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  • 1978.5-1984 FL-FX Service Manual

    Enviado por

    Chris Srsc
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    Harley-davidson motorcycles conform to all applicable u.s.a. Federal Motor Vehicle Safety Standards and Environmental Protection Agency regulations. Any substitution, alteration or adjustment of emission system and noise control components outside of factory specifications may be prohibited by law. The information in this manual applies to the 19781f2 and later FLlFX 120011340cc 4 Speed models menutecturea after January 1, 1978 -.

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    Harley-davidson motorcycles conform to all applicable u.s.a. Federal Motor Vehicle Safety Standards and Environmental Protection Agency regulations. Any substitution, alteration or adjustment of emission system and noise control components outside of factory specifications may be prohibited by law. The information in this manual applies to the 19781f2 and later FLlFX 120011340cc 4 Speed models menutecturea after January 1, 1978 -.

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    Attribution Non-Commercial (BY-NC)
    Baixe no formato PDF, TXT ou leia online no Scribd
    Sinalizar o conteúdo como inadequado
    9K visualizações372 páginas

    1978.5-1984 FL-FX Service Manual

    Enviado por

    Chris Srsc
    Harley-davidson motorcycles conform to all applicable u.s.a. Federal Motor Vehicle Safety Standards and Environmental Protection Agency regulations. Any substitution, alteration or adjustment of emission system and noise control components outside of factory specifications may be prohibited by law. The information in this manual applies to the 19781f2 and later FLlFX 120011340cc 4 Speed models menutecturea after January 1, 1978 -.

    Direitos autorais:

    Attribution Non-Commercial (BY-NC)
    Baixe no formato PDF, TXT ou leia online no Scribd
    Sinalizar o conteúdo como inadequado
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    SERVICE MANU | FL/FX Models 1200/1340cc 4-Speed | 1978% to 1984 Part. 8294 IMPORTANT NOTICE HarléypDavidson motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards andU.S. Environmental Protection Agency regulations effective on the date of manufacture. \ ‘To maintain the safety, dependabiity, and emission and noise control performance, itis essential that e the procedure, epetcation and servic intrusion Inthe manval ae followed. Any substitution, alteration or adjustment of emission system and noise control components outside of factory specifications may be prohibited by law. Harley-Davidson Motor Company 197812 TO 1984 FL/FX 1200/1340cc 4-SPEED SERVICE @ MANUAL The information in this manual applies to the 1978% and later FL/FX 1200/1340cc 4-Speed models manufactured after January 1, 1978 ©COPYRIGHT 1983 HARLEY-DAVIDSON, INC. ALL RIGHTS RESERVED PART NO. 99482—84 CMI - 6M - 3/00 PRODUCT 1 E CHASSIS 2 n ENGINE “3 FUEL SYSTEM ELECTRIC : STARTER 5 TRANSMISSION -_ ELECTRICAL 4 8 oe / Printed in U.S.A. , FOREWORD This service and repair manual nas been prepared with two purposes in mind. First, it will acquaint the reader with the construction of the Harley-Davidson product and assist him in performing basic maintenance and repair. Secondly, will introduce to the professional Harley-Davidson mechanic the latest field-tested and factory-approved major repair methods. We sincerely believe that this manual will make your association with Harley-Davidson products more plea- sant and profitable. HOW TO USE YOUR SERVICE MANUAL Your Service Manual is arranged for quick, easy reference. This manual is divided into numbered sec- tions. Sections are then divided into subjects. Use this, manual as follows: Check the TABLE OF CONTENTS located in the front of each section to find subject desired. 2. Page number is listed across from subject. Page umber consists of section number and page umber. 3. Information is presented in a definite order as follows: Adjustments, Removal Disassembly Cleaning, Inspection and Repair Assembly Installation In figure legends, the number following a name of a part indicates the quantity necessary for one complete assembly. Nore All information for servicing a part should be read before repair work is started to avoid needless disassembly. PREPARATION FOR SERVICE Proper preparation is very important for efficient service work. A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible, and reduce the incidence of misplaced tools and parts, A motorcycle that Is excessively dirty should be cleaned before work starts. Cleaning will occasional- ly uncover trouble sources. Tools, instruments and parts needed for the job should be gathered before work. Ig started, Interrupting a job to locate tools or parts is a needless delay. Special tools required for a job are listed at the end of Section 1. WARNING. Gasoline is extremely flammable and highly explosive under certain conditions. Always stop engine and do not smoke or allow open flame or sparks when refueling (or servicing the fuel system. SERVICE BULLETINS In addition to the information given in this Service Manual, Service Bulletins are issued to Harley-Davidson Dealers from time to time, which cover interim engineer ing changes and supplementary information. Service Bulletins should be consulted for complete information (on the models covered by this manual USE GENUINE REPLACEMENT PARTS WARNING ‘When replacement parts are required, use only genuine Harley-Davidson parts or parts with equivalent characteristics including type, strength and mater Fallure to do so may result in product malfunction and possible injury to the operator andlor passenger. To ensure a satisfactory and lasting repair job, follow the manual Instructions carefully and use only genuine Harley-Davidson replacement parts. Behind the emblem bearing the words GENUINE HARLEY-DAVIDSON is more than three quarters of a century of designing, research, manufacturing, testing and