Illus 126 Removing Starter Clutch

Note Instructions fo - rer-oving starter clutch are included with Harley-Davidson starter clutch and mainshaft ball bearing puller. Part No. 12737-43. Removing Shifter Fork and Shaft AssembSy (To Identify Items, Refer to Illus. 123) 7. Shifter fork shaft (98), is held in position by a set screw (99), head of which will be found in top cover joint face of transmission case (at right end of shaft). With set screw removed, shaft can be driven out by means of a drift inserted in hole provided for...

Removing Lock Ring From Piston

In removing piston pin, first remove lock ring from end of pin that is slotted. Slot permits getting a screwdriver underneath lock ring and forcing it off. Use end of special tool specified below as a rest for screwdriver (see Illus. 73). Pin can then be driven out of piston. Use a drift of proper size to avoid damaging end of pin and piston boss and strike light hammer blows to avoid bending connecting rod. If piston pin is to be used again, examine lock ring on unslotted end of pin and if...

Using Sprocket Shaft As Gauge To Determine Bearing

Servicing Flywheels and Installing Crank Pin First give attention to flywheel washers (24), Illus. 62 or 63. If washer in either flywheel is worn and grooved to any extent, it should be renewed. This hardened steel washer fits into recess in flywheel face around crank pin hole and takes side thrust of connecting rod lower end and bearing. Washer is a close fit in recess and is secured by punching flywheel metal tight against it at several points around outer edge of washer. To remove washer, it...

Illus

CRANKCASE BREATHER (SIDE VALVE ENGINE) 8. Oil seal ring must bear against centrifuge. 9. Oil centrifuge separates oil from air by centrifugal force, allowing only air and a slight oil mist to escape through holes in periphery of centrifuge. 11. Outside breather tube through which air, after having been separated from oil is exhausted to atmosphere. (To Identify Items. Refer to Illus. 56) Oil feed pump and scavenger (oil return) pump are gear type pumps incorporated in one pump body. Feed pump...

Greasing Commutator End Armature Bearing

Lubricating Commutator End Armature Bearing (To Identify Items, Refer to Illus. 79 or 80 Also Refer to Illus. 98) To lubricate bearing (42) it is necessary to first remove end cover (54). Then bearing can be oiled through hole in outer grease retainer (52) or outer grease retainer can be shifted to expose bearing and permit greasing as follows Take out two of the three outer grease retainer screws (53) and loosen the third screw slightly to permit shifting outer grease retainer to one side....

Straightening Bent Or Twisted Connecting

Kets between carburetor and manifold. Install lock washers and carburetor-manifold screws and tighten screws securely. If these screws are not tight, an air leak will result, causing carburetion to be erratic. Attach carburetor support bracket and tighten securely. Disassemble gasoline strainer clean thoroughly before installing. Installing Cylinders (Side Valve Engine) Lubricate cylinder walls, pistons, pins and rod upper bushings generously with engine oil. Also pour about V* pint of oil onto...

Checking Connecting Rod Alignment With Squaring Plate

If rod proves to be out of alignment, it can be straightened by means of a bar inserted through piston pin, as shown in Illus. 71. Use bar of largest diameter that can be inserted through pin. The manner in which piston seats on squaring plate indicates as follows 1. Piston high on same side, both crank pin positions rod is bent. 2. Piston high on opposite sides as crank pin position is changed rod is twisted. 3. Piston square or nearly square with crank pin in one position and high on one side...

Circuit Breaker Head Disassembled

Installing Circuit Breaker and Timing Ignition (O.H.V. Engine) Refer to Illus. 66 also see Timing Ignition By Piston Position, Page 86. Turn engine in direction in which it runs until tappets indicate front cylinder is on compression stroke (directly after front intake valve closes). Continue turning engine slowly until flywheel timing mark is at rear edge of inspection hole in left crank-case. If front cylinder head is off circuit breaker completely assembled, can be installed. Be sure ground...

