Harley Davidson Tech. 1 - Motorcycle Mechanics Institute course notes
Contents
1. Advancer lubricant 1 light adequate lubrication of all moving parts with anti seize Points cam lubrication 1 light coating of H D hi temp grease p n 99862 72 A Rear cylinder fires first B Point cam wide lobe rear cylinder narrow lobe front cylinder 4 Ignition timing A Point gap set gap on wide lobe 018 check gap on narrow lobe should be 018 002 if not recheck advancer for wear or misalignment on cam 5 Static timing A Set point gap on wide lobe than check point gap on narrow lobe B Time off of front cylinder advance back engine 1 2 of piston travel to find front cylinder advance mark C Disconnect coil wire to points D Use diode check on meter set advance plate where beeping from meter is intermittent with points advanced 6 Check dynamic timing with a timing light A 2000 RPM for BPI system B Adjust plate not points 7 Electronic ignition A Inspection 1 plugs wires coil same as BPI 2 VOES vacuum operated electrical switch a vacuum switch b requires a good ground c check for damage B Types 1 Ist year 78 1 2 80 Prestolite points cam mechanical advance adjust air gap 004 006 with a brass feeler gauge 060 065 XL s 2 80 E 83 XL 80 84 big twin Magnavox stage I electronic ignition coil electronic advance 6 wire system 3 to sensor plate 2 to coil 1 to ground 3 L 83 and up XL 84 and up big twin Magnavox2. 25488 86 cover with cams and pinion gear T cams 2 Cover only retrofits all alternator covers 84 1 2 Service of gearcase area i Replace cover order cover and cams as a set ii Replace bushings 1 Must line ream Cams a b 1986 1987 T cams i same cam in 883 and 1100 ii dogbone installed with the chamfer facing cam out 1988 1990 C cams i same cam used in 883 and 1200 ii reduced emissions iii dogbone installed with chamfer facing cam out flywheels a b c d e 3 piece flywheels i 1 piece flywheel halves ii no retrofit except left side wheel from pre comonized to comonized must rebalance oil restrictor in the pinion shaft no rear cylinder advance mark balance factors used to balance at speed higher balance at higher RPM lower lower RPM balance i 1340 60 ii 1100 69 blue iii 883 62 yellow iv 1200 62 white v after 1989 all 883 flywheels are colored green and all 1200 s are red 1991 and later there s a timing mark on right side flywheel 21 Connecting rods 22 23 24 25 wa wm Nw wm a b c d e Dog legged 1982 and later ALL Evos Wrist pin clearance is 2 times that of a B T helps prevent seizure Bearings i Early 1986 were loose rollers with flat thrust washers ii Late 1986 through current use F A G bearings started on day 095 For the first 2 months no th
3. remove tamper plug A It is legal to 1 adjust slow idle RPM 2 adjust fast idle RPM 3 adjust float level 4 adjust accelerator pump spring tension or pin setting 5 adjust choke spring 6 adjust idle mixture if screw is exposed 2 Idle mixture adjustment A Should be performed after ignition timing is set valve train adjustment air filter service and spark plug inspection B Motorcycle must be at operating temperature C Proceedure check manual for initial settings Bendix 72 73 XL and FL FX 1 1 2 turns out Keihin 2 turns out 1 set idle speed to 900 to 1100 RPM left side carb 2 slowly turn mixture screw clockwise to lean out 3 when rear cylinder firing faulters stop turning screw 4 turn screw counter clockwise 1 8 1 4 turn until rear cylinder fires approxamately 75 90 of the time 5 adjust idle speed as necessary IDLE MIXTURE SCREW stock set up 2 turns 1 1 2 turns 1 turn more than this normal less than this jetis too small initial setting jet is too big 3 Fast idle Keihin adjust only with engine cold A Adjust idle for 1500 RPM when choke is in 2 position right side of carb 4 B Misadjustment 1 too little no fast idle 2 too much overrides slow idle adjustment engine races Choke cable adjustment provides full open full closed settings A Keihin carbs provide spring tension adjustment if spring is weak choke plate will open when cranking engine to start will c
4. 1100 or 1200 diameter is the same b 1200 same 1340 but are NOT interchangeable c 1200 have either 12 or a V grove stamped on the edge 16 Tappets a XLsame as B T b No restrictor on Early 1986 c Ristrictor added Late 1986 1990 i Reduces oil to the top end ii Helps keep lifter filled at highway speeds hydraulic lifters as opposed to solid d Tappet working ranges 17 Tappet block 4 speed a To remove from case turn tappet block and lift from case b Tappet to block fit i 0 0008 to 0 0023 ii 0 003 service wear iii there are no stock oversizes available c new o rings are made from silicone rubber and will swell when exposed to oil d oil leaks i tappet block to case oil will be grungy ii small o ring to case oil will be dirt free possible that the counterbore is to deep in the case should be 0 050 0 060 18 19 20 wm ma e iii shim up with a small washer iv use Hylomar to seal Torque to 15 18 ft lbs Gearcase cover a b c d Bolt torque patterns given in Tech Tips 25 2 dowel pins are for centering cover computerized sizes for gear fitment i quadrex room temp of 68 degrees ii measures center to center of bushings down to 0 00000 hundred thousandths iii prints sheet telling what cams to use iv production covers have no markings but information is on file at HD v P amp A covers are color coded for correct cam selection 1 PN
5. 9 16 ID sits on guide shoulder L81 and up 3 4 ID fits over seal sits on head surface F Cylinders cast iron all years 1200cc 3 7 16 bore 1340cc 3 1 2 bore 1 66 78 1200cc 10 fins with a thin base available untill 80 as an option 2 78 1 2 and up 1340cc 9 fins with a thick base 1200cc option a base is cut out for triangle washers round side faces down 3 when boring or honing use torque plates and gaskets 4 cylinder inspection a base surface 003 max warpage b wear limits max clearance 006 cylinder to piston 0015 003 good max taper 002 max out of round 001 c finish 240 plateau when sizing cylinder use torque plates and gaskets G Pistons 1 60 83 Bohnalite USA made H D machined cast in steel strut controls expansion tin coated for break in symetric no wrist pin offset wrist pin clips 72 77 spirolox and 77 and up use Tru arc pistons will be marked with 78 part number or 77 cast into piston can use a spirolox in a Tru arc piston but not the reverse 2 compression ratio a 1200cc high compression 8 1 FLH round dimple in crown b 1200cc low compression 7 4 1 FL no dimple c 1340cc high compression 8 1 FLH rough crown d 1340cc low compression 7 4 1 FL smooth crown 3 wrist pin see service bulletin hand out page 3 15 a 74 pistons have lowered wrist pin locations for use with 030 shor
6. B Check throttle snap back in left right and straight position throttle must turn freely in any front end position C Carburator overflow hose must be routed away from exhaust D Inspect fuel system for leaks or damage hoses fuel valve lubricate VEHICLE INSPECTION 1 Around the vehicle inspection similar to PDI Pre Delivery Inspection see inspection hand out Right rear Right side Right front Left front Left side Left rear ey ea eae OIL CHANGE PROCEEDURE 1 School vehicles A Drain oil into a clean pan and refill tank with original oil B R amp R oil filter reuse old filter 1 when tightening turn oil filter1 3 1 2 turn after gasket contacts housing C R amp R tappet screens on big twins and clean use modified snap on drag link socket 2 Real world A Drain oil from tank 1 drain hoses where used as early as 83 on XL s 2 all H_D s have a drain plug or drain hose 3 fill to proper level with clean oil B Oil filter always lubricate rubber gasket before installation C Do not install return side oil filter until system has been flushed D 84 and later XI engine is on the fuel side install before starting with filter 1 2 full of oil 3 Refilling system A First refill oil tank with recommended oil B Start engine and run until clean oil exits oil filter housing this flushes old oil out of the lines and crankcase C Always replace drain plug gasket CARBURATION 1 Itis illegal to altercarb