Inspecting ex- perience. This is your insurance that the parts you are using will fil right, operate properly and last longer. When you use ‘genuine Harley-Davidson parts, you use the best. PRODUCT REFERENCES When reference is made in this manual to a specific brand name product, tool or instrument, an equivalent product, tool or instrument may be used in place of the ‘one mentioned, All tools mentioned in this SERVICE MANUAL with HD for J preceding the part number must be ordered through: Kent-Moore Too! Division 29874 Little Mack Roseville, Michigan 48066 Loctite Products ‘The Loctite products listed are designed to increase the reliability of fasteners and to aid in minor repairs. If you have any further questions, please call Loctite CONTENTS é at 1-203-246-1223, Ail photographs and illustrations may not necessarily WARNING depict the most. current model or component, but ar based on the latest production information available at Follow the rectlns sted on all Loctite products. D2SGd one ate produ! Read all labels, warnings and cautions carefully before using. Since product improvement is our continual goal, Harley-Davidson Motor Co,, Inc. reserves the right to [ ‘Application Product change specifications, equipment, or designs at any Tock fender braces, mastet | Lock N’ Seale time without notice and without incurring obligation. cylinder bolts, brake anchors, | Adhesive exhaust flanges and general body hardware, WARNINGS AND CAUTIONS Locking crank pin and flywheel | Retaining ae pack Statements in this manual preceded by the words: WARNING or CAUTION and printed in bold face are very Secure upper and lower fork | Stud N' Bearing | important. assemblies, shock absorber | Mount Adhesive mounts, fittings, axle nuts, shift WARNING. lever screws, cylinder head and crankcase studs, and handle Moans there Is the possibility of personal injury to your. barclamps. If or others. Lock adjustment screws and | Wick N’ Lock® assembled parts. Secure foot | Adhesive CAUTION rests and kick starters, Retain brake pedal bushings, | Retaining ‘Means there is the possibility of damage to the vehicle. jain shaft sprockets, counter | Compound We recommend you take special notice of these items. rafts, "oll sens, crv no. 601 kage, euteh hb Sn sprock. ot assemblies waRwina Bond brake podal and Wek | Supereonde™ | roper service and repar Is important forthe 3 Starter pads, Secu loose hand | "Adhesive | able operation ofa mechanical products, The 3 grips. Repair loose windshield vice procedures recommended and described in this moldings, and other rubber, Service Manual are effective methods for performing vinyl and plastic parts. 1rvice operations. Some of these service operations re- Seal teaded {uel ino tings, | Pipe Seaiant | gui the uve of tots spacaly designed forthe pu hyaraulie Brae ine ftings and | with Teflon" | Gogo, These specal tools should be used when and engine plugs fecommended, Make emergency gaskets on- | Gasket the-spot. Seal crankcase cove Eliminator® It is important to note that some warnings against the cylinger locks to crankcase, | Sealant tse of spect serves methods which could damage fue! and oil pumps, and rocker the motorcycle or render it unsé stated in this Ser- i vice Manual. However, please remember that these warnings are not all inclusive. Since Harley-Davidson could not possibly know, evaluate and advise the vice trade of all possible ways in which service might bo done or of the possible hazardous consequences of Prevent galling, seizing and cor- | Anti-Seize rosion on oil drain plugs, spark | Lubricant plugs, front fork and shock as- semblies, swing arm, pivot ercifandh oes each way, we have not undertaken any such broad 2 — —| evaluation. Accordingly, anyone who uses a service pro- Dissolve grease, dirt and oil | Cleaning ‘cedure or tool which Is not recommended by Harley- from parts quickly and safety. Cd Davidson must first thoroughly satisfy himself that Prepare mating surtaces for neither his nor the operator's safety will be jeopardized Loctitie products | _by the service methods selected. “Reg. TM DuPont Corp. Reg. TM Loctite Corp, Harley-Davidson products are manufactured under one or more of the following patents: U.S. Patents — 2986162, 2987934, 2998809, 3116089, 3144831, 3144860, 3226994, 3229792, 3494887, 3559773, 9679359, 3709317, Dos. 225 626. a TABLE OF CONTENTS SECTION 1- PRODUCT Page No. Service : +4 Servicing a New Motorcycle 1 Check At First 500 Miles ININEININ a Safe Operating Maintenanco ..... eee Regular Service intervals 12 Storage : 19 Removal From Storage» 19 Fluid Requirements « +9 Metric Conversion»... : iat Troque Requirements ......s..secsesssesse A Troubleshooting ..............ccccceet49 Engine .. ees Lubrication System hia Electrical System TINT aa Carburetor... IIIa Transmission... TIE Gluten acer TNNI na Brake vss seve lus 445 Handling III as Tools har SECTION 2- CHASSIS Specifications . Dimensions Vehicle Weight. Capacities Front Fork... Adjustments. Torque : Brake Disc Size Tire Data... Vehicle identification Number — 1978%-1960...... Vehicle Identification Number — 1981 and Later... 2-3 Wheels....... aan Front Whee! — FL Models 25 Front Wheel — FX Models . 128 Front Wheel — 1984 FXSTIFXWGIFXE Models... 2-11 Rear Wheel — All FUFX Models, 243 Lacing Wheels — 16 Inch ..... 2a7 Lacing Wheels — 19 Inch cera 218) Lacing Wheels — 21 Inch .. vevetnee ee 220 Truing Laced Wheel......0--s0.++ 221 hacking Gast Fim Runout feeeees BD Tires... perce a22 Brakes... ceceteeleeeeereeses 229 General . 229 AGiistasgikg ef eee erereeenr tenet z ag Page No. Front Brake Master Cylinder — 1981 and Earlier ... 230 Front Brake Master Oylinder — 1982 and Later .... 231 Rear Brake Master Cylinder — 1978% - Early 1979..2.34 Rear Brake Master Cylinder Late 1979-1983 FL/FXE and Late 1979-1982 FX .. 2.05 Rear Master Cylinder Ml creer eee 288 Front Caliper — FL £236 Rront Caliper = OX pect sees) Front Caliper — 1984- FX. i 242 Rear Caliper 1978 74-1980 FLIFX Models. os Rear Caliper 1981-1984 FL Models ee as 1981-1982 FX Models, 1983 FE 1247 Rear Brake Caliper — 1983 FX/FLHS. Except rFXE). 