Removing And Installing Forks

Spring fork only can be removed and replaced, or complete fork assembly (spring and rigid fork) can be removed and replaced as a unit. 1. Set motorcycle on rear stand. 2. Remove spring rod lock nuts (acorn-type). 3. Sit on front mudguard, or otherwise provide weight, to compress fork cushion (lower) springs. The spring rod larger nuts can then be easily removed, freeing upper recoil and upper bumper springs for removal. 4. Free lower end of horn assembly from horn bracket on mudguard. 5. If...

Illus 99 Cutout Relay

With one test point on GEN terminal, and other test point on relay armature, test lamp should light. If it does not, it indicates an open circuit in series (current) coil. If relay passes above tests, and generator is known to be OX, but points do not close, it is an indication that series coil is grounded, or voltage coil grounded prematurely. It is not practical to disassemble relay for repairs. A relay worn or damaged beyond adjustment service should be replaced. Cut-out relay must be...

Meavjring Thickness Of Flywheel Thrust Washer

When a set of collars has been selected ana installed on flywheels, install flywheel assembly into right crankcase. Install sprocket shaft roller bearing assembly and bearing washer m sprocket shaft in the order shown in Illus. 62 or 63, and install left crankcase. No gasket is used on crankcase center joint, and joint should not as yet be coated with gasket cement or sealer. Insert stud at top center of cases and two studs at bottom of cases. Install and tighten nuts, to clamp cases securely...

Summary Of Engine Specifications

Engine 61 3.3125 74 3.4375. Side Valve Engine 74 3.3125 80 3.422. PISTON CLEARANCE IN CYLINDER .001 to .002, measuring piston at bottom of skirt front to rear. Piston shapes to cylinder and acquires more clearance alter short time in service. Measure cylinder about W bom top of bore, front to rear. Warning This fitting clearance applies only to genuine Harley-Davidson taper-cam ground piston, which is smaller at top w -of skirt underneath lower ring, than at bottom...

Ignitionlight Switch Disassembled

To identiy Items, Refer to Illus. 101 See Item 24, under Illus. 102, 103 and 105 for information on switch operating positions. 1. After removing instrument panel cover, disconnecting wires and removing switch from panel, a faulty switch can be disassembled for inspection and repair as follows 2. All switch part positions mentioned below apply with switch upsidedown. Switch must be in OFF position and unlocked. 3. Grasp end of center pin 6 with pliers and pull and move sideways to release...

Removing Generator End Mounting Screws

1947 Harley Davidson Model Rebuild

Disconnect wires from generator switch and relay terminals. 2. Remove the two long screws, through timing gear case cover, that secure end of generator against gear case see Illus. 81 . 3. Remove nut, lock washer and convex washer from end of strap that clamps generator in its cradle on crankcase see Illus. 82 . 4. Side Valve Engine Lift strap high enough to permit raising generator so oil centrifuge on end of generator gear or on armature shaft will clear adjacent gear and allow generator...

Truing And Sizing Connecting Rod Lower Race

Determining Correct Lower Bearing Fit See Checking Connecting Rod Lower Bearing for Excessive Wear and Looseness, Page 40, for information on checking lower bearing in connection with top overhaul and how much looseness may be allowed before bearing must be refitted. After lapping lower races of used rods as necessary, to smooth and true them, or replacing rods with a set with new lower races, install set of rollers and retainers on crank pin rollers must always be new. Check fit of rods on...

Legend For Illus 22 And 23ohv Engine Oiling And Breather System

Harley Oil Pump Governor

Maximum oil pressure regulating valve. D. Governor rotor with centrifugal valve which controls oil pressure at low and intermediate speeds. E. Front chain oiler adjusting screw. F. Scavenge section of oil pump. G. Pinion gear shaft through which oil is forced to connecting rod lower bearings, from which it splashes to cylinder walls, pistons, main bearings, etc. H. Timed Rotary crankcase breather valve. Rotary breather valve is timed to open on downward stroke of pistons, allowing crankcase...

Adjusting Oil Feed Pump

Standard factory setting of maximum pressure adjusting screw is as follows 1940 OJi.V. Model To identify item 14 , refer to Illus. 56 . End of adjusting screw 14 3 e from outer end of valve chamber. Average maximum oil pressure at this setting is about 15 lbs. 1941 to 1947 OJH.V. Models To identify item 14 , refer to Illus. 56 . End of adjusting screw 14 from outer end of valve chamber. Average maximum oil pressure at this setting is about 30 lbs. 1940 and earlier Side Valve Models To identify...

