15466566-HDSMSMR11XXX-Harley Davidson Sportster Models Service Manual Repair 1979-1985 XLCH XLH

l!!!!;;;~~ Harley-Davidson. Inc.
SERVICE MANUAL
XL/XR Models 1000cc 4-Speed
1979 to 1985 Part No. 99484·85
FOREWORD
This service and repair manual has 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, It
will Introduce to the professional Harley-Davidson mechanic the lalest field-tested and factory-approved major repair
methods. We sincerely believe thai this manual will make your associat ion with Harley-Davidson products more plea-
sant and profitable.
HOW TO USE SERVICE BULLETINS

YOUR SERVICE MANUAL
In addition to the information given in this Service
Your Service Manual Is arranged for quick, easy
Manual , Service Bulletins are issued to Harley-Davidson
reference. This manual Is divided Into numbered sec-
Dealers from time to time, which cover interim engineer-
tions. Sections are then divided Into subjects. Use this
ing changes and supplementary information. Service
manual as fol lows:
Bulletins shou ld be consulted for complete information
1. Check the TABLE OF CONTENTS located in the on the models covered by this manual.
Iront 01 each section to lind subject desired.
2. Page number Is listed across I rom subject. Page USE GENUINE ·

number consists 01 section number and page REPLACEMENT PARTS
number.
WARNING
3. Information Is presented In a definite order as
follows:
When replacement parts are requi red, use only genuine
Troubleshooting Harley-Davidson part s or parts with equi valent
Adjustments characteristics Includi ng type, strength and material.
Removal Failure to do so may result in product malfunction and
Disassembly possible Injury to the operator and/or passenger.
Cleaning, Inspection and Repair
Assembly To ensure a satisfactory and lasting repair job, follow
Installation the manual instructions carefully and use only genuine
In figure legends, the number following a name 01 a part Harley·Davidson replacement parts. Behind the emblem
indicates the quantity necessary lor one complete bearing the words GENUINE HARLEY-DAVIDSON is
assembly. more than three·quarters of a century of deSigning,
research, manufacturing, testing and inspecting ex·
NOTE perience.
All Information for servicing a part should be read This is your insurance that the parts you are using wilt
before repaIr work Is started to avoid needless lit right, operate properly and last longer. When you use
disassem bly. genuine Harley-Davidson parts, you use the best.
PRODUCT REFERENCES
PREPARATION FOR SERVICE When reference Is made In this manual to a specific
Proper preparation is very Important for efficient service brand name product, tool or Instrument, an equivalent
work. A clean work area at the start of each jOb will product, tool or instrument may be used in place of the
allow you to perform the repair as easily and quickly as one mentioned.
possible, and reduce the Incidence of misplaced tools
and parts. A motorcycle that is excessively dirty should All tools mentioned In this SERVICE MANUAL with HD
or J preceding the part number must be ordered
be cleaned before work starts. Cleaning will occasional·
Iy uncover trouble sources. Tools, Instruments and through:
parts needed for the jOb should be gathered before work
Is started. Interrupting a Job to locate tools or parts is a Kent-Moore Tool Division
needless delay. Special tools required for a job are 29874 Little Mack
listed at the end of SECTION ONE. Roseville, Michigan 48066
WARNING Loctite Products

Gasoline Is extremely flammable and highly explosive Some procedures in this manual call for the use of Loc·
under certain conditions. Always stop engine, and do tite products. If you have any questions regarding the
not smoke or allow open flame or sparks when refueling correct use of the lOctlte products or where to obtain
or servicing the fuel system. them, please call loctlte Corp. at '·203·246·1223.
L
WARNING CAUTION
Follow the directions listed on all loctite products. Means there is the possibility of damage to the vehicle.
Read all labels, warnings and cautions carefully before
using. We recommend you take special notice of these ilems.
WARNING
CONTENTS Proper service and repair is important for the safe,

reliable operation 01 all mechanical products. The ser·
All photographs and illustrations may not necessarily vice procedures recommended and described in this
depict the most current model or component, but are Service Manual are effective methods for performing
based on the latest production information available at service operations. Some of these service operations reo
the time of publication, quire the use of tools specially designed lor the pur-
pose. These special tools should be used when and as
Since product improvement is our continual goal, recommended.
Harley-Davidson Motor Co., Inc., reserves the right to
change speci fications, equipmen t, or designs at any It is Important to note that some warnings against the
time without notice and without incurring obligation. use of speclfic service methods which could damage
the motorcycle or render it unsafe are stated in this Ser·
vice Manual. However, please remember that these
warnings are not all inclusive. Since Harley·Davidson
WARNINGS AND CAUTIONS could not possibly know, evaluate and advise the ser-
vice trade of all possible ways in which service might be
Statements in this manual preceded by the words done or of the possible hazardous consequences of
WARNING or CAUTION and printed in bold face are very each way, we have not undertaken any such broad
important. evaluation. Accordingly, anyone who uses a service pro-
cedure or tool which is not recommended by Harley·
WARNING Davidson must first thoroughly satisfy himself that
neither his nor the operator's safety will be jeopardized
Means there is the possibility of personal injury to your· by the service methods selected.
self or others.
Harley-Davidson products are manufactured under one or more of the following patents: U.S. Patents - 2986162,
2987934,2998809,3116089,3144631,3144860, 3226994, 3229792, 3434887, 3559773, 3673359, 3709317, Des. 225 626.
II.
TABLE OF CONTENTS
SECTION 1 . PRODUCT Page No. Page No.
Service ........... 1·'