249 Crake Dios ee 281 Bleeding The Hydraulic Brake System rn 261 Stoplight Switch . cee saca) Front Forks — FL Models .... = 253 General . . ao ; Adjustments. ‘Changing The Fork Oil. Front Fork. . aoe Non-Adjustable Fork Stom And Bracket 2.01.1... 255 Adjustable Fork Stem And Bracket .... 2257 Front Forks — FX Models... General... ‘Changing The Fork Oil... ‘i Front Forks — FX Models (Except FXWG & FXST) . 2-59 Fork Stem And Bracket Assembly FX Models (Except FXWGIFXST and FXDG)... Front Fork — FXWG and FXST Fork Stem And Bracket Assembly —- FXWGIFXST . 2.67 Frame And Rear Swing Arm Rear Swing Arm — FLIFX (Except FXST) Rear Swing Arm — FXST..... Rear Shock Absorber .. 273 Adjustment. 273 FXST Swing Arm Shock Dampening . 273 Removal Disassembly FLIFX (Except FXST) . Cleaning, Inspection And Repair — FLIFX (Excopt FXST)....... — ‘Assembly — FLIFX (Except FXST) installation — FLIFX (Except FXST) Removal — FXST . .. Disassembly — FXST Installation — FXST Page No. = 19784-1980 277 2278 2284 2285 1288 é ndlebar Controls And Instruments . 277 rottle Control hi yottle Control — 1981 and Later Clutch Hand Control ‘Speedometer /Tachometer Handlebar Switches Seats eee cece BOF SoloSaddie ...... ao 287 Comfort Flex Seat e222... 288 Frame Mounted Seat... 2s... scsscscscessss.s 298 Fiberglass And Fenders . 295 Fairing And Windshield FL Models... 295 Saddlebags — FL Models . 2.96 Tour-Pak — FL Models (Early) .. 2.98 Tour-Pak — FL Models (Late) 296 Front Fender Replacement FLModels .. -.297 Front Fender Replacement FX Models (1983 and Earlier) .... 297 Front Fender Replacement — FX 1984 Models Rear Fender Replacement FL Models. oo e008 é 1 Fender Replacement | FX Models. 7 2.100 SECTION 3 - ENGINE FLIFX (Except FXST) Specifications. a General Information. Description Gasoline .. Lubrication Repair and Diagnostic Procedure Stripping Motorcycle For Engine Repair Cylinder Head......... 345, ‘Checking Push Rod Adjustment 0.000.202... 324 0 No. Cylinder and Piston .. 923 Disassembling Cylinder and Piston .........0../ 823 Cleaning and inspecting 323 Retinishing Cylinders 324 Connecting Rod Bushing . 3:26 Twisted Connecting Rods...... 0. scssseso..s 387 Assembling Gylindor and Piston... ss. 2... 827 Gearcase.............. voces 828 Oil Pump i JUNI a29 Valve Tappeis and Guides’... 320 Gearcase Cover and Timing Gears... ss... 888 Crankcase 330 General... 339 Flywheel End Piay Check . INN! 539 Disassombling Grankease UII a0 Flywheels so svecvevssessvusvecssevsesewees St Assembling Grankcase a8 FXST Specifications N34 Description va Gasoline va3 Lubrication | v33 Diagnostic and Repair Procedures va Stripping Motorcycle for Engine Repair vaso Cylinder Head veg Removal . vat3 Disassembiy “vats Cleaning andinepection ...... Uva Ropairing Rocker Arms and Bushings v3.16 Replacing Valve Guides va-17 Grinding Valve Faces and Seats, va18 Replacing Valve Seats v319 Lapping Valve Faces and Seats vata Assembling Cylinder Head v3.19 Installing Cylinder Head .... IIIT vaz0 Installing and Checking Push Rid Length v3-20 Cylinder and Piston va-23 Removal Cylinder and Piston v3.29 Cleaning and inspection... 0... 8-28 Ratinishing Cylinder lve Straigtening Connecting Fiods ..... v3.28 Assembling Cylinder and Piston =. v3.28 Gearcase var Oil Pump iivaer Valve Tappets and Guides “vee Goareaso Cover and Timing Gears v3.20 Crankcase . Goneral .... Flywheel End Play Check Disassembly Crankcase . Installing Cylinder Studs. Flywheels ‘Assembling Grankcase SECTION 4- FUEL SYSTEM Specifications Jet Sizes os Fuel Tank Gapacity Torques. : Carburetor Genera! Operation Adjustment: Troubleshooting Removal Disassembly ‘Assembly Installation Air Cleaner. General . Servicing Air Cleaner — FLIFX X(Excopi xs a Removal Installation Servicing Air oe -= oot Removal ..... Installation... Fuel Supply Valve Genera. Removal . leaning nsecion an pai Installation. Fuel Tank General Removal «2... Cleaning, Inspection and Repair Installation... Page No, -.V3-35 v3.35, v3.05, 2V3-95 V3-36 v3.37 Vaea8 f4 at 44 43 48 14d a 49 an seed fat 442 2415 415 448 2416 2416 416 a7, 2417 419 419 419 419 2419 421 st 2424 422 422 Page No. SECTION 5 - ELECTRIC STARTER General Information . ee Specifications .. ot Description : a6 cSt Troubleshooting... eer StarterRelay.... 00... : pa Starter Motor - 197872 to 1982 FL, FLH, FLH-80 And 1979 to 1981 1 Classic. 5-3 Starter Draw Test . 53 Removal. See ee tos) Disassembly . : GeccnnooonE 53 Cleaning, Inspection and Repair ete s Assembly... ees Installation cont a 56 Starter Motor - 1978'2 to 1984 FX, 1982 Classics And 1983-1984 FL dae Starter Draw Test .... Removal... Disassembly... Cleaning, Inspection and Repair. . Assembly. i Installation Solenoid... General Testing the Solencid Removal : Disassembly c Cleaning, inspection and Repair. . Assembly. : Installation . Starter Shaft And Gear Housing (1984 and Earlier All Models 8 Except FXB/FXSB/FXDG)......... see BAS Removal... 5-15 Cleaning, inspection and Repair... 818 Installation .. . ee nis Starter Shaft And Gear Housing (FXB/FXSB/FXDG) 1982 FLHC, 1983-1984 FLH Models And 1984 pe aeseaetae Removal....... . 2519 Cleaning, inspection and Repair... 