7. Check fluid for contamination and level any problem with master cylinder requires rebuilding or replacement fluid change level should be 1 8 from top with reservoir level D Linkage inspection damage wear non stock parts E Adjustment inspection freeplay must exist in most brake systems 1 81 and earlier front master cylinders should have some freeplay 82 and later do not seal do shin 2 85 and earlier rear brake systems must freeplay Front master cylinder 1 72 E 81 Lester has built in freeplay 2 L 83 and up Kelsey Hayes has no freeplay internals are held in place by a ring 5 bore sizes a 82 only had 3 4 bore b 83 95 had 5 8 bore on a single disc and 11 16 on a dual discs c 96 and up had 9 16 on singles and 13 16 on duals Rear master cylinders 1 58 E 79 Wagner Lockheed cast iron a 58 E 72 hydraulic drum b 72 79 disc brakes 2 79 E 87 Kelsey Hayes aluminum requires a minimum of1 32 freeplay not over torque 3 80 and up FLT FXR FXST used remote reservoir freeplay 1 32 4 cartridge type very rarely have to rebuild 5 L 87 and up built in freeplay replaceable cartridge Hoses and lines 1 damage leaks and weather cracking 2 check for bulging or swelling when system is pressurized 3 replace any parts not in excellent condition Calipers 1 damage leaks worn pivot points non stock p
8. Pinion Gear 1 cam endplay must be measured before cover is removed 2 breather gear endplay using a new gasket feeler gauge and a straight edge measure between straightedge and breather gear with the gasket in place than subtract 006 for gasket crush ideal endplay is 005 010 3 cam fitment see hand out page 2 15 a ideal straight no lash b loose fitment noise clatter c tight fitment whine d gear tooth changes cam pinion breather 1 E77 and earlier straight tooth profile 2 L77 and later curved tooth profile machined ring on side of gear i 7 gear sizes identified by color codes 3 never mix old and new style cam breather or pinion parts 4 Cam types a H cam E83 and earlier S cam L83 and 84 b S cam all parts and accessories less duration than H cam more mid range quiter valve train softer 5 Gear inspection a lobes discoloration and pits b bearing surfaces change from INA to Torrington c teeth d dog ear washer installed eats down slant towards rear G 58 72 One shot oiling system 72 and up flat side bushing that lines up oil holes in the bushing with oil passage constant oiling L Solid lifter usage 1 can ruin hydraulic type cam it has no expansion ramp 2 solid ype lifter cams need expansion clearance ramps to reduce shock on cam lobes tappet rollers and valve stems 3 solid lifters provide more ca
9. belt alignment or tension I Pump brakes until firm check for smooth release 80 84 FLT FXRT rear wheel removal A Raise rear wheel B Remove both saddle bags and mulfflers C Remove plug in tower chain housing use long sheilded 3 8 allen socket remove all 5 sprocket bolts D Connect a ratchet strap to upper shock mount and swing arm remove lower shock bolts lower swing arm enough to remove brake caliper anchor bolts E Pull axle 3 4 of the way out F Lift out caliper and hanger and secure out of the way G Deflate tire seperate wheel from sprocket tilt wheel carefully remove caution be careful of inner spacer falling out of wheel Installation Reverse order of removal Don t forget the inner spacer Clean and lubricate bolts Torque sprocket bolts to 65 75 ft lbs cross pattern Torque axle to 60 ft lbs Readjust caliper anchor bolts Mount mufflers forward on bracket Inflate tire Pump brakes HmOmMoOOw gt
10. ground out 1 degree to offset for negative angle in the cover pad area 4 rocker arm end play a specs 004 025 Good is 004 010 b alter end play 1 best method cut a shoulder on the shaft 2 good method chamfer rocker arm spacer 5 8 3 4 countersink 90 degree angle 3 bad method shim the rocker arm do not do this 5 rocker shaft a 66A part number if o ring seat is square 66B part number if o ring seat is beveled b specs shaft to arm 003 max clearance shaft 0015 max wear shaft to box 002 max clearance 1 excessive clearance in these areas will cause flooding of the valve pocket area c see hand out page 3 1 for additional information G Pushrod 1 all 4 identical 2 inspect for a damaged ends b damaged locknuts c max bend 010 H Pushrod Tubes 1 79 and earlier cork gasket flat edge tube 2 L79 84 1 2 o ring gasket lip edge tube for more compression use cork in place of middle o ring 7 CYLINDER HEADS Specs 1 head gasket surface max warpage of 006 2 head gasket types Teflon blue Graphite black Metal fiber gray James gasket with metal fire ring and silicon bead Install all gaskets dry 3 torque 55 75 ft lbs staged 30 45 55 always start next to oil hole DO NOT GO OVER 65 FT LBS TOTAL ALUMINUM 4 fire ring height causes leaking or blown head gasket when excessive 010 clearance between head and cylinder
11. less than 1 240 4 check for bleeding with a multimeter a VDC scale b negative lead to negative lead of battery c positive lead to each battery cap bad is more than 2 2 VDC 5 voltage output can be done with battery in bike a turn ignition lights and accesories on b VDC scale minimum of 11 volts at terminals AIR FILTER SERVICING 1 Paper tap lightly blow it off with air not more than 30 PSI A If filter is oily it can be cleaned with soap and water 2 Foam wash with a strong detergent than rinse when dry apply 1 tablespoon of oil to element squeeze in and use paper towels to soak up excess 3 Gauze K amp N wash in a strong detergent than rinse shake off and air dry not air pressure spray with light coat of K amp N oil on outside until gauze is pink 4 Ham can order of assembly Manifold to head Carburator to manifold Air cleaner backing plate to carburator Align and tighten support bracket last prevents pulling manifold from heads which causes air leaks siaki THROTTLE CABLE ADJUSTMENT 1 Lubricate cable with a light viscosity lubricant 2 Insure proper routing of cables not pinched or crimped 3 Pull open cable with front end straight open throttle wide open A Adjust pull open cable until crank on carb just touches carb stop snug locknut 4 Return cable turn front end all the way to the right lock A Adjust pull closed cable to eliminate freeplay between outer cable and cable spring
12. 1 E82 no drain holes had spigot for evacuator d L82 and up 2 transfer holes no spigot 2 inspection a check for cracks base of roller guides b check for wear max 002 between tappet and guide 3 mounting screws a 66 77 1 4 X 24 b 74 84 1 4 X 20 4 updating a drill both drain holes through to the bottom with a 3 32 bit or use 1 8 I Tappets same all gears not including hydraulic units 1 install with flat sides facing each other a failure to install properly will prevent the exhaust from pumping up 2 inspection 001 max tappet wear and 0015 max roller bearing clearance a inspect tappet screen every time you change oil open end down spring over screen J Hydraulic lifter 1 lifter test a dissassemble lifter unit bleed and clean with contact cleaner b with unit dry manually compress and hold for 6 seconds when released plunger should pop up 2 lifter problem causes a oil pressure need a minimum of 12 PSI at 2000 RPM b oil path restriction tappet screen blocked c tappet installed backwards d gasket misaligned at tappet guide 3 install tappet guide with installation tool in back use every time to align tappets with cam 4 similar noises often mistaken for lifter problems a excessive rocker arm end play b loose cam gear fit c exhaust leak d sticking valve e bent pushrod f worn tappet roller bearing K Cam Breather and
13. 1 oil collects in mini sump 2 oil collects in gearcase cover and drains into mini sump x 3 things control oil return 1 spinning of flywheel and case scraper 2 downward action of the piston creating pressure in the case 3 suction of oil pump return gears PRIMARY DRIVE AND COVER 1 Clutch cable ae Oe sits below oil level Hylomar on threads copper washer under nut don t damage o ring part of cable no seperate part number some cables leak at crimped area replace 88 clutch cable 1 o ring at end 2 adjustable in middle of cable 3 88 primary cover changed for o ring 4 cable will retro fit to 86 2 Clutch adjustment ee disconnect battery slacken clutch cable all the way remove clutch screw lock and spring turn counterclockwise until firm turn clockwise 1 4 to 1 2 turn replace screw lock and spring G adjust cable for1 16 cable freeplay Primary chain adjustment A disconnect negative battery terminal B take out slack in primary chain C rotate wheel to find tight spot D adjust to 3 8 to 1 2 slack Oil level and type A H D sport transmission fluid 1 designed for higher loads 2 retrofits all wet clutches B 4 speed 1 24 oz measured 2 fluid should just dribble out of level plug with motorcycle upright C 5 speed 1 32 oz measured or just up to diaphragm spring on clutch Cover removal A disconnect battery B release chain adjuster C remove clutch screw nut