Servicing a New Motorcycle . . .......••.•. .. ,., Rear Brake Master Cylinder
Sprocket Cover and Brake LinkaQe
.... ,,2·32
........ 2-35
Safe Operating Maintenance. , .... ,. , ., Brake Pedal Adjustment . .... 2·37
Regular Service Intervals . . ........ '·2 DIsc Brake Calipers .. .2·38
Storage .. ..... '·19 Front Caliper Foam Tape InstaJiation . .. 2·40
Removal from Storage ...... 1-19 Front Brake Caliper (1984·1985) .. · .2-40
Fluid Requirements. ... 1-19 Rear Caliper (1982 - 1985) . . ..... 2-43
Metric Conversion Table ......... •• . ... '·21 Brake Discs ..
Torque Specifications. ....... ,·22 Bleeding the Hydraulic Brake Syslem .2·45
Stoplight Fran! Brake Switch. ...... 2·45
Stopligh t Rear Brake Switch. · .2·45
Troubleshooting . ... .. .... ..... .. ... '·23
Engine. . .......... 1·23
lubrication Service Front Forks . . ..... 2·47
Electrical System. .. ,. ' ·24 General ... 2·47
Carburetor. . '-24 Changing Fork 011 .... 2·47
Transmission .. 1-24 Fork Sides ... .2·47
Clutch .•.•.••...•...... 1-24 Fork Stem . . .... 2·50
Brake. .... . '·25
Handling. . ... 1-25
Rear Fork . . ..... 2·53
Disassembly. · ,2·53
Tools . .. '·27 Cleaning and Inspection. .2·54
Assembly. . ... 2·54
SECTION 2 . CHASSIS Rear Shock Absorber . · .2·55

Adjusting Spring .. · .2·55
Removal. · .2·55
Specifications . .2·' Disassembly. .... 2·55
Dimensions. . .... 2·' Cleaning and Inspection. . ..... 2·55
Weights. . ..... 2·' Assembly. ..2·55
Vehicle Weight Ratings . . .2-1
Capacities. .2-1
Adjustments. , .... ,.... . . .2-' Handlebar Controls and Instruments .. 2·57
Torques . ., .. , .. 2·1 Throttle Control - 1979·1980 . . ... 2-57
Brake Disc. . ..... 2·1 Throttle Control - 1981 and Later. .2·58
Tire Data . . ............. 2·2 Clutch Hand Control ..... 2·61
Vehicle Identification Number(V.I.N.). . .......... 2·2 Speedometer, Tachometer . . ...... 2-63
Tires. . .2·2 Handlebar Switch Assembly. . . ... 2·63
Wheels .... 2·5 Fenders .. . ...... 2·65

General .. . .... 2·5 Front Fender. ..... 2·65
Front Wheel ... , .2·6 Rear Fender · ,2·65
RearWheel . ......... 2·9
Lacing Wheels· 16 in ...........• . ..... 2·15
Lacing Wheels· 19 in. . ... , ....••. ....... 2-16 Specifications (XR·1000) . . .. 2·69
Truing Laced Wheel. ... 2-17 Dimensions (XR·1QOO) ...... 2-69
Checking Cast Rim Runout . .... 2-20 Weight(XR-l000). . ..... . . . ....... 2·69
Tires. ..... 2-20 Vehicle Weight Ratings (XR·l000). . .2·69
Capacities (XR·l000) .. 2·69
Adjustments (XR-l000). . .2·69
Brakes . .......• •• . • • , ... .... 2·25 Torques (XR-l000). . .. 2·69
General. ......... . 2·25 Brake Disc (XR·l000) .... 2·69
Troubleshooting. .......... 2·25 Tire Data(XR·l000) ....... .. . . . . .. .. .. . . ..... 2·69
Front Brake Master Cylinder. . .... 2·26
ill.
Page No. Page No.
Wheels (XR·l000) . . .. . .......... . .. . .. . .. 271 General ... . ....... . .... . .. .... .. . .. . ....... . 3·43
Front Wheels (XR·1000) ...... • . . . ••... . . .. 2·71 Checking Flywheel End Play. . . .... . .. .. 3·43
Rear Wheels (XR·1000) . . . . .. . .... . ..... . .. 2·71 Disassembly. . .. . .. 3·43
Flywheels . ... . .. . .. . .. . .... ... . . . . .. . .... .. . 3-44
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 3-52
Brakes (XR·l000) . . . . .. 2·73
Front Brake MasterCylinder(XR·1000) . .. . ....... 2·73
Front BrakeCaliper(XR·1000) .... . ........... . .. 2·74 Specifications (XR·l000) . .. .. . .. . 3·55
Handlebar Controls Engine (XR·l000) ....... . .. . .. . .. . .... . ... 3·57

and Instruments (XR·l000) . . . .U7 General Information (XR-l000) ............ . .. . .. 3·57
Throttle Control (XR·1000) . . ... . .. . ....... 2·77 Lubrication (XR-1000) ... . ....... . ........ . ..... 3·57
Clutch Hand Control (XR·1000) .. . .... . ..... . .. . . 2·77 Stripping Motorcycle for Engine Repair (XR·l000) . . 3·60
Cylinder Head (XR·l000) .. .. . .. . .... . .. .3·63