519 Installation S19 SECTION 6 - DRIVE oi" felts : Clutch Lubricants, Sprockets Primary Case Torques Chains And Sprockets Primary Chain General Adjustment Disassembly Cleaning, Inspection and Repair Sprocket alignment dry luton Sprocket alignment wet clutch Assembly Secondary cua And Sprockets Adjustment Lubrication Removing and installing Transmission Sprocket oval ining, inspection and Repair Installation Belts And Sprockets Primary Belt General Adjustment (1980 and Early 1981) ‘Adjustment (Late 1980 and Later) Disassembly and Assembly Sprocket Alignment Secondary Drive Belt and Sprocket . Adjustment and Alignment Removal and Installation Transmission Sprocket Removal Cleaning, inspection and Repair Installation vee Dry Clutch neral justments fassembly Cleaning, Inspection and Repair Assembly vi 61 64 61 64 6 61 61 et 66 66 67 68 68 68 68 en ett ett ett et ett 612 ers ea 615 es 615 615 645 a7 617 -8-17 B17 618 620 Wet Clutch General Adjustments Disassembly Cleaning, Inspection and Repair Assembly Primary Chain/Belt Case General Disassembly ‘i Cleaning, Inspection and Repair Assembly, SECTION 7 - ENGINE Specifications Mainshatt Main Orive Gear Mainshatt : Countershatt Shifter Cam (1976 V4 Early 1979) Torques Lubricants Service Wear Limits General ioe Description Adjustments Shifter Assembly. Shitter Cover - Drum Shifter 197814 -Early 1979... shitter Cover Plate Shifter” Later 1979 And Later. Shifter Forks Adjustment Disassembly Cleaning, Inspection and Repair Assembly Transmission Case Removal Cleaning, inspection and Repair Installation Replacing the Main Drive Gear Bearing Spacer Oil Seal Side Cover - Electric Start Side Cover: Kick Start ... Starter Clutch - Kick Start Models Only Countershatt Mainshaft and Main Drive Gear 023 623 623 625 625 626 629 629 629 6.29 629 ra 7A re 7A 7 ura 74 13 73 75 78 Ta 13 743 714 748 745 wr a7 718 718 7418 749 7.20 721 7.23 7.28 SECTION 8 - ELECTRICAL Specifications Ignition System 1979 And Earlier ignition Timer Troubleshooting Adjusting Sensor Air Gap Checking Advance Timing With Strobe Timing Light Setting Retarded Timing With Circuit Tester Disassembling And Assembling Ignition System 1980 And Later Description Troubleshooting Checking Advance Timining With Inductive Timing Light Vacuum Operated FXST Electric Switch (V.0.E.S.) Setting Retarded Timing Removing Ignition Components inspecting And Replacing Parts Installing ignition Components Spark Plugs General inspecting Spark Plugs Setting Spark Plugs, Installing Spark Plugs Ignition Coil Cescription Troubleshooting Replacing Spark Piug Cables 85 a7 39 39 10 ea ea B12 B12 B13 a4 B45 B15, B15, B15 B15, eT B17 817 2847 Ignition-Light Switch Generat : Disassembling Ignition-Lignt Switen FLIFLHSIFXWG Cleaning, Inspection And Repair ‘Assembling Ignition-Light Switch Charging System General Troubleshooting Disassembling Alternator Cleaning, Inspection And Repair Assembling Alternator Replacing The Rogulator Battery, General Battery Care Testing The Batiory Charging The Battery Lights......... Headlamp (19784-1960 FL) Headlamp 1981 and Later FL) Headlamp FX Models Headlamp Adjustment Passing Lamps Turn Signals Horn Wiring Diagrams a9 820 320 21 821 B21 323 323 823 823, 825 8.25 8.25 825 826 827 8.27 827 8.28 328 8.29 8.29 a1 vii, e PRODUCT SUBJECT PAGENO. 1.Service c 14 2. Troubleshooting ‘ 1413 altace eee eee eee ete seed? SERVICE SERVICING A NEW MOTORCYCLE WARNING For th rider's personal welfare, all the listed service ‘and maintenance recommendations should be fol- wed, because they may affect the safe operation of ‘the motoreyal ‘Service Operations to be performed before delivery to customer are specified in the Motorcycle Set Up Manual, Part No, 99946-84, Also, the important Instruc- tions included with each new motorcycle. ‘The performance of new motorcycle initial service is re- uited to keep warranty in force, and to ensure proper emissions systems operation, After a new motorcycle has been driven its first 600 ‘miles and again at approximately 2600 miles, a Harley. Davidson dealer should perform the following initial ser vice operations, CHECK AT FIRST 500 MILES 4. Change engine oil 2. Replace olf filter. 3. Clean tappet oll screen, 4. Clean primary chain housing magnetic drain plug.” 5. Inspect air cleaner and service as required, 6. Check and adjust chains/belts. 7. Check battery electrolyte level. Check and clean connections, 8. Check rear brake pedal adjustment and free play, 9. Inspect brake pad linings and discs for wear. 10. Check brake fluid level and condition. 11. Check clutch adjustment, 12, Inspect fuel valve, lines and fittings for leaks. 18. Inspect oil lines and brake system for leaks, 14, Oil the foliowing: front brake handlever, throttle Control cables, choke control cable, clutch control cable and handlever, seat suspension bushings*, Seat post roller and bolt.” 15. Grease the following: foot shift lever bearings eat bar bearings", seat post*, rear fork pivot bear Ings, 16. Check tightness of all fasteners, 17. Check tire pressure and inspect tread, 18. Check engine low and fast idle speed adjustment. 19. Check operation of throttle and choke controls, 20. Check operation of all electrical equipment and switches 21. Check whee! spoke tightness.* 22, Lubricate rear chain if required.* 23. Check primary case vacuum.” 24, Change transmission oil and clean magnetic drain plug. 25, Clean fuel tank fiiter screen.* 26. Check front and rear fork bearing adjustment, 27, Road test. * If applicable to equipment. SAFE OPERATING MAINTENANCE Good maintenance means a safe machine. A careful check of certain equipment must be made after periods of storage and frequently between the regular service intervals to determine if additional maintenance is necessary. The following items should be checked: 4. Tires for correct pressure, abrasions or cuts. 2. Ghain/belt for proper tension and lubrication, 3, Brakes, steering and throttle for responsiveness. 