Adjusting Drive Chains

Inspect the adjustment of chains at least every week and adjust them if necessary. Adjustment of front chain can be checked through inspection hole provided in chain guard. Chains must not be allowed to run loose enough to strike guards or other chassis parts, because when that loose, they cause motorcycle to jerk when running at low speed, and there is excessive wear of chains and sprockets. The rear chain requires more frequent adjustment than front chain. As chains stretch and wear in...

Servicing Saddle Spring Post

To Identify Items and Part Numbers, Refer to Illus. 20 Spring combinations with part numbers that make up saddle spring post assemblies, Part Nos., 3122-36, 3123-36, 3121-36, 3123-36A, 3125-36, are listed. New motorcycles are furnished with standard saddle spring post assembly unless other than standard is specified on order. The illustration shows following parts of saddle spring post assembly 1. Spring tension adjusting nut. After raising saddle, remove saddle post clamp nut 5 , which is...

Engine Lubrication

Engine lubrication is a circulating system. A gear-type feed pump OJH.V. Engine or a vane-type feed pump Side Valve Engine , draws oil from the tank and delivers it to crankshaft under pressure. Pressure can be regulated. A gear-type scavenger pump returns oil from engine base to tank. OJi.V. Engine Refer to schematic diagram of oil pump, Illus. 23, and engine oiling system, Illus. 22. Side Valve Engine, 1940 and Earlier Models Refer to schematic diagram of oil feed pump, Illus. 25, and engine...

Illus 15 Push Rod Cover Disassembled

ADJUSTING VALVE TAPPETS SIDE VALVE ENGINE 1. Tappet adjusting screw with which adjustment is made, after slightly loosening nut 2 . 2. Tappet adjusting screw lock nut. ADJUSTING VALVE TAPPETS SIDE VALVE ENGINE 1. Tappet adjusting screw with which adjustment is made, after slightly loosening nut 2 . 2. Tappet adjusting screw lock nut. The intake valves are those nearest the carburetor. Adjust tappets so that there is .004 to .005 clearance between intake valve steins and tappets, and 007 to .008...

Removing And Installing Oil Pump With Engine Installed In Chassis

To Identify Items, Refer to Illus. 56 1. Remove stop lamp switch and oil pressure switch. Remove oil return pipe. Remove oil feed pipe and install nipple cap. Part No. 358315 on oil tank feed pipe nipple to prevent oil from running out, or drain tank. 2. 1940 Model pump is secured to crankcase by six nuts after removing the six nuts, remove pump cover and gasket 1941 and later Model pump is secured by one cap screw, one flat head screw and five nuts, one of the nuts is extra long to provide...

Oil Bath Type Cleaner

A few motorcycles are in service equipped with an oil bath type air cleaner. Clean and refill air cleanerapil gt cup at .leasUeach time engine oil tank frequently under dusty,conditions. ' Remove oil cup and gt baffle, thoroughly clean them and refill to indicated level with same grade of new oil as used in engine. Do not fill oil cup above indicated oil level as a higher level will restrict passage of air through cleaner and upset carburetion to the extent that engine may not start at all, or...

General Lubrication

Note If predominating service conditions are either wet or muddy, or very dusty, the 750 and 1500 mile greasing intervals should be reduced to 500 and 15 Every 5000 miles, or at least once a year, pack generator commutator end bearing with high melting point grease Harley-Davidson grade A grease . See Lubricating Commutator End Armature Bearing, Page 105. 16 Lubricate front wheel brake handlever and control cable every 750 miles or whenever operation of brake indicates lubrication is necessary....

Adjusting Carburetor

To Identity Items, Refer to Illus. 108 Before attempting to correct faulty engine performance, attention should be given other items which have a direct bearing on, and can affect carburetor adjustment as well as engine performance. A. See that throttle and spark controls are correctly adjusted. B. Remove drain screw from bowl of carburetor. Drain and flush bowl to eliminate dirt and water. C. Drain and flush gasoline strainer. D. Check air cleaner to be sure passage of air through cleaner is...