SECTION 3 - ENGINE Removing (XR·l000) . . ... 3-63
Disassembling (XR·l000j . . . . . 3·63
Replacing Rocker Arm Bearings (XR·l000) .... . ... 3-63
Specifications . .3·1 Replacing Valve Guides (XR-1000) ... . . . .. . ...... 3-63
Generallnformalion . . . . .. . .. . .. . .... . .. . .. . .. . . 3·5 Refacing Valve Seat (XR-l000) . . .. .. . 3-65
Description. . . . . . . . . . . . . . . ........ 3·5 Replacing Valve Guide Seals (XR·l000) .... . .. . ... 3-66
Gasoline .. . ....... . .. . ............. . ....... . . 3-5 Valve Seat Inserts (XR-l000) .. . ..... . .... . ..... . 3·66
Lubrication . . . ... . . . .. . ..... . .... . .. . . .. . . .... 3-5 Push Rods (XR-l000) . . 3·66
Repair Procedure. . .......... 3·10 Assembling Rocker Cover and Installing (XR·1000) .3·66
Stripping Motorcycle for Engine Repair . . . ..... . .. 3·11 Installing Cylinder Head (XR·l000) . . .. 3·67
Valve Clearance Adjustments (XR·l000) . . .. . 3·67
Cylinder Head . ........... . . . .. 3·15 Cylinder and Pistons (XR·l000) . . . 369

Removal. . ....... 3·15 Removing (XR·l000) . . .... 3·69
Disassembly . . . . 3-16 Fitting Cylinder to Piston (XR·l000) ..... . .... . .. . 3·69
Cleaning and Inspection. . .... 3·18 Fitting Piston Rings (XR-1000) .... . ..... . ....... . 3·70
Replacing Rocker Arm Bushings .... . .. 3·18 Assembling (XR·l000) .. ..... 3·70
Va lve Guides . . .... .. . .. . .... . .. 3-18
Replacing Valve Guide .... 3·19
Refacing Valve. . .... 3·20 Gearcase (XR·l000). .. 3·71
Refacing Valve Seat. . . . .. .... . .. 3·20 Valve Tappets and Guides (XR.l000) . .. . 3·71
Valve Seat Inserts. . ...... 3·21 Gearcase Cover and Cam Gears (XR·l000) ........ 3·71
Cylinder Head Assemb ly. . . . . . . . . . . . . . . • . . . 3·22 Replacing Needle Bearings and BUShings (XR-1000) 3·74
Cylinder Head Installation . . . ....... . .... . .. 3·22 Gearcase Assembly (XR-l000) . .. .. . . .. . ........ 3·75
Adjusting Tappets...... . ..... . .... . . .. .3·22
Push Rod Removal and Installation. . . .. . .... 3·23
Crankcase(XR·l000) ..... . ..... . .. . .. . .. 3·77
Fitting Rod Bearings (XR·1QOO) . . . . .... . .. .. . 3·77
Cylinder and Piston .. 3·25
Removal . . . . 3·25
Cleaning and Inspection. . . . .. . .. . .... 3·25
Refinishing Cylinder . ... . .. . . 3-25
SECTION 4 . FUEL SYSTEM
Fitting Piston Rings . . . . .... 3·27
Connecting Rod Bushing. . . .......... . .... 3-28
Assembling Cylinder and Piston. . .. .. . ... . 3-29
Specifications . . . ... 4·1
Jet Sizes ... . .. 4·1
Fuel Tank Capacity . . . 4·1
Gearcase . . . . .... 3·31 Torq ues ............ . .. . ... . . . ....... 4·1
Oil Pump. . . 3·31
Valve Tappets and Guides. . . . 3·35
Gearcase Cover and Cam Gears . . ..... . . 3-38 Carburetor . .. . .. . .... • .. .. . . 4·3
Oil Filter. .3-42 General .. . .. 4·3
Operat ion . . .. .. . . ....... .. .. 4·4
Adjustments . .. . . . .... . . . . .. . .. .• . . . . .. . 4·7
Crankcase . . .. 3·43 Removal. ... . .... • . . . . .. . 4·8
iv.
Page No. Page No.
Disassemb ly. . ... 4·8 Electric Starter System 1979-1980 ...... 5·'
Troubleshooting. .4·9 Specifications ...... 5·1
C!eaning, Inspection and Repair ........ 4·11 Description . 5,
Assembly 4·16 Troubleshootmg 5·'
Installat ion. .4·16 Starter Relay 5·'
Starter MOlor ... 5·2
Solenoid 5-5
Air Cleaner . 4·17 Starter Drive Shalt and Housing . . .. 5-7
Genera l . . .... . 4·17
Servicing Air Cleaner. 4·17
Removal 4·17 Electric Starter System 1981 -1985 · .5-9
Inspection and Repair ... 4·18 Description .... 5-9
Inslallatlon .. 4·18 Troubleshootmg. · .5·9
Operation 5-10
Starter Relay. . .. 5-12
Fuel Supply Valve · .4·19 Removal. . ........ ... 5·12
General .4-19 Testing Assembled Starter .. 5·12
Removal . .4-19 Disassembly, Inspection, Repair and Assembly .... 5·14
Cleaning, Inspection and Repair ........ 4·19 Installation. 5·16
Installation 4· 19
Electric Starter System (XR-l 000) ... .5.17