4, Brake fluid level and condition, Hydraulic lines and fittings for leaks. Also, check brake pads and discs for wear, Cables for fraying or crimping and free operation. Engine oll and transmission fluid levels, Wheel spoke tightness, if applicable. Headlight, tailight and directional light operation. REGULAR SERVICE INTERVALS IMPORTANT Orr: chart outlines recommended Mainte- To prevent over-greasing, use hand grease gun on all Js and Lubrication intervals after performance of ser- grease fittings, vice on a new motorcycle and the initial breakin period. Regular Maintenance Intervals — FL/FX MILEAGE INTERVALS Tey [Fst | bev | een | eve | Ben ten zoo | 500 | 2500 | so00 | 7500 | 10000 | Spring or Fall rea xi | om |e (ree x Cin prety Rousing agi ln g™ xo fe Tespc al cleaner ana sone 2 x foe [ox x [x Cheekand aust chainsioete Te ~ ‘Check biter eloctiyie lvl check and clean connestions Ta a ~ F check brake pa ining a dies for weet ~ ee et || | eck Bake Hid level anc constion _ Tex [oe [oa xo Check chsh adjustment =e Te a Inspec el valve, ines ana ings for aks — ee — [inspect ones and brake syst foreaks x [oj we Pe © the folowing en rake Pandieve, oie gona ables, xe [xe foe em cee (ae ana co en ec ‘Shwck operation ot tat x pox [x | _ | chwok operation fat elect ca | | 9 —_] ‘Check wheel spoke sghiness” __ x_[ x x fx PO Lubrcale rer chain requed x pe foe fe [ “Gheok ignition ning and vaevor RoBe —E ox ef x 7 condition of spark pigs an replace 1 nec=888"7 [| x x | _ | Soa eae ag) el a is (aa [ene varomission 5 aaj x] x ee {Ghange vanes coeenanian ae | eae | x Check primary caso vecuun™ oe x [7 7 ee) ise et nn 1 aac [oe pe Te x — eck nt and ear fork bearing adatom “ef Pe [neck cnsiion fear sbockabearer erbusnna |__| px 2 ee _uviate te folowing fot shit ever Bearing, seat Bar bonrager seat paste fom puck bowing | x fix fe te |x | brea tote conto ap sleeve ard peedontar cable | — [x] | = Chango ont toned a Tae [ Repack whe earings wilh e350 TI = — P ‘Lubricate the belt drive compensating sprocket rubber dampers| t Rateroandsonrarous | L 7 ee est : — TT 7 a ee “it appicabe 10 equipmant an 3 16 5 mg 2910 8 1. Tail/stop lamp 6. Brake master cylinder 12. Hydraulic shock absorber 2. Oil filter 7. Engine serial number 13. Adjustable passenger 2A. Oil filter — 1982 & earlier 8, Oll pump and pret ee footrest 3. Carburetor air cleaner —_9, Starter motor and 1 14, Brake pedal 4. Hydraulic fork 410. Transmission ol filler plug 415. Choke knob 5. Rear chain/bolt adjuster 11. Battery 16. Ignition-light s1 Figure 1-1. FLH Right Side View 1915 12 110 9 7 1. Tum signal lamps 6. Rear sprocket and chain/belt 11. Jiffy stand 2. Headlamp 7. Oil tank drain plug 12. Timing inspection hole plug 3. Carburetor choke knob 8. Oil tank fill plug and dipstick 43. Rectitler, regulator module 4. Gas tank valve 9. Clutch inspection cover 44, Steering lock 5. Ignition colt 10. Front chain inspection cover 15. Shifter Figure 1-2. FLH Left Side View 1. Tallistop lamp 6. Brake master cylinder 12, Passenger footrest 2. Oil filter 7. Engine serial number 18, Brake pedal 2A. Oil filter — 1982 & earlier 8. Starter motor and relay 14, Choke knob 3. Carburetor air clean« 9. Transmission oll filler plug 16. Ignitionight switch 4. Hydraulic fork 10. Battery 5. Rear belt adjuster 11. Hydraulic shock absorber Figure 1-3, FLHS Right Side View 2 aw 9 76 1. Tum signal lamps €. oll tank tit plug 12, Timing inspection 2. Headlamp and dipstick hole plug 3. Carburetor choke knob 8. Clutch Inspection cover 13. Rectiflar/regulator module 4. Gas tank valve 10. Front chain inspection 14, Steering lock 5. Ignition coll ‘cover 15. Shifter 6. Rear alt 11, sity stand 46, lgnitionight switch 7. Oll tank drain plug 14 Figure 1-4. FLHS Left Side View i 2. Tall/stop lamp ll fitter 2A. Oil filter — 1982 & earlier 5, Rear chain adjuster 6. Brake master cylinder 7. Engine sorlal number 10, Battery 11, Hydraulic shock absorber 12, Passenger footrest 3, Carburetor air cleaner —_8, Starter motor and relay 18. Brake pedal rear 4. Hydraulic fork 9. Transmission oil filler plug 14. Transmission oll level plug Figure 1-5. FXE Right Side View 6 3 12 18 11 10 917-7 4. Turn signal lamps 7. Oll tank drain plug 1. Rectifier, regulator module 2, Headlamp . Oil tank fill plug and dipstick 14. Steering lock 3. Carburetor choke knob 8. Clutch inspection cover 16. Shifter 1. Gas tank valve 5. Ignition coil 1 sprocket and chain 10. Front chain inspection cover 11, ditty stand 12, Timing inspection hole plug 16. Ignitionsight switch 17. Chain case drain plug Figure 1.6. FXE Left Side View 15 4. Tall/stop lamp 2. oil filter 2A. Oil filter — 1982 & earlier 3. Carburetor air cleaner 4. Hydraulic tork 5. Re 6. Brake master cylinder 7. Engine serial number 8. Starter motor and relay 9. Transmission oll filler plug 10. Battery 11, Hydraulic shock absorber 12. Passenger footrest 18. Brake pedal rear 414, Transmission oil level plug Figure 1-7. FXSB Right Side View 16 3 12:15 11 10 9 7 7. Oil tank drain plug 8. Oil tank fill plug and dipstick 9. Clutch Inspection cover 10. Front belt inspection cover 14. Jiffy stand 12, Timing inspection hole plug Figure 1-8, FXSB Left Side View 13, Rectifier, regulator module 14. Steering lock 16, Shitter 16. Ignition-tight switch 4. Tail/stop lamp 6. Brake master cylinder 12, Passenger footrest 2. Oil fitter 7. Engine serial number 13. Brake pedal rear 2A. Oil filter — 1982 & earlier 8. Starter motor and relay 14. Transmission oil level plug 3. Carburetor air cleaner —_9, Transmission oll filler plug 16. Kick starter 4. Hydraulic fork 10. Battery 5._Rear chain adjuster 11. Hydraulic shock absorber Figure 1-9. FXWG Right Side View eae on 4. Tum signal amps 1.0 tank dain plug 12, Rect, eguatr module 2 Headlamp & Oiltank ti pug and dpstck 1 Stocg lock © carurter choke nod. uchinapacion cove 18 sitar e@ 4 Gas tank ave 10: Font chain inspection cover 16 gnltenght witch &:Igton sa 11 Sty sta 0 Shan ease erin pg 8: Roar sprockat and chain 12: Timing Inspection hele plug Figure 1-10. FXWG Lett Side View 17 sa t \ wi2i4i3 118 4. Front brake hand lever 8, Rear turn signal lamp ‘14. Transmission oll drain plug 2. Front brake master cylinder 9. Tail/stop lamp 46. Transmission oil filler plug 3. Throttle grip control 10, Rear chain adjuster 46, Rear brake master cylinder 4. Carburetor air cleanor 11, Passenger footrest 47, Rear brake pedal 5. Kick starter 42. Oil tank drain plug 418. Ignition module 8. Olt tank fill plug & dipstick 19. Electric starter motor _-—_—18, Rear brake fluid reservoir 7. Battory (under seat) Figure 1-11. FXST Right Side View —I4 P\ VN has 4. Front turn signal lamp 8 Voltage regulator 1. Chain case drain plug 2. Cluten hand lever 8. Timing ingpection hole plug 14. Rear sprocket & drive chaln & Headlamp 10. Primary chain 45. Ignition coll 4 Storing lock inspection cover 16. Fuel supply valve & Hom 11. sity stand 17. tition tight switch & on titer {2 Clutch inspection cover 