Repair Manual
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Aftermarket equipment / Manual organization / Notes, cautions and warnings / Safety first / Service hints / Serial numbers / Parts and parts numbers / Torque specifications / Fasteners / Lubricants / Gasket sealer / Threadlock / Gasket remover / Expendable supplies / Basic hand tools / Test equipment / Precision measuring tools / Cleaning solvent / Other special tools / Mechanic's tips / Ball bearing replacement / Oil seals
CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Testing electrical components / Emergency troubleshooting / Engine performance / Electric starting system (1965 Electra-Glide) / Charging system / Voltage regulator (Delco-Remy) / Ignition system / Fuel system / Engine noises / Engine lubrication / Clutch / Transmission / Electrical problems / Excessive vibration / Front suspension and steering / Brake problems
CHAPTER THREE / PERIODIC LUBRICATION, MAINTENANCE AND TUNE-UP
Routine safety checks / Maintenance intervals / Cleaning your Harley / Tires and wheels / Periodic lubrication / Periodic maintenance / Non-scheduled maintenance / Tune-up / Breaker point ignition service / Carburetor adjustment / Storage
CHAPTER FOUR / ENGINE
Panhead engine overview / Service precautions / Special tools / Servicing engine in frame / Engine / Rocker arm cover/cylinder head / Pushrods / Valves and valve components / Cylinders / Pistons and piston rings / Tappets and tappet guides / Oil pump / Timing cover and timing gears / Timing cover / Timing gears and camshaft / Crankcase and crankshaft / Engine break-in
CHAPTER FIVE / CLUTCH, PRIMARY DRIVE AND STARTER DRIVE
Primary chain / Motor or compensating sprocket assembly / Primary chain housing / Starter drive (1965) / Clutch booster
CHAPTER SIX / THREE- AND FOUR-SPEED TRANSMISSION AND KICKSTARTER
Shift linkage adjustment / Hand shift cover / Foot shift cover / Shift forks / Transmission / Transmission overhaul / Main drive gear oil seal replacement / Kickstarter and starter clutch
CHAPTER SEVEN / FUEL AND EXHAUST SYSTEMS
Linkert carburetor / Fuel tanks / Fuel shutoff valve / Exhaust system
CHAPTER EIGHT / ELECTRICAL SYSTEM
Battery / Circuit breakers / Ignition coil / Electric starter / Starter solenoid / Lighting system / Instrument panel / Switches / Horn / Charging system / Generators / Generator (3-brush generator) / Generator (standard 1958-on) / Generator (fan cooled 1949-1964) / Polarizing the generator / Voltage regulator / Fuses and circuit breakers
CHAPTER NINE / WHEELS, HUBS AND TIRES
Front wheel / Rear wheel / Wheel hubs / Driven sprocket assembly / Drive chain / Laced wheels / Wheel balance / Tires / Tire repairs (tube-type tires) / Wheel alignment
CHAPTER TEN / SPRINGER FRONT FORK
Front shock absorber / Spring fork / Rigid fork / Steering damper / Steering adjustment
CHAPTER ELEVEN / HYDRA-GLIDE FRONT SUSPENSION
Front forks / Fork removal / Steering head and stem / Steering head bearing race / Steering adjustment
CHAPTER TWELVE / REAR SUSPENSION
Rear shock absorbers / Swing arm
CHAPTER THIRTEEN / BRAKES
Front drum brakes / Rear mechanical drum brake (1948-1957) / Mechanical brake inspection / Rear hydraulic drum brake (1958-1965) / Hydraulic brake drum and shoe inspection / Rear master cylinder (1957-1965) / Brake pedal assembly / Brake bleeding
CHAPTER FOURTEEN / FRAME, BODY AND FRAME REPAINTING
Service stands / Footboards / Seat / Handlebar controls / Handlebar / Frame
CHAPTER FIFTEEN / RESTORATION
Panhead history 1948-1965 / Buying old parts / Photos / Original paint restoration / Fuel tank emblems / Upholstery / Chromed parts / Rubber or vinyl parts
INDEX
WIRING DIAGRAMS |