Fuel Tank . · .4·21 Removal (XR-1000) . . .... 5·17
Genera l ...... 4·21 Installation (XR·1000) . . .5·17
Removal . 4·2 1
Cleaning , Inspection and Repair . 4·21
Installation. 4·21
SECTION 6-
DRIVEITRANSMISSION
Carburetor (XR-t 000) ........ 4·25
General (XR-l000). 4·25
Operation (XR·1000) . . ....... 4·25 General Information . ..... . 6-\
Adjustments (XR-l000). 00 Description 6·'
Removal (XA·l000) . . ... 4·32
Disassembly (XR·1000). 4-32
Cleaning , Inspection and Repair (X R·l000) . 4-34 Specifications (1979 - Early 1984) .... 6-3
Assembly (XR·l000) . 4-34 Transmission .... 6·3
Installation (XR·l000). .... 4·35 Clutch . .... 6·3
Primary Chain ......... . . ....... . 6·3
RearChain .... 6·3
Air Cleaner (XR-tOOO) . ..... 4-37 Kick Starter. · .6-3
General (XR· l 000). . 4-37 Gear Box · .6-3
Servicing Air Cleaners (XR· l 000). ......... 4·37 Mainshalt Group 6-3
Installation (XR· 1000) . .......... 4·37 Counters haft Group _ .6-3
Torques. . ......... . . ..... 6-4
Service Wear limits. . 6·4
Fuel Supply Valve (XR-l000) . . ... 4·39
General (XA-l 000) . . ..... ... 4·39
Removal (XR-l000) . .4·39 Chains (1979 - Early 1984) . . .6-5
Cleaning , Inspection and Repair (XR·l000j ........ 4·39 Front Cham . . ...... 6·5
Installation (X R·1000j . . ........... 4-39 Rear Chain ........ _. . .6·6
Fuel Tank (XR-l000) ...... . .... .. 4-41 Clutch (1979 - Early 1984) . . ..... 6·9
General (XR·l000). · .4·41 General ................ 6·9
Removal (XA.1000j . ...... 4·41 Controls . . ...... 6·9
Repair(XR- l 000) ..... ...... .. _. . 4-41 Disassembly . .6-13
Ins tallation (XR· l 000j. ...... 4-41 Inspection and Repair. . ..... 6· 13
Assembly 6·14
SECTION 5 - ELECTRIC STARTER Transmission (1979 - Early 1984) ........ 6-17

y-
Page No. Page No.
General . . ..... 6·17 Ignition System 1979 . . . .. . . 7·3

Disassembly. ......... 6·1 7 Description. . . .......... 7-3
Inspecllon and Repair ...... 6·18 Operation .... .... ....................... 7-3
Assembly . . ......•....... 6-22 Troubleshooting . . ..................... 7·4
Lubrication. ........... . .... 6-25 Adjusting Sensor Air Gap .. ..... ..... . ....... 7-4
Checking Advance Timing with Strobe Timing Light. 7-5
Setting Retarded Timing with Circuit Tester. . . .. .. 7-5
Kick Starter· 1979 XLCH .......... ...... 6·27 Removing Ignition Timer Components. . ....... 7-6
General .... 6·27 Inspection and Replacing Parts .. .. . _. .......... . 7-7
Disassembly. . . .. 6·27 Assembling Ignition Timer Components. . . ... . . 7-7
InspeCtion and Repair. . ... 6·28
Assembly. . .. 6·28
Ignition System 1980·1982. . ..... 7·9
Description. . .... 7·9
Specifications (Late 1984 and 1985) .... 6·31 Troubleshooting. . ..... . ... ... .......... . 7·10
Transmission .. 6·31 Check Advance Timing w ith Strobe Timing Light ... 7·'1
Clutch. . . . 6·31 Sett ing Reta rd ed Timing . . .. . 7·"
Ma inshaftGroup .6-31 Remov ing Ignit ion Components. . .... .. 7· 11
Countershaft Group. . ... 6-31 In spection and Replacing Parts ..... . 7·12
Torques . · .6-31 Installing Ignition Components....... .. . . . ..7·12
Service Wear Limits. · .6·31
Chains (Late 1984 and 1985) ..... 6·33