48, Carburetor choke knob 7. Shift over 18 Figure 1-12. FXST Left Side View STORAGE If the. motorcycle will not be operated for several months, such as during the winter season, there are several things which should be done to protect parts ‘against corrosion, to preserve the battery and to prevent {the build-up of gum and varnish in the carburetor, ‘This work should be performed by your local Harley: Davidson dealer or other qualified mechanic following Service Manual procedures. WARNING Gasoline Is flammable. Do not store motorcycle having {gasoline in tank within the home or garage where open 1mes, pilot lights, sparks or electric motors are pre- sent. 1. Fill gas tank and add a gasoline stabilizer. Use one fof the commercially available gasoline stabilizers, following the manufacturer's instructions. Run the engine until the gasoline stabilizer has had a chance to reach the carburetor float bowl. Turn fuel supply valve off, oR Drain all fuel from the gas tank and carburetor float bow! and coat the inside of the tloat bow! With light oll, Spray the inside of the gas tank with, one of the commercially available cust preventa tives. Follow the manufacturer's instructions. 2. Fill the oil tank and pinch off or remove and plug the line leading from the bottom of the oil tank 10, the feed fitting (marked "F") on the oil pump. This will eliminate the possibility of oll seeping past the ccheck ball into the oil pump and filling the engine flywheel! compartment with oil, 3. Remove the spark plugs, inject a few squirts of engine oil into each cylinder and crank the engine 5 or 6 revolutions. Reinstall spark plugs. 4. Adjust the chainsibelts. 5. Check tire inflation. If the motorcycle will be stored for an extended period of time, securely support the motorcycle under the frame so that all weight is off the tires. 6. Wash painted and chrome plated surfaces and ap- ply a light film of oil to exposed unpainted sur- faces. WARNING dises or brake pads. Do not apply any oil to bral 7. Remove the battery from the motorcycle and fully charge, Store the battery above freezing tempera: tures, trickle charge once a month and keep the electrolyte level above the plates. 8. If motoreycle is to be covered, use a material such as light canvas, that will breathe. Plastic materials, that do not breathe promote the formation of con: densation. REMOVAL FROM STORAGE 1. Fill the battery with water to the proper level. Charge and install it, WARNING After extended periods of storage and prior to starting vehicle, place transmission in gear, disengage clutch and push vehicle back and forth a few times to ensure proper clutch disengagement. 2, Remove and inspect the spark plugs. Replace if necessary. 3, Clean and oil the air cleaner element. 4. Remove the carburetor float bowl, clean it and ccheck the float level, 6. If fuel tank was drained, fll it with fresh gasoline. 6. Ifoll feed line was pinched off or plugged, unplug it and reconnect. 7. Start the engine and run until it reaches normal operating temperature. 8. Drain and flush the oil tank. Install a new oil filter and fil oi tank with the proper grade oll. Check the transmission oil level 9. Perform all of the checks in the PRE-RIDING CHECK LIST in the Owner's Manual. FLUID REQUIREMENTS Harley-Davidson Oil Use. proper grade of oil for the lowest temperature ex- pected before next oll change period as follows: ‘Air Temperature Use | (Cold Engine Starting Harley-Davidson Conditions _| Oil Grade | 0°to 100°F. - Normal Power Blend ‘and severe oper- ‘Super Premium ating conditions Premium W™ Above 80°F. Exlra Heavy Grade 60 | Above 60°F, Regular Heavy | ‘Above 40°F. Medium Heavy = 20° 10 40°F. Special Light | 19 Harley-Davidson Chain Grease, Chain Saver and Chain Spray signed especially as a chain lubricant. Penetrates in- r bearings for a long chain life, Harley-Davidson Poly-Oil Designed especially for lubricating the FXB/FXSB com- pensating sprocket rubber dampers. Gasoline Use a good quality leaded or unleaded gasoline. For 1980 and earlier models, use premium grade (84 pump octane or higher). For 1981 and later models, use any. ‘rade gasoline (89 pump octane or higher) Brake Fluid Use only D.0.T. § Hydraulic Brake Fluid. METRIC CONVERSION TABLE ——}} (0039) 25.9842] 592.283 91 3582) ).007 025] 6 16280/1% 421; 3% Bata oore|2e ane co 2a] ez aozl|ane ami| a weavl+ seaolan eon 0118) 27 4.063] 60 2.362| 93 3.661] 003 076|% 17.462! 2% 5290] 34 06.39 o1s7| 28 s.102) 6» 2.401/ 94 3701} |.004 r02| 7 17.790! 21 53.24) 2% 97.31 [29 1.42) 62 24ai] 95 3.740) 005 .127/ x 19050|2¥ 5397|3% e890 20320) 2% 9558) 3% 90.49 2060822 55.99/36 91.44 22.228| 2% 7.18] 3% 9207 22.860| 2.3 58.42| 3% 93.66 23.812|2% 58:74) 3.7 93.98 25.40 }ex 60.32| 3% 95.25] 2699/24 6096/38 9652 1% 2857 25 e350} 9% on .0236| 301.181) 63 2.480| 96 3.779) |.006 152 o27s|91 1.220] 64 2619] 97 3819] |.007 1708 0315| 32 1.260) 65 2589) 98 3850 |.o08 203, 0354) 33 1.299) 66 2598 99 3.897) |.009 229 1.9394) 34 1.338) 67 2638| 100 3.937|/.010 254 0787| 36 1.378) 68 2.677! 101 3.976) 1181] 361.417] 69 2.716) 102 4.016) 2 3 4 5 .1968| 38 1.496] 71 2,795] 104 4.094! 5, 704 6 2362/39 1.595) 72 2.834! 105 4.124) |.040 1.016: 1% 30.16 2% 65.091 3.9 99.06] 8 3149/41 1.614) 74 2913/ 107 4.212) 9 0 ases|1x 3175 [2% 6667]4 1016 3543) 42 1.653) 75 2.953) 108 4252)! s 1.598, 1.3 93.02 |2%4 68.26] 4% 102.19 3937/43 1.693, 76 2.992) 109 4.291/|.070 1.778! 1% 33.34 loa 68.58) 4.1 104.14 34331) 481792) 77 sani] 110 a:szi||.0s0 2002/16 aaa | av oes) ax 104.277 12 araa) 4519772) 78 aor) 11 4370|) 000 2206/14 3556 |28 71.12] 4% 106.36 f3 sre) 46 tery) 79 a.at0) 112 aoa) /.1 2540] 1% 9651 | 2% 71.48) 42 106068 149512] 47.850! 