W!F
WIRE
FX
V..'
\-
52 v
-l
COLOR CODE
js
/^ BN = Brown
30
KZHt^3'
BK = Black
GN = Green
6N
R = Red
W = White
Y = Yellow
13
rH
BE = Blue
I
V = Violet
O = Orange
GY = Gray
T = Tan
PK = Pink
WIRING DIAGRAMS
395
3. Socket-plug combination
4. Socket-plug combination
5. Wiring harness
7. Horn switch
10.
11.
12.
13.
35. Tail/stoplight
36. Tachometer
20. Horn
43.
44.
45.
46.
47.
WIRING DIAGRAMS
396
i
i
COLOR CODE
\n BK = Black
BN = Brown
r^r* GN Green
i^Y/ R =Red
I *
40
35
W = White
Y = Yellow
BE = Blue
V = Violet
O = Orange
GY = Gray
T
= Tan
397
WIRING DIAGRAMS
34.
35.
36.
37.
6. Tail/stoplight
7. Battery positive terminal
40. Connector
28.
29.
30.
31.
32.
33.
SWITCH CONNECTIONS
Position
Contacts
Accessory
1-4
Off
mmm*
Ignition, light
and accessory
Ignition, light
and accessory
2-4-5-6
2-3-4-5-6
WIRING DIAGRAMS
398
FUSIBLE WIRE FX
A^fl-ill r-^^-T;
-~o \
50
51
FUSIBLE *iK'
WIRE
VVIRE
an
'
oii-.i.
COLOR CODE
BK = Black
BN = Brown
GN = Green
R = Red
W
= White
Y = Yellow
BE =
Blue
V = Violet
O r Orange
GY = Gray
T
= Tan
PK = Pink
399
WIRING DIAGRAMS
4. Socket-plug combination
5. Wiring harness
6. Headlight beam switch
7. Horn switch
48.
49.
50.
51.
52.
400
WIRING DIAGRAMS
1978-1979 FL/FLH
COPPER
STUD
SVViTCH CONNECTIONS
POSITION
I CONTACTS
ACCESSORY
OFF
IGNITION.
LIGHT &
ACCESSORY
14
2-4-6-6
2 3-4-5 6
IGNITION.
LIGHT &
ACCESSORY
COLOR CODE
BK = Black
/ f BN s Brown
37
32
GN = Green
R = Red
W
= White
Y = Yellow
BE r
V
Blue
Violet
O = Orange
GY = Gray
T
= Tan
WIRING DIAGRAMS
401
1978-1979 FL/FLH
1. Front terminal board (terminals 1 to 11)
2. Switch (terminals 1 to 6)
3. Regulator-rectifier module
26.
27.
28.
29.
35.
36.
37.
38.
17.
18.
19.
20.
WIRING DIAGRAMS
402
1978-1979 FX/FXE
COLOR CODE
BK = Black
35' * BN = Brown
^
ft) GN = Green
1/
R = Red
53
48
W = White
Y
= Yellow
BE = Blue
V = Violet
O = Orange
GY = Gray
T
= Tan
PK = Pink
403
WIRING DIAGRAMS
1978-1979 FX/FXE
1. Headlamp housing
2.
3.
4.
5.
6.
Socket-plug combination
Socket-plug combination
Socket-plug combination
Wiring harness
Headlamp beam switch
7. Horn switch
8. Ignition timer
9. Wire connector
32.
33.
34.
35.
36. Tachometer
11.
12.
13.
14.
15.
16.
17.
18.
21.
22.
23.
24.
Headlamp socket
Engine stop switch
Front stoplight switch
Ignition coil
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
WIRING DIAGRAMS
404
1978-1979 FXS
COLOR CODE
BE = Blue
BK = Black
BN = Brown
R = Red
GN = Green
V = Violet
GY = Gray
O = Orange
PK = Pink
W = White
Y = Yellow
TN = Tan
405
WIRING DIAGRAMS
1978-1979 FXS
1. Headlamp housing
2.
3.
4.
5.
6.
7.
8.
9.
Socket-plug combination
Socket-plug combination
Socket-plug combination
Socket-plug combination
Socket-plug combination
Socket-plug combination
Wiring harness
Headlamp beam switch
13.
14.
15.
16.
17.
18.
19.
20.
21.
23. Horn
42.
43.
44.
45.
46.
47.
48.