14. 5 head bolt should be assembled with lube or never seize 6 additional information on page 3 2 of hand out Cylinder prep for re assembly 1 clean in soapy water 2 clean and lube with a paper towel and motor oil light weight 3 clean drain hole with a brush 1980 heads 1 cast iron guides longer with shoulder 2 head has machined surface for new style lower valve spring collar collar now rests on head surface instead of valve guide shoulder 3 L81 a cst iron guides longer with shoulder b ream or hone for proper clearance intake 0015 exhaust 0025 c valve guide seals umbrella type seals NOTE do not use loctite on a valve guide seal Valves 1 hard valves Eaton hard chrome US made Nittan black nitride coating Japan made 2 stem diameter 80 valve diameter same as earlier models 81 valve is approximately 003 larger stem OD 3 80 and 81 valves are recommended for use with all cast iron guides 4 medium hard valves 57A and 66 valves are compatible with cast iron guides but not recommended due to short service life 5 soft valves 57 60 valves never use soft valves with cast iron guides causes valve sticking Springs and hardware 1 spring ID silver 82 and earlier red orange L82 84 prevents coil bind with S cam 2 top retainer mid 81 and earlier thicker L81 and up 050 thinner for seal clearance 3 bottom collar 79 and earlier
15. C Connecting rods 1 41 73 long rods no longer available if old style pistons are retained for use with new style short rods a piston to flywheel clearance must be checked at BDC should be 1 8 min b compression ratio will be reduced from 8 1 to 7 6 1 2 74 82 short rods with slot 030 shorter center to center 3 82 E83 short rods with hole 4 L83 84 short rods offset with hole dog leg rods 10 times the fatigue resistance reduces bend and twist wider web on female rod requires new flywheels with relief 9 Oil pump A oil type 1 40 degrees and lower 10 40 multigrade 2 40 80 degrees 20 50 multigrade 3 80 degrees and up 60 weight extra heavy 4 80 95 degrees SAE 60 5 95 degrees and up SAE 70 B oil pressure when blows lifters 1 measure at operating temperature 180 220 degrees 2 spec idle 3 5 PSI 2000 RPM 12 35 PSI Feed system 1 gravity feed to F fitting on pump 2 check valve a 2 3 Ib spring and ball seals pump and prevents drain down engine is not running a leaking check valve causes tank drain down and oil out of breather on start up a to repair lap seat with bead blasted Evo pushrod end it s the same size as the check ball 3 after engine is running check valve opens and oil flows to tappet screen and top end 4 lower end passasge opens at 5 10 PSI regulating piston moves upward to open passage oil flows through crank case and ge
16. Harley Davidson Tech 1 1 Intro Dates a 883 started in early 1986 to present b 1100 started in late 1986 to late 1987 c 1200 started in early 1988 to present Case breather sportsters from 1986 1990 Iron sportsters from 1957 1985 2 3 4 5 6 7 8 9 Compression Ratio a 9 1 on ALL models Rocker covers a Big Twins B T and Sportsters XL can be interchanged as a set i Top end breather covers must be used on top end breather motors ii Print o seal gasket and inner cork or rubber chimney are the same for B T and XL iii All rubber gaskets from late 1989 till current iv XL rocker arms and shafts are the same as the B T Rocker arm play is 0 003 to 0 013 between rocker arm and rocker box endplay Bolts are hardened and CANNOT be replaced or mixed with unhardened bolts Rocker shaft to Rocker box clearance for all XL s is 0 0007 to 0 0022 ID to OD clearance 9 16ths 18 tap is used to push out rocker arm bushings from the opposite side then press in new bushings Pushrod tubes a 1986 1990 i multipiece tube ii both top and bottom seal against an o ring Cylinder Head a Early 883 egg shaped chamber and sand cast b Late 883 round hemispherical shaped chamber die cast c 1986 to early 1987 1100 egg shaped chamber sand cast d Late 1987 1100 and all 1200 round hemispherical shaped chamber die cast e Late 1100 heads were milled 0 040 i That milling did
17. RAKE 1 72 E 80 caliper body is the same for front and rear differance is in the piston 3 pistons 3 retraction rates color painted on pucks A Plain front CO 1 2 sho B Red front or rear C Gold rear most retraction Changes A 77 80 wave washer was added to aid in retraction B 73 E 81 boomerang bracket was used C L 81 84 Y bracket replaced boomerang D L 80 84 cut groove and put square ring in body no longer in the piston 1 retraction rate 1 undercut determines rate of retraction MPRESSION TESTING Proceedure A Remove spark plugs and join wires together with 1 plug to prevent arcing and possible fire B Open throttle to wide open position C Turn engine over until compression tester shows less than 5 psi increase per compression stroke D Both cylinders should read within 10 of each other E Most H D engines will produce 100 psi or more Differance of more than 10 between cylinders or compression below 100 psi uld be diagnosed A Put 1 tablespoon of motor oil in cylinder and test again 1 psi higher now rings are not sealing 2 psi same suspect valve or gasket sealing problem PUSHROD AND TAPPET ADJUSTMENT 1 see tech 1 notes check pushrod adjustment than run engine and change oil FRONT AND REAR SUSPENSION 1 Check for any loose fasteners check for any damage 2 Check for any noticable dampening 3 Check for any fluid or air leaks FORK STEM BEA
18. RING INSPECTION 1 Check for any looseness in bearings 2 Check that front end pivots smoothly A cables should not be binding movement 3 Check adjustment A FLT FLHT swing method 1 disconnect clutch cable from handlebar 2 support vehicle evenly off of the ground 3 pull front end to left lock and let go front end should swing past center twice and stop somewhere near center B All other models except springer use 1 2 fall away method 1 disconnect clutch cable and any other restrictive cables 2 support vehicle evenly off of the ground 3 put front end in balanced position 4 set pointer for reference and move front wheel to the left and than to the right a note where the front end falls away in each direction 5 left and right fall away marks should be 1 2 apart REAR SUSPENSION 1 There should be no noticeable side play in rear fork 2 There are several types of rear fork bearing designs A Tapered bearings require grease and adjustments B Solid stainless plug and Teflon bushing requires no service C Silicone rubber clevblock design requires no service 3 Always check torque specs on any fasteners 4 4 speed swing arm bearing adjustment proceedure A Remove everything from swing arm and let it hang free B Connect fish scale to axle C Lift swing arm with fish scale check weight 12 15 Ibs D Torque pivot bolt to increase weight by 2 pounds AIR ASSISTED SUSPENSION 1 FLT FLHT FXR
19. T moselshave front and rear sysstems A Always check manual during service with no loss air gauge see manual for specs B Check for leaks in 2 ways 1 loss of pressure as read on gauge 2 using soap and water 2 Anti dive check A Hold front brake ignition off and bounce front end B Hold front brake ignition on and bounce front end same amount there should be noticeable increase in spring tension WHEEL AND TIRE INSPECTION AND SERVICE 1 Tires wear replace tire if wear pattern is uneven wear bars are exposed or vehicle handles poorly A Damage inspection replace tire if sidewall shows damage such as cracks or puncture replace tire if tread area puncture is sideways to carcas or puncture size is greater than1 4 also inspect for correct mounting bead seated evenly and tire rotation 2 Service tire pressure should be set to factory specs and should not exceed maximum listed on side wall 3 Wheels spin wheel to inspect for any damage or out of true A Feel for bearing end play 002 006 B Cast wheels if out of true or cracked replace 1 max runout radial 1 32 lateral 3 64 C Spoke wheels check spoke tightness each spoke should emit a high pitched ring when tapped all spokes should sound the same 1 max runout radial and latera 1 32 MISC LUBRICATION 1 Wheel bearing grease can p n 99855 89 cartridge p n 99856 92 A Except 80 81 FLT B Any taper bearing C Any part with a grea