Ignition System 1983·1985 . . .... 7·15
Description. . .7·15
Front Chain. · .6-33 Troubleshooting. . . .. . .. . .. .. ..... _.7·15
Rear Chain . · .6-33 Check Advance Timing with St robe Timing Light ... 7,17
Vacuum Operated Electric Switch (V.O. E.S.) ....... 7·17
Clutch (Late 1984 and 1985). . .. 6-35 Selling Retarded Timing. ..7·18
General. · .6-35 Ignition Component Removal. . 7·19
Troubleshooting. . .. 6-35 Inspection. . ...... ... . . .... 7·20
Clutch Release Mechanism 6-35 Ignition Component Installation. ..7·20
Clutch Removal · .6·37
Clutch Installation. ... . . ... . . ..... 6-37
Disassembly .. · .6-37 Ignition· Light Switch ....... ....... ..... .7·21
Inspection and Repair ..... •.... . .. 6-39
Assembly. .. . . . .. ...... . 6-39
Spark Plugs .. .. 7-23
General .. 7-23
Transmission (Late 1984 and 1985) . . .6·40 Inspect in g Spark Plugs .7·23
Access Cover Removal .6·41 Sett ing Spark Gap .. .... 7·23
Shifter Mechan ism Removal and Disassembly.. ..6-42 Installing Spark Plugs . . ....... . • . ..7·23
Mainsl1aft and Countersha/t . . .. ... ....... .. . 6-42 Cleaning Spark Plugs ... ........• . . . ...... 7·23
Cleaning, Inspection and Repa ir .......... . . .. . .. 6·42
Assembly. . .......... 6·43
Shifter Mechanism Assembly. . ............ 6-45 Ignition Coil . . .............. . .. 7·25
Countershalt and Mainshafl Assembly. . . 6·45 Description. .7-25
Establishing Proper Gear Spacing. . ....... . 6·46 Troubleshooting. .7·25
Gear Engagement ... .. .... ... 6·46 Replacing Spark Plug Cable. . ... .... . ... . .. 7·25
Establishing Mainshaft and Countershaft End Play.6·47
Installation. . ........... 6-48
Lu brication.. . ........... 6-48 Generator(1979· Early 1984) ........... . 7·27
General .. . .7·27
Generator Output Test ....... _.. _...... ..... . .. 7·27
Removal. . . _... 7·27
SECTION 7 • ELECTRICAL Disassembly. . .. ... 7·28
Generator Test. ......... . . .. ....• • . . ... .. 7·28
Cleaning, Inspection and Repa ir. . ............ 7·31
Specifications. .. .. . . . 7-1 Commutator Repa ir ...... . ....... .. .... .. . .. .. 7·31
Polarizing Generator. . .... . . 7·33
Ignition Timing. .. . .. . . .. . 7-1
Spark Plugs .......... . . ..... 7-1
General. .... . .. 7-' Regulator (1979· Early 1984).. . ... . .. 7·35
Bulb Chart. · .. 7-1 General . . .. . . .. . . ........... .... . 7·35
vi.
Page No. Page No.
Checking Charging System. .. 7·35 Ignition Timing (X A·l000) . . .......... . .. 7·51

Spark Plugs (XR.tOOO) .7·51
General (XR·1000) . . .... 7·51
Charging System (Late 1984 and 1985). '·39 Bulb Chart (XR·1000) .... 7·5t
Gene ra l . . .. . .. . 7·39
Troubles hooting . . ... 7·39
Replacing Regulator . ...... 7·43 Ignition System (XR·l000) . '·53
Description (XR. 1000). .7.53
Troubleshooting (XR.tOOOj 7·54
Battery . . .7·45 Check Advance Timing with Strobe Timing llghl
General. . ..... 7·45 (XR·l 00J). . ......... 7·55
Ballery Care. ...... . 7·45 Selling Retarded Tlmlflg (XA·1000j . .7·55
Testlflg Battery. ...... 7·45 Removing Ignit ion Components (XR·, OOOj. . 7·56
Charging Ba ttery . .. 7·46 Inspecting and Replacing Parts (XA· 1000) . .7·56
Servici ng . .. .... 7·46 Insta lli ng Ig nit ion Components (XR· l000) 7·56
Recla imi ng Su lpha ted Ba ttery 7·46
Ignition·Ught Switch (XR·l000) ........ . '·59

Lamps ... 7·47 Horn (XR·l000) . . ... . .. . .. '·59
Headlamp ..... 7·47
AdjuSting Bea m ....... 7·47
Spark Plugs (XR·l000) . '·59
. . 7·47 General (XR·10ooj. . . . .. 7·59
Bulbs.
..... 7·49 Installing Spark Plugs (XR·1000j. . .. . .. 7·59
Horn.
Specifications (XR·l000) ... . .. . . . 7·51 Wiring Diagrams
vii.
PRODUCT
I
SUBJECT PAGE NO.
1. Service ............. 1-1