406
WIRING DIAGRAMS
1980-1984 FXS/FXEF/FXB
right f r c n t
BfcAKE
SWITCH
START | EMOlWE
j RCKTTUK^
iUTCCH
HORN
ILUM/
1
oiu
C*(S
HORki
W.K
4H
BUJ
uT GftU
IHEADLAMP
\/IO
[L&FTTUKK
407
WIRING DIAGRAMS
1980-1984 FXS/FXEF/FXB
swactf
U4HT1MC
KM.
Attf>.
msm
fOCMTCEAe
Turn SViWAL
ISFTRSMC
TURMSfcSWAL
WIRING DIAGRAMS
408
1980-1982 FXE
R\&HrT F*ONT
TURM9*^JAL
FWONT
stcAxe
start
| enciiwe
KJSHTTUKM
[|Jli-t-v-m
0G P iU
-S UiVJT <\
*MV *
/iff I
LuftfT-/uKT
ftM
TAN
HG*t>l.KtfT
1
bfej
*T*L-
ffLK
WA>.
EAR
AUHT
-OR6-
;,--n
MOttN
|WADLATP
i LEFT TURK
409
WIRING DIAGRAMS
1980-1982 FXE
5WITCH
orct
ci e r r
tR'K'R
ftS'K'R
O'l wsss.
SWITCH
SWrXM
StATTCH
Lm-J -t-^=^-tUtt-JLttjLTI1
PISHT eCAR
TUKW $ViWAV-
LEFTREAft
410
WIRING DIAGRAMS
1980-1984 FXWG
(PART 1)
14 GA.
GROUND AT RIGHT
HARNESS CLAMP
COLOR CODE
BK = Black
BN = Brown
BE = Blue
GY = Gray
GN = Green
TN = Tan
Y = Yellow
R = Red
O = Orange
PK = Pink
V = Violet
W
= White
WIRING DIAGRAMS
411
1980-1984 FXWG
FRAME GND.BOtT
STATOR
LEFT REAR
DIRECTIONAL LAMP
j NO CONNECTION
1 CONNECTION
OIL SWITCH
POSITION 8
OFF
KEY SWITCH POSITION:
POS. 1-ACC.
POS. 2 - OFF
POS. 3 - IGN. & ACC.
IGNITION CIRCUIT
STARTING CIRCUIT
CHARGING CIRCUIT
RUN
LIGHTS
Ii
412
WIRING DIAGRAMS
1980-1981 FLHS
\
START SWITCH
STOP SWITCH
DIR SWITCH
STOPLIGHT SWITCH
CONNECTOR
HEADLAMP PLUG
COLOR CODE
BK = Black
BN = Brown
BE = Blue
I NO CONNECTION
if CONNECTION
TN = Tan
= Yellow
HORN SWITCH
IGNITION SWITCH
POSITION
R = Red
OFF
O - Orange
RUN
PK = Pink
V = Violet
W
= White
SWITCH
DIMMER SWITCH
GY = Gray
GN = Green
DIRECTIONAL
LIGHTS
i w*
WIRING DIAGRAMS
413
1980-1981 FLHS
KEY SWITCH POSITION:
POS, 1 - ACC,
POS. 2-OFF
a
COPPER
STUD
SPEEDOMETER
RIGHT REAR
OIRECTIONAL LAMP
Ht-BEAM
LAMP y
LEFT REAR
DIRECTIONAL LAMP
REAR PLUG
FRONT PLUG
414
WIRING DIAGRAMS
1980-1984 FL/FLH
START SWITCH
KILL SWITCH
DIR SWITCH
RIGHT PASSING LAMP
LIGHT SWITCH
CONNECTOR -M
CONNECTOR
FLASHER SWITCH r
DIRECTIONAL
SWITCH
DIMMER SWITCH
HORN SWITCH
LEFT PASSING LAMP
WIRING DIAGRAMS
415
1980-1984 FL/FLH
KEY SWITCH POSITION:
POS. 1-ACC.