20. a allen plug on cover b bottom of filler plug threads D venting flat plate shifter two holes in top cover 1 oil leaks at clutch tower usually indicates overfill or vent plugged Shifter mechanism shifter cam moves forks pawl arms move cam pawl carrier holds arms pawl carrier springs recenter carrier after shift shift shaft moves pawl carrier MOOS Inspections A shifter plate inspections 1 bent or worn more than 010 replace 2 check for smooth fimger movement 3 do not re use snap ring B pawl arm inspection 1 hook area wear 2 pawl spring wear C pawl carrier inspection 1 broken or out of place causes limp shifter D cam follower inspection 1 bad spring ID cad plated too stiff coil binds 2 good spring ID black P N 34068 52 E shifter shaft inspection 1 popping out of groove use washers to shim 19 Sprockets A left hand threads 1 mainshaft clutch hub nut and sprocket nut B lock brake or lock in 2 gears to remove sprocket nut C tab washer lock 83 and earlier 1 early style lock bend tab only once 2 torque nut to 80 90 ft lbs and use locktite 262 D allen lock 83 and later 1 torque nut to 80 90 ft Ibs 120 max 2 allen screw location must prevent nut from loosening 3 retro s to all 80 models E sprocket types dished 36 79 installs with dish towards transmission 80 85 flat F sizes 22 24T Ok for clearance to tranny 25 26T may require mac
21. any clearance than torque front mount D inspect clearance between top mount and frame shim for 0 clearance than torque Engine and tranny proceedure A install engine B loosely bolt primary to engine C with tranny and plate loose bolt primary to tranny D shim primary than torque engine and primary than torque tranny and primary E torque tranny and plate Rocker box installation torque pattern Head bolt installation torque pattern Rocker box A Cut out provides clearance between cover and frame when engine is hot 1 engine expands approxamately 040 measured from cylinder deck to top of rocker box B Rocker shaft location 1 degree negative angle places rocker arm lower on valve side spins valve to prevent lead build up quieter supposed to keep arm thrusted to one side C Gasket torque to 12 15 ft lbs 300 percent increase when engine reaches operating temperature assemble dry or with lithium grease H D says dry D Max warpage 006 E 78 1 2 late style rocker box Boss under front for ham can mounting and shortened boss on back left side using shorter stud F Rocker arms 2 types 1 front exhaust rear intake and front intake rear exhaust 2 case hardened max wear or pitting more than 005 replace pad or socket area 3 66 70 rocker arms were copper plated 66 arms 71 up iron arm with more even wear 66A arms will retro fit 82 up had a
22. ar case cover to pinion bushing return a oil flows through pinion shaft right side flywheel and crank pin b the oil lubricates the rod bearings c splash from rods lubes the pistons pin bushings and lower end bearings 5 relief passage opens at 12 18 PSI L73 81 oil directed to return side L81 and up directed to feed side relief 6 hydrolocked oil oil trapped above relief piston L73 80 down tower to ID large cap 81 E82 to gear case ID small cap 80 and earlier had short piston and a rod to limit travel L82 has long piston to block relief hole when not running to prevent drain down rod deleted long piston is its own travel limiter also make a groove so oil can get to hydrolock passsage when retro fitting D Breather system 1 pressures positive piston moving downward negative piston moving upwards 2 function oil movement a pistons move downward breather valve window is open and flywheel area blows oil into the gearcase 1 gearcase area normally positive 2 cylinder area normally positive transfers through tappet guide holes b when pistons move upwards breather window closes and a negative pressure is created 1 flywheel area normally negative c there is a push pull effect which helps drain oil from the top end d oil seperator hole at bottom of breather trap feeds to hole in breather valve bore at the 5 o clock position connects with breather trap area h
23. arts 2 calipers must be free floating fasteners tight 3 pad condition correct parts damage wear uneven or less than 1 16 thickness requires replacement a 1 2 pad thickness is better 4 half shim goes between piston and pad rotor must turn into cut in pad full goes between back side of caliper and pad a purpose of half shim is to clean rotor and pad Discs 1 damage max warp 008 max runout 008 dial indicator mounted to front fork leg and spin disc thickness minimum thickness is stamped on the rotor check in at least four places with no more than 002 variance 2 rotor is the only part with the part number stamped on it hand out pages 5 17 to 5 21 bulletins on brakes and pads Disc and pad sets DISC PAD 73 mild steel organic 78 hard stainless semi iron black color 79 very hard stainless semi iron copper 84 very hard stainless 11 12 rotor semi iron copper 84A 30 hole anti symmetrical semi iron copper 94 softer stainless semi iron gray BRAKE FLUID 1 Description Dot 3 glycol based clear hygroscopic eats paint and plastic 5K miles have no markings has 3 4 mark Sep 76 service internal components cup inside master cylinder Dot 5 silicone based purple aerates won t harm paint or plastic 15K miles 2 yellow and 1 white dots has 750 mark note when you have metal to rubber use Dow Corning 44 for metal to metal use anti seize BANANA B
24. ary oil feed oil retrieved by engine vacuum 1 primary is oil fed oil is retrieved by engine vacuum 25 water vacuum at 1500 RPM vent pinched B friction plates 020 max warpage can be scuffed up C steel plates 010 max warpage scars 1 32 or more replace grove wear 020 max D installation friction plate first and last crankcase seal installs lip in to keep engine oil out of dry primary 11 Clutch adjustment data A flat plate shifter wet or dry clutch 13 16 measurement B ratchet top shifter wet or dry clutch 1 2 measurement C 5 speed wet clutch 3 4 turn out 12 AP wet clutch A 84 1 2 89 with 4 and 5 speed transmission B lubricant level bottom of clutch with motorcycle upright and level Derby cover removed fluid to bottom edge of diaphragm spring C type H D primary chain case lubricant 1 1 2 quart change every 5 000 miles D primary housing extra fasteners added for rubber mountin 85 and 86 for rigid mount engines 1 printo seal gasket 2 primary vent through mainshaft and transmission vent vent plugged oil leak 3 crankshaft seal installs lip lip side out to keep primary chain case lubricant from going into the engine E clutch adjustment 1 service set up check at 500 miles than every 5 000 miles 2 proceedure a disconnect battery b apply max slack to clutch cable c loosen clutch screw and locknut d inspect and adjust spring tension 1 spring attitude
25. ause a lean mixture Air leak problems A Symptoms 1 erratic idle 2 spit back through carb 3 hesitation surging 4 poor performance detonation 5 slow return to idle Air leak diagnosis A Using contact cleaner spary around manifold area throttle shaft B Air leaks produce a change in idle speed when contact cleaner is sucked in DO NOT SMELL EXHAUST IT WILL RESULT IN DEATH C Commercial tools for air leak detection are snap on propane leak detector electronic air leak detector PRIMARY DRIVE always have battery disconnected before opening primary drive 1 Inspection A tight spots check chain slack all the way around more than 3 8 differance between tightest and loosest spot replace chain B corrosion link damage or heat damage replace chain C inspect adjusters for excessive wear fastener tightness and bracket condition D oil levels XL on sheet FL 65 84 1 2 none adjustment A XL 3 8 5 8 chain link height use inspection cover B Big twin 5 8 7 8 FINAL DRIVE J Inspection A Replace any chain that shows 1 any rust between rollers and side plates 2 has battery acid corrosion 3 has more than 1 2 differance between tight and loose spots 4 has roller or side plate damage 2 to 5 measures longer than 12 7 8 for 20 links 6 has kinks B Replace any sprocket that shows wear 1 teeth should almost have square teeth no hooks or fins Adjustment Always ad
26. cer and check for grooving install new seals pre lube lip 3 spline leaks 82 85 use p n 11166 o ring to seal splines new spacer p n for use with o ring chain 35079 84 belt 35070 84 81 and earlier clean all parts with contact cleaner before assembly 26 Bearing changes A B C 36 E 77 44 loose roller bearings around main drive gear 1 available in STD 0004 and 0008 over size M 77 85 caged bearings to change early countershaft free bearings to caged you need 1 late cluster gear 2 late countershaft threaded 2 groove or notched 3 late case races throw out bearing 1 36 M 75 automobile style bearing best style 2 M 75 85 wafer style bearing takes the same load as auto style bearing won t live with a constant load clutch adjustment is critical has a sheet metal oil slinger Batteries 1 Penned in date on top should not sit on shelf for over one year see service bulletin M1020 A Number year B Letter month C Example 8L Dec 88 Late model chart for battery coding see hand out Putting battery into service miiu leket 1 2 Take off vent plug Remove cap farthest from vent set on hole Install vent tube blow in tube it should move the cap Check strength of the electrolyte it should be 1 265 1 270 Fill each cell with electrolyte to lowest level set aside for 30 minutes Rock battery to release trapped air and fill t