2. Troubleshooting .......... . ... ••....•.•.. ....... 1-23
3. Tools. . ........ .. . . . .1-27
SERVICE
SERVICING A NEW MOTORCYCLE 11. Check fuel valve, lines and fittings for leaks.
12. Check oil lines for leaks.
WARNING 13. Lubricate rear chain if necessary.
14. Grease or oil all paints indicated for 2500 miles at·
For the rider's personal welfare, all the listed service tention in the REGULAR MAINTENANCE INTERVAL
and maintenance recommendations should be followed CHART.
because they may affect the safe operation of the 15. Check front fork bearing adjustment.
motorcycle. 16. Check tightness of all fasteners.
17. Check wheel spake tightness, if applicable.
Service operat ions to be performed before delivery to 18. Check tire pressure and inspect tread.
customer are specified in the Motorcycle Set-up 19. Inspect air cleaner and service as required .
Manual. 20. Check engine low and fast idle speed adjustment.
21 . Check throttle and chOke control adjustment.
The performance of new motorcycle initial service is re- 22. Check operation of all electrical equipment and
quired to keep warranty in force and to ensure proper switches.
emissions systems operation. 23. Check and adjust tappet clearance.
24. Road test.
After a new motorcycle has been driven its first 500
miles and again at approximately 2500 miles, a Harley-
Davidson dealer should perform the following initial ser- SAFE OPERATING MAINTENANCE
vice operations.
Good maintenance means a safe machine. A careful
check of certain equipment must be made after periods
Check at First 500 Miles of storage and frequently between the regular service
intervals to determine if additional main tenance is
1. Drain oil tank through drain plug, flush with necessary.
kerosene and refill with fresh oil.
2. Replace oil Ii Iter, if applicable. The following items should be checked :
3. Drain transmission through magnetic drain plug ,
clean plug, and refill with fresh oil. 1. Tires for correct pressure, abrasions or cuts.
4. Check and adjust chains. 2. Chain for proper tension and lubrication.
5. Check battery electrolyte level and add distilled 3. Brakes, steering and throttle for responsiveness.
water if necessary. 4. Brake fluid level and condition. Hydraulic lines and
6. Check rear brake pedal adjustment. fittings for leaks. Also, check brake pads and discs
7. Inspect brake fluid level and condition. Check hy. for wear.
drau lic brake lines and fittings for leaks. 5. Cables for fraying or crimping and free operation.
8. Inspect brake pad linings and brake discs for wear. 6. Engine oil and transmission flu id levels.
ft. Check clutch adjustment. 7. Wheel spoke tightness if applicable.
10. Clean fuel tank filter screen. 8. Headlig ht, taill ight and directional light operation.
,.,
REGULAR SERVICE INTERVALS
The followi ng chart outlines re commended Ma in-
tenance and Lubric at ion interva ls after perf orman ce o f
service on a new motorcycl e and th e init ial break-in
period. Refer to the followi ng figures when using the
ch art.
MILEAGE INTER VALS

SER VICE TO BE PER FORMED
Every First Every Every Every EYery Every
10,000 Spring or F.1l
300
'", ''''
,
5000
, ''''
, , ,
C::_~a"-ge engi~e~~
1- , , , , ,
RBEla!:, oil Iil t.e!
Check tappet ad justment
"--- ,
"--- ,
, , , -
Clean condition of spark plugs and replace ,/ necessary

~-
,
--- , ,
Re~ l ace spar~ plugs
--- , , , , , ,
Inspect alf cleane. and servIce as reqUired
, , , , ,
~heck an~ adl us~c~a'ns
, , , , -
,
Check ~ear ~rak_e p!'~al adjustment
, , , , ,
Inspect brake !luid level and condition
, , ~ ~-
,
-
,
Che<:k brake lIulI:l level and condition
Check brake .pad ~1 ~Jngs and discs 10. wear
, , ~ , , , -
, , , , ,
Check clutCh adjustment
, , , , ,
Check luel tank Ill1er screen
--
~heCk luel .al.~.ynes and "HI~gs lor leaks
, , , , ,
, , , -
, ,
Chec_~ .?,~~s and brake system f~r lea k~
, , , , , ,
Lubrica te the rear chain
- -~
, - -, - , , ,
Oil the front brake and clutch handlevers
, , , -
, ,
a,l the throttle. chOke and clu tch cables
, , , , ,
Grease the speedom~ter dme
, , , , , ,-
Check tightness of all l asteners
, , ~ -
, , , -"-----
Check wheel spoke tightness II applic able
, , , , , --
Check t"e pressure and Inspect tread
, , , ,
Check ~gnition timing
, , , -
, ,
Check engine low and la st idle speed adJus~~ent
, , , ,
Check operation ot throWe and choke controls
, "---
, , , ,
Check Operation 01 all electncal eq uipment and SWitCheS
, ~-~
, , ,
Change t ransmiSSion oil
, , , ,
---
Clean tr ansmi SSion magnetic dram plug
, , ,
Check battery e leclrolyte level: check and clean connections
, ,
Grease the throttle control grip s leeve
, ,
Grease the speedometer cable
, -
, ,
Check rear shock rubber bushing condition
- - - -- , , ,
Check front lork beanng ad justment
- - -- , ,
Repack wheel beanngs With grease
,
Repack rear lark beanngs With grease
, , ,
Change front fork 011
Road lesl , , , , , ---
Ol te Comple tl d:
'·2
''''''
11
1. Tail/stop lamp 5. Headlamp 9. Drive chain