89 3.149] 113, 4.aa9)| 4 ar7s|1y 38.10 |2% 7302) 4% 107.95 15 s905| 48 1.890) 81 a.1a9) 114 a4eul| 4.762) 1% 2969 29 73.661 43 109.22 16 6299] 49 1.929] @2 3.228] 115 4527||.2 5.080116 4064 2% 74.61) 4% 109.54 CO —S—C—COONSCOCCO‘_tC 18 7086/51 2.008} 84 3.307| 117 sso | 7.620| 1% 4286 | 3% 77.79 44 111.76 FE rt—“—™O™O—O—r—~—~—C—C—C—C—C~Ci~SCs—SC—C—CsCsCisCsisCtistsSC 20 7874/53 2086] 86 3.386 119 4605) « 9525/17 44.45 |3% 7997/ 4% 11420 21 8268/58 2.126) 87 3.425| 120 10.160]18 45.72 |3% 2096 4% 115.99 22 8661/55 2.165) 88 3.464] 121 11.412) 1% 46.08/32 8128 46 116.84 23 ~ 9055] 86 2.205] 9 as04] 122 40a) / 12.700) 1% 47.62 | 3 8296) 4% 117.47 @ ft _suco|sy _22ud 90 asco) ts aoe | tezen 19 seat [33 e007] 4 119.06} TORQUE REQUIREMENTS fasteners, use the values listed in the table below. Torque specifications for specific components are Torque figures are in ftibs except those marked with an e in each respective section. For all other asterisk (*) which are in indbs, Leal Body Size or Outside Diameter rastener| tye | TeNsite | savers | BOW St ; | street Ts] TsT*]* | pee] ee OO} we ] ae] ag | Peale St | 788 | oats ||| | mpi | [| TI saz | 120.000 | CARBON was] 2z"] 0 | as |e | ot ‘STEEL ro ‘HEAT TREAT MEDIUM | rT] i | 1, —s 133,000) CARBON 13 | & | a | at] tua | ase | ais | 360 | s70 | 00 StL | 88° are . | : a iueouw } & ses 150,000 | CARBON 18 | 2 | a7 | m8) na | 169 | 230 | 360 | 00 | 700 SL | RE | canon | S| sooner ign canon Hee’ | 369900 |ateneD ve | | | ee} ws) | 20] | | 0 cat Sthew euBERED | I" soccer | zoo [Fig canaon | Ser 2.000 | OUENCHED a] we] ae io ale | sékew SeuPeneD lelea | stups | use SAE 2,5 an 8 values wien gra i row with tof stint srnath VA e TROUBLESHOOTING ‘The following check list of possible operating troubles, and their probable causes will be helpful in keeping your motorcycle in good operating condition. More than One of these conditions may be causing the trouble and all should be carefully checked. WARNING Tho troubleshooting section of this manual is intended lely as a guide to diagnosing problems. Carefully ‘read the appropriate sections of this manual betore per- forming any work. Observe all cautions and warnings. ENGINE Cranking Motor Does Not Operate or Does Not Turn Engine Over 4, Engine un switch in OFF position. 2. Ignition ewiteh not on & Discharged battery, loose or corroded connections (Colencia chatters). 4. Starter control circuit, relay of solenoid defective. 5. Electric starter shaft pinion gear not engaging, Engine Turns Over But Does Not Start 1. Gas tank empty, 2. Gasoline valve turned off 3, Gasoline valve or filter clogged. 4. Discharged battery, loose or broken battery ter- minal connections. 5. Fouled spark plugs. 6. Spark plug cables in bad condition and arcing or cable connections loose, 7. Ignition timing badly out of adjustment. 8, Loose wire connection at coil, battery connection or at plug between ignition module and sensor. 9. Defective ignition coil 10. Defective ignition module or sensor. 14. Sticking or damaged valve or tappets too tight, 12. Engine flooded with gasoline as a result of over: choking. 13. Engine and transmission oll too heavy (winter operation). Starts Hard 1. Spark plugs in bad condition or have improper gap or are partially fouled, 2. Spark plug cables in bad condition and arcing. 3. Battery nearly discharges. 4. Loose wire connection at one of the battery ter minals or at coil 5. Carburetor controls not adjusted correctly. 6. Defective ignition coll 7. Engine and transmission oll too heavy (winter operation). 8. Timing advance weight sticking in advanced posi- tion (1979 and earlien). 8. Ignition not timed property 40. Gasoline tank cap bent or plugged, or carburetor fuel line closed off restricting fuel flow. 11. Water or dirt in fuel system and carburetor. 12. Choke disc stuck in open position, 13. Air leak at intake manifold, Starts But Runs Irregularly or Misses Spark plugs in oaa condition or partially fouled. ‘Spark plug cables in bad condition and arcing, Spark plug gap too close or too wide. Detective ignition coil Defective ignition module or sensor, Battery nearly discharged, Damaged wire or loose connection at one of bat tery terminals or coil, or at plug between ignition sensor and module, 8. Intermittent short circuit due to damaged wire in- sulation, 9. Water or drt in fuel system and carburetor or filter. 10. Gasoline tank cap vent plugged or carburetor vent line closed off. 14. Carburetor controls misagjusted, 12. Weak or broken valve springs. 13. Air leak at intake manifold or air cleaner. 14, Damaged intake or exhaust valve, 18. Incorrect valve timing. A Spark Plug Fouls Repeatedly Incorrect spark plug for the kind of service. Piston rings badly worn or broken, Fol mixture 100 rich (see carburetor trouble chart) Valve guides badly worn Valve guide seais badly worn, Pre-Ignition or Detonation (Knocks or Pings) 1. Excessive carbon deposit on piston head or in ‘combustion chamber. Incorrect spark plug for the kind of service. Defective spark plugs Ignition timing advanced, Fuel octane rating too low. Overheating 1. Insufficient ol! supply or oll not circulating. 2. Leaking valves. 3. Heavy carbon deposit, 4. Ignition timing retarded. 5. Low power - timing advance weights stic tarded position (1979 and earlier), 9 in re Valve Train Noise 1. Low pressure caused by oll feed pump not func: tioning properly or oll screen obstructed, 2. Hydraulic tappets not adjusted properly. 3. Defective hydraulic tappets, 4. Bent push rod. 5. Cam or cam gears worn, 6. Rocker arm binding on shat. Valve sticking in guide. Excessive cold oil pressure. Excessive Vibration 1. Upper mounting bracket loose, broken or improper: ly spaced. 2. Lower mounting bolts loose. 3. Broken frame. 4. Front of rear chain badly worn or links tight as a result of Insufficient tubrication. 5. Transmission andlor transmission sub-mounting plate loose in chassis. Wheels and/or tires defective. Internal engine problem. LUBRICATION SYSTEM Oil Does Not Return to Oil Tank oll tank empty. ‘Scavenger pump gear key sheared, Oil feed pump not functioning. Restricted oll lines or fittings. Restricted oll filter, gine Uses Too Much Oil or Smokes cessively 1. Breather valve incorrectly timed. 2). Piston rings badly worn or broken. 3. Ghain oller adjusting screw adjusted for an ex: cessive amount of ol (1982 and earlier). Insufficient chain case vacuum. Valve guides worn Engine Leaks Oil From Cases, Push Rods, Hoses, Etc. 4. Loose parts. 