27. dapter through drilled holes and fills cavity 3 Builds 2 4psi activates sending unit and oil light turns off 4 Cold oil pressure high oil pressure 5 Pressure regulator bleeds off excess oil to gearcase opens at 16 18psi 6 Regulator left out or stuck open lifter collapse and oil pressure drop 7 Oil through filter to center of filter 8 Oil through check valve a Opens at 4 6psi b Check valve creates backpressure activates sending unit faster c Arrow on valve indicates direction of flow d Should point towards adapter with o ring to the outside counter bore e If installed backwards it will damage the o ring and create unfiltered path for oil flow f Late 1987 has a new valve rubber ball spring and new fitting i Ball to change in material and size m 950 1 Some sticking shut 2 Also redesign of adapter g 1992 production change ball was changed again has a tail PN 33116 86A iv oil back to pump through large hose v through pump and into engine case and gearcase cover vi first to lower end 1 restrictor on pinion shaft reduces oil flow to rods 2 increases oil flow to top end vil path through gearcase cover and case sends oil to tappet blocks lifters pushrods and rocker arms viii all other areas are splash and drip Iron heads 80 oil to bottom end 20 to top end Evo engines 20 oil to bottom end 80 to top end ix oil returns though cylinder drain holes and pushrod tubes
28. feed Gear clearance inner and outer gear i Wear limit 0 004 ii Use shaft to center gears in body Seal lip numbers side toward feed side Oil pressure i Measure at the top plug in the case or the sending unit on the filter housing 1 Factory specs 1 7psi at idle and 5 30psi at 2500 rpm 2 If taken at the sending unit readings will be double Oil flow i Flows from oil tank to the pump cover ii Feed gear pressurizes oil through small hose to housing 1 Special hoses 2 different fitting sizes no sealant needed iii Oil filter adapter housing 1 Pressurized oil to adapter housing 2 Enters adapter through drilled holes and fills cavity 3 Builds 2 4psi activates sending unit and oil light turns off 4 Cold oil pressure high oil pressure 5 Pressure regulator bleeds off excess oil to gearcase opens at 16 18psi 6 Regulator left out or stuck open lifter collapse and oil pressure drop 7 Oil through filter to center of filter 8 Oil through check valve a Opens at 4 6psi b Check valve creates backpressure activates sending unit faster c Arrow on valve indicates direction of flow d Should point towards adapter with o ring to the outside counter bore e If installed backwards it will damage the o ring and create unfiltered path for oil flow f Late 1987 has a new valve rubber ball spring and new fitting i Ball to change in material and size m 950 1 Some sticking shut 2 Also redesign
29. flat 010 2 spring tension adjustment i back out adjuster plate bolts 1 2 to 1 turn at a time ii note position of bolts A B or C ili change position as necessary iv replace bolts 1 2 to 1 turn loctite 222 on bolts and torque to 6 5 8 ft lbs e adjust clutch screw Sspeed 1 turn in until it touches 2 back out 3 4 turn and tighten locknut f adjust clutch screw 4speed 1 turn to position clutch arm 13 16 from transmission top 2 tighten locknut g adjust cable to provide 1 8 to 3 16 cable freeplay between cable end and lever bracket F diaphragm spring installs convex out G adjuster plate provides three positions for spring attitude adjustment H pressure plate release plate is held in with a tapered snap ring installs with taper out I updates 1 mid92 parts and accesories change adjuster plate no longer provides 3 positions for spring adjustment suggest to use shims if necessary to space outward 13 Clutch plates A 6 driven plates 1 friction materials a STD 84 1 2 to 8 4 86 no asbestos heavy use could ruin b screaming eagle type 8 5 86 to 5 12 88 paper construction much better friction c sintered bronze type 5 13 88 to 89 production almost indestructable some slippage with heavy use 2 service minimum thickness 078 max warpage 011 3 never wipe with rags or dip in solvent 4 always oil new plates before installation B 7 driven plates s
30. flywheel halves ii no retrofit except left side wheel from pre comonized to comonized must rebalance b oil restrictor in the pinion shaft c no rear cylinder advance mark d balance factors used to balance at speed higher balance at higher RPM lower lower RPM balance i 1340 60 ii 1100 69 blue iii 883 62 yellow iv 1200 62 white v after 1989 all 883 flywheels are colored green and all 1200 s are red e 1991 and later there s a timing mark on right side flywheel Connecting rods a Dog legged 1982 and later ALL Evos b Wrist pin clearance is 2 times that of a B T helps prevent seizure c Bearings i Early 1986 were loose rollers with flat thrust washers ii Late 1986 through current use F A G bearings started on day 095 d For the first 2 months no thrust washers were used added late May i Stepped for clearance wider cage e Service just like the B T bearings i 1 bearing size 3 sizes of crank pin Sprocket Shaft a 5 speed shaft is 0 750 longer than 4 speed i Rotor and stator moved to sprocket shaft from clutch shell ii Rotor pressed and screwed to socket 48 Pinion shaft and race 49 50 lt ri a b c 1986 only unitized caged bearing pressed into case i Race pressed onto shaft 1 185 1 195 from flywheel race ii Grind to size 1 2485 1 249 16rms finish 1987 current uses F A G bearing i 3 pieces 1 outer race pressed into ca
31. hining the case for clearance 20 Kicker cover A spring and shaft align tab at 5 o clock position B kicker gear dowel align at 7 o clock position 1 when together in the case the dowel and the tab are aligned 21 Starter clutch and outer gear has rectangular keyway A starter clutch gear 2 ratios 1 early 14T discontinued 2 late 16T more leverage 22 Shifter forks A shaft e clip always replace B steel all gears 36 p n counter and main are different C fork blocks 1 36 E 76 rounded 1 notch 2 L 76 E 79 square 1 notch 3 L 79 85 square 2 notches D nuts face towards each other torque to 12 ft lbs E nut locks bend only once 23 24 shims adjust forks gear spacing shims go between fork and block only shift finger rollers top hats 1 long drum roller 2 short plate shifter and the XL 3 always replace Qm Countershaft hand out page 3 14 A 36 77 threaded 1 grove 77 79 threaded 2 grooves 80 83 notched B max bend 003 runout max wear 001 C Ist gera free wheeler largest OD half speed bushing max clearance 004 total 1 thrust washer next on shaft D Ist and 2nd gear shifter clutch new mounts in either direction max backlash 010 E 2nd gear free wheeler second largest OD half speed bushing max clearance 004 total F countershaft cluster 3rd and 4th gear most expensive speedo drive in between 3
32. ill current iv XLrocker arms and shafts are the same as the B T 29 Rocker arm play is 0 003 to 0 013 between rocker arm and rocker box endplay 30 Bolts are hardened and CANNOT be replaced or mixed with unhardened bolts 31 Rocker shaft to Rocker box clearance for all XL s is 0 0007 to 0 0022 ID to OD clearance 32 9 16ths 18 tap is used to push out rocker arm bushings from the opposite side then press in new bushings 33 Pushrod tubes a 1986 1990 i multipiece tube ii both top and bottom seal against an o ring 34 Cylinder Head a Early 883 egg shaped chamber and sand cast b Late 883 round hemispherical shaped chamber die cast c 1986 to early 1987 1100 egg shaped chamber sand cast d Late 1987 1100 and all 1200 round hemispherical shaped chamber die cast e Late 1100 heads were milled 0 040 i That milling did not continue on the 1200 Torque pattern gt gt gt Front cylinder 1 3 1 8 turn at a time Torque to 7ft lb then 14ft Ib Rear cylinder Then turn 4 turn 90degrees 35 Early head bolts have large spacers later ones have a flange built onto the stud changed 90 91 a Lightly oil bolt after cleaning used as anti seize 36 Rocker arm bolts longer bolt is on the pushrod side 37 Valves a 883 has the smallest b 1100 from 1986 to early 1987 were the same as the B T 1340 valves c 1100 in late 1987 decreased diameter of valves i Late 87 1100 and al