POS. 2 - OFF
P08. 3-IQN.4ACC
POS. 4 - ION., ACC. A LIGHTS
STARTER RELAY
COPPER
STUD
SPEEDOMETER
RIGHT REAR
HI-BEAM
LAMP
FENDER
,TIP LAMP
Lata 1962
and later
A
CONNECTOR
LEFT REAR
DIRECTIONAL LAMP
J NO CONNECTION
REAR
PLUG AND
COLOR CODE:
(Bk) BLACK
(7) YELLOW
(BN) BROWN
*> CONNECTION
IGNITION SWITCH
(BE)BLUE
(jT)red
(^o) ORANGE
POSITION B
(gy)gray
(pk)pink
(GN) GREEN
(V) VIOLET
(tn)tan
(w) WHITE
PLUG
RECEPTACLE
OFF
RUN
LIGHTS
tt4 *
WIRING DIAGRAMS
416
1982-1983 FLHS
START SWITCH
STOP SWITCH
OVR SWITCH
STOPLIGHT SWITCH
CONNECTOR
HEADLAMP PLUG
COLOR CODE
BK = Black
BN = Brown
BE = Blue
j NO CONNECTION
if CONNECTION
GY = Gray
GN = Green
TN = Tan
IGNITION SWITCH
POSITION B
= Yellow
a Red
OFF
O = Orange
RUN
PK =
Pink
= Violet
= White
LIGHTS
I M*
DIRECTIONAL
SWITCH
DIMMER SWITCH
HORN SWITCH
WIRING DIAGRAMS
417
1982-1983 FLHS
(30A)
SPEEDOMETEH
HI-BEAM
LAMP
LEFT REAR
DIRECTIONAL
LAMP
VOLTAGE
REGULATOf
REAR PLUG
FRONT PLUG
WIRING DIAGRAMS
418
1983-1984 FXE
RIGHT DIR.
SWITCH
STOP SWITCH
STARTER
SWITCH
RIGHT
DIRECTIONAL
LAMP
STOPLIGHT SWITCH
SPEEDOMETER
DIRECTIONAL
FLASHER
GROUND UNDER
CKT. BKR.
CLIP
HEADLAMP ANE
PLUG
(FRONT VIEW)
LEFT
DIRECTIONAL
LAMP
HORN SWITCH
DIMMER SWITCH
LEFT DIR.
COLOR CODE
BK = Black
NO CONNECTION
BN = Brown
BE =
Blue
CONNECTION
GY = Gray
GN b Green
TN = Tan
Y = Yellow
R
Red
O = Orange
PK = Pink
V s
Violet
W = White
IGNITION SWITCH
POSITION B
OFF
RUN
th
liiL
LIGHTS
SWITCH
WIRING diagrams
419
1983-1984 FXE
STARTER MOTOR
STARTER
GROUND
FRAME
GROUND BOLT
MAIN CIRCUIT
BREAKER (30A)
GROUND STRAP
HORN
RIGHT REAR
DIRECTIONAL LAMP
TAIL LAMP
LEFT REAR
DIRECTIONAL LAMP
RECEPTACLE
O^S^H
HANDLEBAR GROUND WIRE
REAR PLUG
FRONT PLUG
1966 1984
SERVICE MANUAL
SHOVELHEAD
1966 1984
Chapter One
General Information
Chapter Two
Troubleshooting
Chapter Three
Periodic Lubrication, Maintenance & Tune-up
Chapter Four
Engine
Chapter Five
Clutch, Primary Drive, Transmission & Kickstarter
Chapter Six
Fuel & Exhaust Systems
Chapter Seven
Electrical System
Chapter Eight
Front Suspension & Steering
Chapter Nine
Rear Suspension
Chapter Ten
Brakes
11
12
Chapter Eleven
Index
Chapter Twelve
Wiring Diagrams
CONTENTS
VI
CHAPTER ONE
1
GENERAL INFORMATION
Manual organization
Notes, cautions and warnings
Safety first
Lubricants
Serial numbers
Parts replacement
Service hints
Torque specifications
Fasteners
Test equipment
Mechanic's tips
CHAPTER TWO
TROUBLESHOOTING......................_
Operating requirements
Troubleshooting instruments
Emergency troubleshooting
Engine starting
Engine performance
Engine noises
Engine lubrication
Clutch
Transmission
Charging system
Starting system
Electrical problems
Ignition system
Breaker point ignition troubleshooting
Breakerless ignition troubleshooting
Excessive vibration
Carburetor troubleshooting
Front suspension and steering
Brake problems
CHAPTER THREE
Suspension adjustment
Tune-up
Breaker point ignition service
Breakerless ignition service (late 1978-1979)
Breakerless ignition service (1980-on)
Carburetor adjustments
41
CHAPTER FOUR
ENGINE
96
Engine principles
Servicing engine in frame
Engine
Rocker arm cover/cylinder head
Cylinder
Pistons and piston rings
Oil pump
Gear case cover and timing gears
Pushrods
Crankcase
CHAPTER FIVE
Primary chain
Primary belt