2. Battery and oil tank cover 6. Ignition timer cover 10. Rear brake master cylinder
3. Carburetor air cleaner 7. Rear brake pedal 11. Rear shock absorber
4. Gasoline supply valve 8. Electric starter 12. Turn signal
Figure 1·1. Right Side View, 1979 Model XLH-1000
10
1. Tail/stop lamp 5. Ignilion coil 9. Drive chain

2. Battery and oil tank cover 6. Ignition timer cover 10. Rear shock absorber
3. Carburetor air cleaner 7. Rear brake pedal 11. Turn signal
4. Gasoline supply valve 8. Starter crank pedal 12. Rear brake master cylinder
Figure 1·2. Right Side View, 1979 Model XLCH·1000
1·3
"'"
'2 15 11 10 9 8 5
1. Gas cap 6. Regulator 10. Transmission olileni plug

2. Carburetor choke knob 7. Rear shock absorber 11. Gear shllter
3. Ignitlon.Ught switch 8. JUly stand 12. Generator
4. Horn 9. Transmission and Iront chain 13. Steering lock
5. Oil lank drain plug compartment oil tiller plug 14. Turn signal
15. Highway footrest
Figure 1·3. left Side View, 1979 Model XLS·l000
11
1. Tailfstop lamp 5. Gasoline supply valve 9. Orlve chain

2. Oil tank filler cap 6. Headl.mp 10. Rear brake master cylinder
3. Battery 7. Rear brake pedal 11. Rear shock absorber
4. Carburetor air cleaner 8. Electric .farte' motor 12. Turn signa'
Figure 1·4. Right Side View, 1980 Model XlH·l000
,-4
"'"
"
1. Gas cap 6. Regulator 10. Transmission 0111&1181 plug

2. Carburetor choke knob 7. Rear shock absorber 11 . Gear shifter
3. Ignition.llght switch 8. Jilly stand 1:2. Generator
4. Horn 9. Transmission and front chain 13. Steering lock
5. 011 tank drain plug compartment oil filler plug 14. Turn signal
15. Highway footrest
Figure 1·5. Left Side View, 1980 Model XlS·1000
""
11
1. Tall/stop lamp 5. Gasoline supply valve 9. Drive chain

2. 011 tank filler cap 6. Headlamp 10. Rear brake master cylinder
3. Battery 7. Rear brake pedal 11 . Rear shock absorber
4. Carburetor air cleaner 8. Electric starter motor 12. Turn Signal
13. Brake hand lever
Figure 1·6. Right Side View, 1981 Model XlH ·1000

!5!! 16
14
1. Gas cap 7. Rear shock absorber 12. Generator

2. Carburetor choke knob 8. Jiffy stand 13. Steering lock
3. Ignltion.light switch 9. Transmission and front chain 14. Turn signal
4. Horn compartment 011 filler plug 15. Highway footrest
5. Oil tank drain plug 10. Transmission oil level plug 16. Clutch handlever
6. Regulator 11 . Gear shifter
Figure 1·7. left Side View, 1981 Model XlS·1000
18!3
1. Tall/stop 'amp 5. Rear brake pedal 9. Rear shock absorber

2. 011 tank tiller cap 6. Electric starter motor 10. Turn signal
3. Carburetor air cleaner 7. Drive chain 11. Brake hand lever
4. Headlamp 8. Rear brake ma.ter cylinder 12. 011 drain plug
Figure 1·8. Right Side View, 1982 Model XlH
1·6
•
1. Gas cap 7. Jiffy stand 12. Steering lock

2. Carburetor choke knob 8. Transmission and front chain 13. Tum signal
3. Ignltlon·llght switch compartment 011 filler plug 14. Highway footrast
4. Horn 9. Transmission 011 level plug 15. Clutch handlev.(
5. Regulator 10. Gear shifter 16. Gasoline suply valve
6. Rear shock absorber 11. Generator 17. Battery
Figure 1·9. left Side View, 1982 Model XlS
""
1. Tall/stop light 5. Rear brake pedal 9. Rear shock absorber

2.011 lank tiller cap 6. Electric starter motor 10. Turn signal light
3. Carburetor/.lr cleaner 7. Drive chain 11. Front brake handlevef
4. H8adlamp 8. Rear brake master cylinder 12. Front brake master cylinder
Figura 1·10. Right Side View, 1983 Model XLH

2121
1. Gas cap 7. Transmission and primary chain 12. Highway footrest

2. Carburetor choke knob 011 filler plug 13. Clutch handlever
3. Ignition.tight switch 8. Transmission 011 level plug 14. Gasoline supply valve
4. Horn 9. Gear shifter 15. Battery
5. Regulator 10. Generator 16. 011 tank drain plug
6. Jiffy stand 11 . Steering lock
Figure 1·11 . left Side View, 1983 Model XlS
""
1. Tall/stop light 6. Electric starter motor 10. Turn signal light