33. just at the tightest spot Measure chain alignment With axle alignment tool measure swing arm pivot to axle distance With alignment tool attached to chain at rear sprocket check alignment of chain gauge E By sighting chain for alignment between sprockets chain deflection is checked at bottom strand F Fasteners 1 torque axle nut and replace cotter pin 2 snug axle adjuster screw and locknut 3 readjust brake on mechanical brake models Rear chain R amp R Loosen rear axle nut and chain adjuster Bump wheel assembly towards the front Remove the old master link Attach the new chain with old master link Pull old chain to feed new chain on to sprockets Insure new chain is correct length 1 correct new length should put axle almost all the way forward 2 chain can be shortened 2 links at a time with a chain breaker a grind staked ends of pins off appropriate links with a grinder b use chain breaker to push pins out G Install new masterlink squeeze side plates over pins using vice grips and a small nut install safety clip so closed end points toward direction of travel VOW gt ano Oe gt BRAKE SYSTEM l Inspections A Master cylinder and linkage damage or leakage failure to return fully when released or sponginess when applying pressure B Perform a stationary test squeeze lever or depress pedal as hard as possible to make sure the system will not leak or fail make sure system releases and wheel turns freely C
34. l 1200 valves are the same size ii The change resulted in better mid range d XL s have longer valve stems than B T e There are no service values available 38 Cylinders a Different castings between the 3 different motors i 883 1100 and 1200 stamped into bottom right corner of cylinder ii cylinders are all the same length and use the same sleeve iii sleeve is just bored out more for the larger displacement 1 stock bore a 883 3 00 b 1100 3 35 c 1200 3 50 d 883 can be bored out to 1200 39 pistons 40 41 42 43 ma wm wm wm a Karl Schmidt German b 1986 to early 1989 no offset on piston for 883 and 1100 install either direction c late 1989 to present 883 and 1200 pistons have offset with the arrow on piston crown facing forward d As of October 1994 883 pistons are coated with Teflon for break in Piston pin a 883 is shorter than 1100 or 1200 diameter is the same b 1200 same 1340 but are NOT interchangeable c 1200 have either 12 or a V grove stamped on the edge Tappets a XLsame as B T b No restrictor on Early 1986 c Ristrictor added Late 1986 1990 i Reduces oil to the top end ii Helps keep lifter filled at highway speeds hydraulic lifters as opposed to solid d Tappet working ranges Tappet block 4 speed a To remove from case turn tappet block and lift from case b Tappet to block fit i 0 0008 to 0 0023 ii 0 003
35. ld read OL check both leads Ac voltage output checks checks the rotor 1 set meter to vac and place leads pin to pin 2 run bike at idle and read meter 3 run bike at 2000 RPM and read meter reading should be double 4 run bike at 3000 RPM and read meter reading should be triple idle 20 vac 2000 rpm 40 vac 3000 rpm 60 vac Current draw 1 set meter with red lead in 10 amp position 2 turn on ignition high beam passing lamp etc except brake light read meter if under 7 amps turn on brake light 3 check total loads against total amps in charging system 4 must have a minimum of 305 amps returning after loads to maintain battery Regulator 1 ground from shiny edge of fin to to ground should read OL 2 system draw key off 10A scale should read zero 3 disconnect regulator lead at circuit breaker so system drain test again minimal amount of drain ok 4 regulator bleed check each pin should be zero WHEEL R amp R 1 wa Key points Tmo OW D gt Do not disconnect chain Remove chain or belt guard Don t remove caliper assembly compress piston by hand and tie up out of the Don t loosen chain or belt adjusters Remove axle slide wheel forward and remove air from tire Remove chain or belt from rear sprocket and remove rear wheel G On reinstallation be sure brake pads are aligned properly before inserting brake disc H Recheck adjusters and adjust if necesary chain or
36. m lift than hydraulic lifters M Breather gear 1 66 E77 steel straight tooth small nipple end 2 L77 E81 steel curved tooth large nipple end 3 L81 and up Zytel plastic curved tooth uses 6 slot window N Pinion and oil pump gear 1 pinion 58 E77 full tooth gear with straight profile L77 84 half tooth gear with curved profile color coded availability 2 inspection space rcollar should have end play a check oil pump drive gear installation install so iinner chamfer faces flywheels 3 oil pump drive gear 66 72 5 tooth 73 84 6 tooth 4 oil pump driven gear 66 72 25 tooth 5 1 ratio 73 84 24 tooth 4 1 ratio better can retro fit as a set O Gear case cover 1 66 69 peanut style 2 70 72 cone style one shot oil flow 3 73 84 cone style full flow oil flow P Torque pattern for cam cover installation Q Cam timing 8 LOWER END A commonized and pre communized parts hand out page 2 16 commonized parts L81 and later service bulletin M829A 1 reason for change more economical to manufacture and better fit at taper commonized pre commonized pinion shaft 90 degree to keyway 135 degrees right side flywheel crankpin rear cyl advance lazy 8 no lazy 8 B Changes to crankpin after commonized 1 L81 L82 140 center oil hole 2 L82 84 090 center oil hole 3 84 and up large offset oil hole
37. models except 1100 or 1200 mainshaft 4th gear clutch gear 1 needle bearing 2 running 1986 thrust washer it has a loose fit a oil slots to the outside don t use 3 1987 ratio change a E 17T b L 18T ID by groove in teeth c taller 1st through 3rd Mainshaft 1 003 max bend 2 check with freewheeling gears and V blocks 6 Countershaft A B lst gear smallest diameter gear 1 needle bearings Countershaft 2nd and 3rd gears 1 same ratio since 1957 2 M 906 gear diameter reduced running 1986 a must be used on 1100 b early or late style ok on 883 Countershaft 4th gear 1 step towards door thrust washer 2 1987 ratio change a E 27T b L 26T grove on face of gear 3 flip KM transmission plate over a measure from end of splines to slider b use chart in manual to determine washer size End play 1 mainshaft 006 020 no preload 2 countershaft 004 015 use spoke to pull on shaft 3 proceedure a install without washers b measure end play and write it down c use charts in manual to determine washer size d reassemble and double check door bolt torque 14 ft lbs GENERAL 66 69 generator bottom end 70 84 AC generator cone motor magnet spins around windings Installation of engine right side A rock motor corner to corner to check fit B torque down rear motor mount C check front mount and frame for clearance shim
38. not continue on the 1200 Torque pattern gt gt gt Front cylinder 1 3 1 8 turn at a time Torque to 7ft lb then 14ft Ib Rear cylinder Then turn 4 turn 90degrees 10 Early head bolts have large spacers later ones have a flange built onto the stud changed 90 91 a Lightly oil bolt after cleaning used as anti seize 11 Rocker arm bolts longer bolt is on the pushrod side 12 Valves a 883 has the smallest b 1100 from 1986 to early 1987 were the same as the B T 1340 valves c 1100 in late 1987 decreased diameter of valves i Late 87 1100 and all 1200 valves are the same size ii The change resulted in better mid range d XL s have longer valve stems than B T e There are no service values available 13 Cylinders a Different castings between the 3 different motors i 883 1100 and 1200 stamped into bottom right corner of cylinder ii cylinders are all the same length and use the same sleeve iii sleeve is just bored out more for the larger displacement 1 stock bore a 883 3 00 b 1100 3 35 c 1200 3 50 d 883 can be bored out to 1200 14 pistons a Karl Schmidt German b 1986 to early 1989 no offset on piston for 883 and 1100 install either direction c late 1989 to present 883 and 1200 pistons have offset with the arrow on piston crown facing forward d As of October 1994 883 pistons are coated with Teflon for break in 15 Piston pin a 883 is shorter than