Compensating sprocket
Primary chain/belt case
147
Transmission
Shifter adjustment
CHAPTER SIX
FUEL AND EXHAUST SYSTEMS
203
Air cleaner
Fuel tank
Carburetors
CHAPTER SEVEN
ELECTRICAL SYSTEM
223
Starter
Circuit breaker
Switches
Horn
Starter solenoid
Lighting system
CHAPTER EIGHT
FRONT SUSPENSION AND STEERING
269
Front wheel
Front hub
Wheel balance
Steering head
Tire changing
Tire repairs (tube-type tires)
Front fork
CHAPTER NINE
REAR SUSPENSION
313
Wheel balancing
Tire changing
Rear swing arm
Shock absorbers
Rear wheel
Rear hub
CHAPTER TEN
BRAKES
Rear drum brake (1966-1972)
Disc brakes
Disc brake pad replacement
Brake caliper
329
Brake disc
Rear master cylinder
Brake hose replacement
Bleeding the system
CHAPTER ELEVEN
INDEX
369
CHAPTER TWELVE
WIRING DIAGRAMS
373
MOTORCYCLE INFORMATION
MODEL:
YEAR
VIN NUMBER:
ENGINE SERIAL NUMBER:
TIRE PRESSURE*
Front
Rear
Sidecar
psi
kg/cm2
psi
kg/cm2
psi
kg/cm2
5.10x16
20
1.41
24
1.69
5.00x16
12
.84
18
1.26
5.10x16
20
1.41
26
1.83
5.00x16
12
.84
20
1.41
1.41
20
1.41
14
.98
20
1.41
1966-1969
Solo
With passenger
22
1.55
26
20
1.83
5.00x16
14
.98
20
1.41
Solo
20
1.41
24
1.69
With passenger
20
1.41
26
1.83
Solo
24
1.69
26
1.83
With passenger
FL series (rider with sidecar
Passenger or 150 lb. load)
24
1.69
28
1.97
22
1.55
26
1.83
Solo
20
1.41
24
1.69
With passenger
FX series (except FXWG)
20
1.41
26
1.83
Solo
24
1.69
26
1.83
With passenger
26
1.83
28
1.97
30
2.11
26
1.83
1970-early 1976
FL series
FX series
Late 1978-on
FL series
FXWG
Solo
With passenger
30
28
1.97
2.11
FL series (rider with sidecar
Passenger or 140 lb. load)
22
1.55
26
1.93
20
1.41
CAUTION: Maximum pressuire for a II tires is psi (2.53 kg/cm2).
NOTE: These pressures are based on 150 1b. (68.04 kg) rider weight. For each extra 50 lb. (22.68 kg), add 2 psi
(0.14 kg/cm2) @ rear. 1 psi (0.07 kg/cm2) . @ front and 1 psi (0.07 kg/cm2) @ sidecai tire. Do not exceed
maximum pressure of 36 psi (2.53 kg/cmz).
ENGINE AND TRANSMISSION OIL CAPACITY
Quantity
4 quarts (3.78 L, 3.3 imp. qt.)
1 V2 pints (0.71 L, 0.62 imp. qt.)
Oil tank
Transmission
VI
Through 1975
DOT 3
1976-0 n
DOT5
Fork oil
1966-1969
1970-on
Battery top up
Distilled water
Transmission
HD transmission lubricant
Specific gravity
State of charge
1.110-1.130
Discharged
Almost discharged
One-quarter charged
One-half charged
Three-quarters charged
Fully charged
1.140-1.160
1.170-1.190
1.200-1.250
1.230-1.250
1.260-1.280
Type
1966-1974
HD No. 3-4
1975-1976
HD No. 5-6
1977-1979
1980-on
HDNo. 5R6AorHDNo.5RL
Gap
0.025-0.030 in. (0.63-0.76 mm)
0.028-0.033 in. (0.71-0.84 mm)
0.038-0.043 in. (0.96-1.09 mm)
1966-1969
1970-early 1978
Late 1978-on
brands
VII
Quantity
1966-1969
Wet
Dry
1970-early 1978
FX Series
1970-1972
Wet
Dry
1973-early 1978
Wet
Dry
FL Series
1970-early 1977
61/2 oz. (192.2 cc, 6.76 imp. oz.)
7 oz. (207 cc, 7.28 imp. oz.)
Wet
Dry
Early 1977-early 1978
Wet
Dry
Late 1978-On
FL Series
Wet
Dry
FX series (except FXWG)
Wet
Dry
FXWG
Wet
Dry
TUNE-UP SPECIFICATIONS
1966-1969
Retarded
5 BTDC
Automatic
35 BTDC
1970-Early 1970
Breaker point gap
Ignition timing
Retarded
5 BTDC
Advance
34-36 BTDC
Late 1978-on
Late 1978-1979
1980-0n
Ignition timing
Compression
Electronic
Standard
1966-eariy 1978
Late 1978-1984
Late 1976-1984
VIII