2. Imperfect seal at gaskets, push rod cover, washers, etc. 3. Restricted oii return tine to tank. 4. Rostricted breather hose to air cleaner. Excess Oil Out of Crankcase Breather (Air Cleaner) Insufficient chain case vacuum Oit not returning to oll tank il lines or passages restricted. Gearcase cover gasket not sealing Leakage between passages and pockets in gear- case cover and gearcase @.... Oil Out of Crankcase Breather When Starting Engine 1. Ol! pump check ball stuck open. 144 2. Poor seal between feed and return gears in pump. ELECTRICAL SYSTEM Alternator Does Not Charge 1. Defective regulator-ectifier module. 2. Module not grounded. 3, Loose or broken wires in charging circult. 4. Defective stator coils 5. Defective rotor. Alternator Charge Rate Is Below Normal 1. Defective regulator-ectiier module. 2. Defective stator colls. 3, Weak or defective battery. 4, Loose or corroded connections. CARBURETOR Floods 4, Inlet valve sticking. 2. Inlet valve andior valve seat worn or damaged. 3, Dirt or other foreign matter between valve and its seat. 4, Excessive “pumping” of hand throttle grip. 5. Leaky or defective float. 6. Float misadjusted. TRANSMISSION Shifts Hard Bent shifter rod. Glutch dragging slightly Transmission oil too heavy (winter operation). Shifter forks (inside transmission) sprung. Corners worn off shifter clutch dogs (inside trans- mission), Jumps Out of Gear 1, Shifter rod improperly adjusted. 2. Shifter forks (Inside transmission) improperly ad- Jjusted. 3, Shifter engaging parts (Inside transmission) badly ‘worn and rounded. CLUTCH Slips 1. Clutch controts impropery adjusted. 2. Insufficient clutch spring tension. 3. Wom andlor soaked friction discs. Drags or Does Not Release 4. Clutch controls improperly adjusted, 2, Clutch spring tension too tight, 3. Friction dises gummy. 4. Glutch shell keys or hub studs badly worn, 5. Clutch discs warped. Chatters 1. Clutch hub friction disc rivets loose. 2. Friction discs or steel discs worn or warped, BRAKE Does Not Hold Normally 4. Master cylinder iow on fluid. 2. Brake line contains air bubbles. 3. Master or whee! cylinder piston worn or parts defective, 4, Brake pads impregnated with grease or oil 8. Brake pads badly worn (1/16 in. minimum lining thickness). 6. Brake disc badly worn or warped. 7. Brake fades due to heat build up - brake pads drag sing or excessive braking. 8 Brake drags - insufficient brake pedal or hand lever free play. HANDLING Irregularities 1 2. 3. 10. 1" Loose wheel axle nuts. Tighten to 50 ft-lbs max- imum, Excessive wheel hub bearing play. Rear wheel out of alignment with frame and front wheel. Rims and tires out-of-true sideways (tire run-out should not be more than 3/82 in). Rims and tires out-of-round or eccentric with hub {lire run-out should not be more than 3/32 in) Irregular or peaked front tire tread wear. Tires Improperly inflated. Check TIRE DATA, Sec- tion 2, Tire and wheel unbalanced, Steering head bearings loose, Correct adjustment and replace pitted or worn bearings and races. See FORKS. Heavy front end loading. Non-standard equipment ‘on the front end such as heavy radio receivers, ex- tra lighting equipment or luggage tends to cause unstable handling, Off-center loading. NOTES Part No. J 26900-14 Small Hole Gauge Part No. HD-23798 Vacuum pump VAN Part No. HD-01289 Rim Protectors, Part No, HD-26700 Bead Expander Be CO ee ~ Part No. HD-20000 Tire Repair Kit Part No. HD-32030 Piston Squaring Plate Part No. HD-21000 Tire Spreader Part No. HD-33071 Wheel Bearing Race Remover and installer te) Part No, HD-33413 Carburetor Idle Adjustment Tool Part No. HD-33443 Tappet Guide Alignment Toot Part No. HD-33416 Universal Driver Handle art No. HD-33418 Universal Puller Forcing Screw Part No. HD-39813 Inductive Timing Light Part No. HO-34107 Valve Guide Gauge/Cutting Toot Part No. HD-24190 Fork Seal (FX) Part No. HD-34834 Fork Seal (FXWG - FXST) ‘Spring Compressor Wi Part No. HD-34199 Pushrod Height Gauge i | Part No. HD-34643 Valve Guide Seal Too! ro a) —_— Part No. HD-24623 Piston Pin Retaining Ring Instal Part No. HD-34728 Valve Guide Hone (8 mm) —_— Part No. HD-34624 Cylinder Stud Installer Part No. HD-34726 Valve Guide Hone (9 mm) 1419 C9 Part No. HD-34731 Shoulderless Valve Guide Installer Part No, HD-8404 Hose Clamp Tool Part No, HD-94438-79 Push Rod Adjustment Gauge Part No. HD-34816 Ol Pressure Switch Wrench Part No. HD-94465-81 Ignition Test Adapter 9 © —— Bearing Race Oe 1-20 Part No, HD-94546-41 Flywheel Shaft Nut Wrench xp Part No, HD-94547-80 Crankshatt Bearing Toot Part No. HD-94645-41 Clutch Hub Nut Wrench L c_i © Part No. HD-94585-55C Pinion Ge Socket Part No. HD-94660-37A Mainshaft Locknut Wrench Part No. HD-94589-29 Cylinder Base Nut Wrench (8/16") os Part No. HD-4681-80 Spoke Nipple Wrench =~ ) 1635-41 Mainshatt Ball Bearing Lock Nut Wrench Part No. H0-94700.52B Shock Absorber Spanner Wrench Part No. HD-94752-77 Float Gauge Part No, HD-95017-61 Lock Ring Pllers External rt No. HD-95020-66 Rear Chain Link Press Too! Part No, HD-94806-57 Rocker Arm Bushing Reamer Part No. HD-95021-29A Chain Breaking Too! al a Part No, HD-95500-80 Wheel Truing Stand Part No, HD-95635-46 All Purpose Claw Puller o Part No. HD-95637-48 Wedge Attachment for Claw Puller —— 1 iui | Part No. HD-95760-89 Bushing and Bearing Puller Tool Set (Includes Items 1, 2, 3 and 4) Items § (HD-05768-6: (HD-95769-69), 7 (}4D-95770-69) and 8 (HD-05771-69) ‘optional extras, Fone Part No. HD-95850-42 Transmission Mainehatt Starter Clutch and Bearing Puller art No, HD-98960-414 Clutch Hub ‘and Chain Housing Puller Part No. HD-95660-42 Maln Drive Gear Oil Seal Too! Part No. HD-95666-42A Sie Part No. HD-95960-52B Alternator Rotor Puller Part No. HD-95970-32A Piston Pin Bushing Too! Part No. HD-96216-49 Large internal Lock Ring Pliers Part No. HD-96137-52A Flywheel Support Plate Part No. HD-96221-80 Oil Filter Wrench { «

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