39. nt Torx screws it A 30 40 in lbs B loctite encapsulated on threads 3 Before removal measure transmission shaft end play 4 To remove access cover shock dowel pins or heat around dowel pins TRANSMISSION XL 4 SPEED General 4 Speed Direct drive 1 to 1 ratio in 4th gear Sliding gear Sprocket 21T Right hand threads 65 90 ft Ibs MOOW gt Check end play of main shaft and counter shaft before removing access door Gear spacing can be accomplished by changing shift forks and or spacer washers A Forks come in standard 005 010 or 020 sizes This changes spacing of individual sliding gears B Different thickness washers used to adjust spacing of gears on countershaft C Use go no go method of spacing in hand out Cam follower detent problems M 949 A L84 E87 Steel zinc B M87 L87 aluminum C L87 90 aluminum w counter bore Mainshaft A Ist gear largest dia gear 1 M 934 recall 061 a 87 28T gear some break switched back to 52A gear 27T 2 Radius on all Ist gears to case for lubrication a press off on with the bearing races mainshaft 2nd and 3rd gears 1 same ratio since 57 2 3rd gear end play reduced by thicker washer running change 1986 a will retro fit to 1957 3 M 906 late gears smaller diameter a must be used on all 1100 s b early or late model ok on 883 c prevents root contact caused by 1100 shaft flexing d OK to mix early or late style on all xl
40. o upper level Charge battery at 1 10 amp hour rating until fully charged full charge is 70 1 280 specific gravity 4 Battery type A 19 amp black with yellow caps 5 B 22 amp white with green caps C 32 amp black with green caps Battery data A Conventional charge a minimum of 6 hours max temperature of 113 degrees F B Low maintenance charge a minimum of 12 hours C Check specific gravity of a battery after it has charged let sit for a couple of hours before checking 6 Battery charger type A Taper rate charger 2 4 6 8 ratings use 2 amp charge after first hour it should indicate 1 2 amp charge B Christie fixed rate charger good for bringing a dead battery back to life 7 Servicing a used battery A Visual inspection case and terminals B Inspect battery carrier C Check for sulphation and sediment flaking D Connect battery tight clean connections 2 finger method use dialectric grease or petroleum jelly on terminals 1 loose connections cause voltage spikes that damage electrical components 8 Battery testing A Check specific gravity with a hygrometer full charge is1 270 1 280 at 80 degrees 1 for every 10 degrees hotter add 004 points 2 for every 10 degrees cooler subtract 004 points 3 max cell variance is 050 points B Load testing wear safety glasses 1 formula 1 2 the cold cranking amps 2 minimum voltage at end of testing is 9 6 volts 3 don t test with a specific gravity of
41. of adapter g 1992 production change ball was changed again has a tail PN 33116 86A iv oil back to pump through large hose v through pump and into engine case and gearcase cover vi first to lower end 1 restrictor on pinion shaft reduces oil flow to rods 2 increases oil flow to top end vil path through gearcase cover and case sends oil to tappet blocks lifters pushrods and rocker arms viii all other areas are splash and drip Iron heads 80 oil to bottom end 20 to top end Evo engines 20 oil to bottom end 80 to top end ix oil returns though cylinder drain holes and pushrod tubes 1 oil collects in mini sump 2 oil collects in gearcase cover and drains into mini sump x 3 things control oil return 1 spinning of flywheel and case scraper 2 downward action of the piston creating pressure in the case 3 suction of oil pump return gears Harley Davidson Tech 1 26 Intro Dates a 883 started in early 1986 to present b 1100 started in late 1986 to late 1987 c 1200 started in early 1988 to present Case breather sportsters from 1986 1990 Iron sportsters from 1957 1985 27 Compression Ratio a 9 1 on ALL models 28 Rocker covers a Big Twins B T and Sportsters XL can be interchanged as a set i Top end breather covers must be used on top end breather motors ii Print o seal gasket and inner cork or rubber chimney are the same for B T and XL iii All rubber gaskets from late 1989 t
42. oles align on negative pressure to draw oil from bottom of the trap e hole in breather valve at 9 o clock position is for primary oil return and should create a minimum of 25 water vacuum in the primary at 1500 RPM with vent line pinched dry clutch model 3 crankcase vent fitting located above oil pump connects to oil tank to prevent excessive pressure or vacuum 4 crankcase breather fitting lowest fitting on back of case connected to air cleaner to reroute vapors through the engine 5 evacuator system used on E81 E82 models hose connected pushrod tube area to cylinders system did not work causing oil consumption carbon deposits and pushrod tube leaks 6 typical breather and return system problems cause oil carryover a return restriction b over filled oil tank c leaking check valve d damaged breather valve or case e seperator hole plugged f breather trap gasket leaking E Return system 1 oil drains to bottom of gearcase 2 thick gears return pick up oil 3 oil returns to tank through fitting next to F fitting at top of pump 4 oil may also flow through filter and cooler before returning to tank F Updates 1 L82 engine oil changes reduce top end fitting to 090 do this to all shovels 2 drill the 2 holes through in the tappet guide 3 oil pump return hand out page 3 9 4 lip side of seal towards feed gears 10 Dry clutch A 30 84 1 2 dry multiplate with chain drive prim
43. rd and 4th gear G case race heat case to press in 1 threaded 1 groove shaft shouldered race on kicker side no shoulder on other race use loose roller bearings 2 threaded 2 groove shaft is 005 smaller in OD need different bushings used with caged bearings 3 notched shaft same as 2 groove Mainshaft A different lenght shafts pushrods also 1 36 64 short kickstart 2 65 69 long electric start 3 70 E 80 longer AC generator 4 L 80 E 84 same length different diameter 5 L 84 85 longest wet clutch B max bend 003 max wear 001 C Ist and 2nd gear fixed pressed on FL early FX and late FX D 3rd gear free wheeler bearing offset causes a little whine steel on steel always replace clip E 3rd amd 4th gear clutch marked high on one side for correct installation dog ramps should angle to point towards rear max backlash 010 F 4th main drive gear free wheeler bushing clearance 004 good 001 002 1 installation of bushing requires a special tool and the direction is important spiral or closed groove end installs toward the seal leave enough room for the seal 1 4 5 16 hone or ream to size 2 endplay L 77 81 0025 0135 M 77 and earlier and 82 85 010 025 25 Drive gear area leaks A B to locate use solvent or kerosene in transmission areas 1 seal to case 2 seal to spacer polish spa
44. rust washers were used added late May i Stepped for clearance wider cage Service just like the B T bearings i 1 bearing size 3 sizes of crank pin Sprocket Shaft a 5 speed shaft is 0 750 longer than 4 speed i Rotor and stator moved to sprocket shaft from clutch shell ii Rotor pressed and screwed to socket Pinion shaft and race a b c 1986 only unitized caged bearing pressed into case i Race pressed onto shaft 1 185 1 195 from flywheel race ii Grind to size 1 2485 1 249 16rms finish 1987 current uses F A G bearing i 3 pieces 1 outer race pressed into case 2 inner race pressed onto shaft 3 separate bearings ii 4 sizes of bearing ili races press to different depths see service manual 1988 to current pinion shaft i Pinion shaft is straight no splines ii Pinion gear is light press fit and keyed to shaft 1 Reduces gear runout better cam fit iii New pinion gear iv Nut has NO locktab so use locktite and torque to specs Breather system 4 speed a b Same as alternator iron XL engine i Plastic baffle ii Umbrella valve Small hole under the valve to relieve oil buildup at breather i Hole must be open or air cleaner will get oil Oil pump 4 speed a b c d e f 2 Operation is the same as 77 pump Feed gear height 0 001 0 011 above pump cover Feed gears were enlarged to supply lifters i Return gears are still larger than
45. s D remove fasteners Clutch release A powdered metal B M 923 late model parts 1 angle of ramp and coupler changed helps prevent breakage caused by misalignment C retro fits as set to 84 1 2 Motor sprocket and chain same since 57 A torque to 150 160 ft lbs use Loctite 242 B use lock link tool to hold sprocket Motor sprocket nut A it was first a grade 2 hex nut B than a grade 5 hex nut C now a grade 8 nut with a flange D torque to 150 165ft lbs Use Loctite 262 Source of oil leaks at primary gasket surface shift shaft seal to cover foot peg shaft starter motor clutch cable screw adjuster mi Ow gt CLUTCH XL 4 SPEED General A snap ring assembly B can be removed piece by piece or as a complete assembly C use a clutch spring compressor for disassembly Clutch spring A diaphragm same strength as old double coil B special washers round edge to spring Clutch A fiber friction drive 1 010 max warpage 2 130 minimum thickness 3 when installing new soak in oil for at least 5 minutes B steel driven 1 010 max warpage 2 060 minimum thickness 3 stamped steel smooth rounded edge faces out Spring plate A check for loose rivets B measure for variance max of 020 Rotor A part of clutch shell assembly magnets are fragile 6 Clutch hub bearing A beefed up L86 reduces looseness ACCESS DOOR XL 4 SPEED Stator mou
