Removing Assembled Engine From Chassis For Complete Overhaul

When it is obvious that engine needs a complete overhaul, rather than possibly only an upper-end job, proceed as follows:

(If motorcycle is used with sidecar or package truck, remove it.)

1. Disconnect battery ground connection.

2. .Remove instrument panel cover: 1946 and earlier Models require removal of speedometer lamp switch knob, front hexagon head screw, two side screws and cover side plate; 1947 Models require removing cap screw and cover side plate.

3. Disconnect shifter lever bottom bolt.

4. Drain gasoline from both tanks. Disconnect gasoline pipe from left tank and disconnect tank interconnecting pipe from right tank.

5. Remove gasoline tanks: This requires removal of the two front end bolts (upper and lower) and two stud nuts at rear between tanks directly behind saddle bar hinge bracket. (Saddle post clevis pin must be removed and saddle bar must be hinged forward.)

6. Remove cylinder head bracket: Pay particular attention to shim washers between cylinder head bracket and frame lug; these will have to be refitted when reinstalling engine. O.H.V. Engine —choke lever need not be removed from bracket—disengage choke rod from lever by turning bracket.

7. Remove spark plugs to avoid damaging. Use Harley-Davidson special wrench. Part No. 1192940.

8. Disconnect throttle control wire at carburetor and remove carburetor control wire housing from front clamp.

9. O.H.V. Engine: Disconnect spark control wire at circuit breaker and free spark control wire housing from relay bracket.

Side Valve Engine: Disconnect spark control wire at circuit breaker and free spark control wire housing from front cylinder base stud.

10. Remove brake lever from brake cross-over shaft, and remove right footboard and brake pedal assembly. ^ ...,

11. Remove muffler and^r^^^xMust.pip^fcontl exhaust pipe, and rear exhaxist^ipe^|Sepipn; = If motorcycle is used' with'?si^ecar,f^J^^age truck, lower front connection 'tie rod miust be removed to free front exhaust pipe.

12. Drain oil tank or install nipple cap. Part No. 358315. Remove oil pump feed pipe, oil tank vent pipe, and oil return pipe.

13. Motorcycle equipped with relay only: 1946 and Earlier Models—-disconnect wire from each of the two terminals at one end of relay. 1947 Models—disconnect wires from all relay terminals.

14. Disconnect oil pressure switch wire from pressure switch terminal.

15. Remove the two engine mounting bolts from right side. Front bolt nut stays in place beneath generator and does not require holding while removing or installing bolt.

16. Remove mesh type air cleaner, or air intake, and gasoline pipe. If equipped with oil bath air cleaner, refer to operation 10 under "Disassembling O.H.V. Engine," Page 37, or operation 12 under "Disassembling Side Valve Engine," Page 40.

17. Disconnect circuit breaker low tension wire from coil rear terminal—if wire is shielded, disconnect metallic shielding from coil rear lower terminal.

Motorcycle equipped with relay only: 1946 and earlier Models—-disconnect wire from generator terminal marked "switch." 1947 Models-disconnect wires from generator terminals marked "switch" and "relay."

Motorcycle equipped with current and voltage regulator: Disconnect wires from generator terminals marked "switch" and "relay," and remove generator end cover screw securing metallic shielding.

18. Remove left footboard and studs.

19. Remove outer front chainguard.

20. Remove engine sprocket nut (right thread) using Harley-Davidson special wrench, Part No. 1264526. It will be necessary to strike wrench handle with a hammer to loosen nut. Free sprocket from shaft taper by striking flat surface, near outer edge, a light but sharp rap with a hammer being careful not to strike sprocket teeth or sprocket shaft threads. Sprocket and chain are then free to be removed. Bend ears of screw lock away from head of each of the three cap screws which secure front end of inner chain guard to crankcase, and remove cap screws and lock.

21. O.H.V. Engine: Free speedometer cable housing from crankcase top center stud. Side Valve En-

Harley Sprocket TattooSporster Motor Schematics
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