46. se 2 inner race pressed onto shaft 3 separate bearings ii 4 sizes of bearing iii races press to different depths see service manual 1988 to current pinion shaft i Pinion shaft is straight no splines ii Pinion gear is light press fit and keyed to shaft 1 Reduces gear runout better cam fit iii New pinion gear iv Nut has NO locktab so use locktite and torque to specs Breather system 4 speed a b Same as alternator iron XL engine i Plastic baffle ii Umbrella valve Small hole under the valve to relieve oil buildup at breather i Hole must be open or air cleaner will get oil Oil pump 4 speed a b c d e f 2 Operation is the same as 77 pump Feed gear height 0 001 0 011 above pump cover Feed gears were enlarged to supply lifters i Return gears are still larger than feed Gear clearance inner and outer gear i Wear limit 0 004 ii Use shaft to center gears in body Seal lip numbers side toward feed side Oil pressure i Measure at the top plug in the case or the sending unit on the filter housing 1 Factory specs 1 7psi at idle and 5 30psi at 2500 rpm 2 If taken at the sending unit readings will be double Oil flow i Flows from oil tank to the pump cover ii Feed gear pressurizes oil through small hose to housing 1 Special hoses 2 different fitting sizes no sealant needed iii Oil filter adapter housing 1 Pressurized oil to adapter housing 2 Enters a
47. se fitting 2 H D high temperature grease p n 99862 72 A Points cam 3 Anti seize some brake caliper pins axles front brake lever pins throttle sleaves 4 Triflo Lubit 8 Tufoil teflon lubricant p n 94968 85TB cables bracket and lever pivot points shift linkage clutch lever locks and hinges and fuel valves IGNITION SYSTEMS 1 Battery point ignition BPI A Spark plug condition 1 broken porcelain detonation 2 shiny black coating oil burning 3 dry black coating rich condition 4 yellow deposits deposits burned to insulator B Coil wires 1 plug wire a visual inspection of insulation for cracking b terminal for looseness or corrosion c trouble shoot for bad wire using water mist wire will arc to ground 2 primary wire a terminals loose at coil b bad connection of wire to terminal 3 Ignition coil a inspect for cracks at mounting area b plug wire terminals and primary wire posts C Points Condenser 1 inspect contact points replace if pitted across more than 1 3 of surface replace if any damage is noted or if rubbing block is worn 2 always replace condenser when replacing points 3 advancer mechanism typical high wear areas springs pins shafts and weights typical damage area small locating pin at cam pin 2 Maintenance A Spark plug gaping B C 1 bend side electrode to adjust 2 do not use automotive style adjuster use wire gauge 3 adjust gap to 028 032
48. service wear iii there are no stock oversizes available c new o rings are made from silicone rubber and will swell when exposed to oil d oil leaks i tappet block to case oil will be grungy ii small o ring to case oil will be dirt free possible that the counterbore is to deep in the case should be 0 050 0 060 iii shim up with a small washer iv use Hylomar to seal e Torque to 15 18 ft lbs Gearcase cover a Bolt torque patterns given in Tech Tips 25 b 2 dowel pins are for centering cover c computerized sizes for gear fitment i quadrex room temp of 68 degrees ii measures center to center of bushings down to 0 00000 hundred thousandths iii prints sheet telling what cams to use iv production covers have no markings but information is on file at HD v P amp A covers are color coded for correct cam selection 1 PN 25488 86 cover with cams and pinion gear T cams 2 Cover only retrofits all alternator covers 84 1 2 44 45 46 47 wm wm ww d Service of gearcase area i Replace cover order cover and cams as a set ii Replace bushings 1 Must line ream Cams a 1986 1987 T cams i same cam in 883 and 1100 ii dogbone installed with the chamfer facing cam out b 1988 1990 C cams i same cam used in 883 and 1200 ii reduced emissions iii dogbone installed with chamfer facing cam out flywheels a 3 piece flywheels i 1 piece
49. stage II VOES 7 wire system voilet wire to VOES C V O ES 1 grounded advanced high pressure 2 ungrounded retarded low pressure mode throttle position load voes violet wire advance economy 1 8 1 4 high closed on grounded retard power 1 2 wide open low open off ungrounded D Magnavox rotors silver 80 83 stage I gold 83 and up stage II E Rotor cup 1 window closed sensor ground 0 VDC at green wire 2 window open sensor not grounded power supplied to red wire up to 4 5 5 5 VDC 90 and up 1OVDC 3 rotor spins at half engine speed F Ignition coils collapsing field 1 63 79 points coil low output 17 KV 2 80 83 electronis coil higher output 22 KV 3 84 and up mailbox style 28 KV 4 screamin eagle 39 KV 5 check for voltage at input and output of coil a primary must be 9 6 vdc minimum G Rev limiters 1 X1 models 5400 RPM 2 big twin 5200 RPM 3 screamin eagle 8000 RPM CHARGING SYSTEM 1 Components A B C D Battery Stator Rotor Regulator Quick test of charging system A B Use meter across batteryon bike not running check VDC Recheck with bike running voltage should increase 13 5 15 vdc this is not conclusive Stator coil of wire Jaw To check stator disconnect regulator set meter to ohms and check lead to lead Should have resistance check manual for specs Check for grounds lead on stator to ground shou
50. teels 1 84A plates may not fit over 84 hub 2 service minimum thickness 044 max warpage 011 install with rounded side out all plates should slide freely over the hub 14 Clutch shell A ring gear and sprocket are shrink fit same slippage of ring gear noted on early productions B do not pry on shell fingers breakage 15 Clutch hub A pressed into hub bearing which is pressed into shell with clips for retention B installing and removing hub ruins bearing C hub nut must be torqued over tightening cracks taper area torque to 50 60 ft lbs use loctite 242 D check key height 119 max E clean taper with contact cleaner 16 17 18 F updates 1 84A hub some problems noted in 91 and 92 a runs eccentric to shaft b not fully machined c splines to large for 84A steel plates 2 clutch problems a misadjustment b wrong lubricant c low level lubricant d customers driving habits Transmission transmission top is removable in frame must move oil tank A 4 speed constant mesh sliding gear direct drive 1 to 1 ratio in 4th gear B history 1 36 Ist year of manufacture 52 E79 drum type shifter ratchet top L 79 85 flat plate shifter C lubricant H D Transmission Lube not sport transmission lube semi synthetic gear lube 1 good alternative 84 140 hypoid gear oil 2 quantity 24 ounces 3 4 quart 3 level indicator motorcycle must be upright and level
51. ter connecting rods b 53 and 55 pistons have higher wrist pin location for use with longer rods 36 and 41A 4 piston clearance 001 002 with a max of 006 5 Mahle pistons L83 84 a German made b very hard 12 silicone content c approximately 100 grams lighter than Bohnalite d wire type pin clip use special Kent Moore tool to install gap at 12 00 e wrist pin offset closer to rear of piston 1 arrow faces forward 2 lug under skirt to left 3 pin closer to rear 6 Mahle piston shape a diamond turned process barrel faced b can retro fit to all 1340cc shovel head engines c things in common with the EVO rings pins clips nly difference is shovel pistons are domed Evo are flat top 7 rings a 3 piece oil control 1340cc Dec 78 and later 1200cc Jan 79 and later b 3 piece oil control set features 1 top ring barrel face 2 2nd ring reverse twist taper face scrapes on the way down twists and hydroplanes on the way up 3 bottom ring 3 piece rails top and bottom expander in the middle less cylinder wall tension than 1 piece ring faster break in i L78 and earlier engines use 1 piece cast iron oil control ring and 2 chrome plated compression rings 4 3 piece set will retro to earlier pistons H Tappet guides 1 4 variations a 66 76 1 2 1 small drain hole countersunk screw holes b 76 1 2 E81 small drain hole straight screw holes c L8
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