2. 011 tank filler cap 7. Drive chain 11. Front brake handlever
3. CarburetorJalr cleaner 8. Rear brake master cylinder 12. Gasoline supply valve
4. Headlamp 9. Rear shock absorber 13. Front brake master cylinder
5. Rear brake pedal
Figure 1·12. Right Side View, 1983 Model XlX
'·8
1. Horn 7. Primary chain Inspection & 11 . Jiffy stand
2. Voltage regulator transmission 011 filler plug 12. 011 tank drain line
3. Generator 8. Transmission 011 level plug 13. Ignition module
4.011 filter 9. Clutch access plug 14. Battery
5. Timing Inspection hole plug 10. Transmission & chain case 15. Ignitlonllight switch
6. Shift lever drain plug 16. Choke knob
17. Clutch hand lever
Figure 1-13. XLH Left Side Vlew- Early 1984 Model
1. Headlamp 6. Carburetor air cleaner 11 . Rear chain adjuster

2. Front turn signal lamp 7.011 tank fill plug & dipstick 12. Rear brake master cylinder
3. Front brake master cylinder 8. Rear turn signal lamp 13. Electric starter motor
4. Front brake hand lever 9. Tail.lstop lamp 14. Rear brake pedal
5. Throttle control grip 10. Rear sprocket & drive chain 15. Steering lock
Figure 1·14. XLH Right Side Vlew- Early 1984 Model

'·9
""
1. Hom 7. Primary chain Inspection & 11 . Jiffy stand

2. Voltage regulator transmission all filler plug 12. 011 tank drain line
3. Generator 8. Transmission all level plug 13. {gnlllan module
4. Oil filter 9. Clutch access plug 14. Battery
5. Timing Inspecllon hole plug 10. Transmission & chain case 15. Ignlllonlllght switch
Figure 1·15. XlS Left Side Vlew- Early 1984 Model

2. Front turn signal lamp 7. 011 tank till plug & dipstick 12. Rear brake master cylinder
3. Front brake master cylinder 8. Rear tum signal lamp 13. Electric starter motor
4. Front brake hand lever 9. Tall/stop lamp 14. Rear brake pedal
Figure 1·16. XLS Right Side Vlew- Early 1984 Model

1·10
1. Horn 7. Primary chain Inspection & 11 . Jiffy stand
2. Voltage regulator transmission 011 filler plug 12. 011 tank drain line
3. Generator 8. Transmission 011 level plug 13. Ignition module
5. Timing inspection hole plug 10. Transmission Be chain case 15. Ignltlonllight switch
Figure 1-17. XLX Left Side V.lew, 1984 Model XLX
""
1. Headlamp 6. Carburetor air cleaner 11. Rear chain adjuster

2. Front turn signal lamp 7. 011 tank fill plug & dipstick 12. Rear brake master cylinder
3. Front brake master cylinder 8. Rear turn Signal lamp 13. Electric starter motor
4. Front brake hand lever 9. Tall/atop lamp 14. Rear brake pedal
Figure 1·18. XLX Right Side View, 1984 Model XLX

1-11
999iron .. om
""
13
1. Gas Cap 5. Transmission and primary 9. Headlamp

2. Ignition/llght switch chain 011 tiller plug 10. Steering lock
3. Horn 6. Transmission 011 level plug 11 . Clutch hand lever
4. Jilly stand 7. Gear shifter 12. Battery
8. Generator 13. Tail/ stop light
Figure 1-19. XR·1000 Left Side View
;99iron. )nl
2310
1. Gasoline supply valve 5. Rear brake pedal 9. Rear shock absorber

2. 011 tank filler cap 6. Electric starter motor 10. Turn signal light
3. Carburetor/air cleaner 7. Drive chain 11. Front brake handlever
4. Choke knob 8. Rear brake master cylinder 12. Front brake master cylinder
Figure 1·20. XR·1000 Right Side View
1-12
""
1. Ignition coli 7. Primary chain inspection & 11. Jiffy stand

2. Horn transmission oil filler plug 12.011 tank drain line
3. Voltage regulator 8. Transmission oil level plug 13. Ignition module
5. Timing inspection hole plug 10. Transmission & chalncase 15. Ignition-light switch
17. Clutch handlever
Figure 1-21. Left Side View, Late 1984 Model - XLS
2373
1. Ignition coli 7. Primary chain inspection & 11. Jiffy stand

2. Horn transmission oil filler plug 12.011 tank drain line
3. Voltage regulator 8. Transmission 01l18V81 plug 13. Ignition module
5. Timing Inspection hole plug 10. Transmission & chaincase 15. Ignltlon·light switch
17. Clutch handlever
Figure 1·22. Left Side View, Late 1984 Model - XLH
1·13
""
1. Ignition coil 7. Primary chain Inspection & 11. Jiffy stand

2. Horn transmission all filler plug 12. Oil tank drain line
5. Timing inspection hole plug 10. Transmission & chain case 15. Ignltlonllight switch
Figure 1-23. XlX Left Side View - Late 1984 Model
2528
1. Ignition coli 7. Primary chain Inspection & 11 . Jiffy stand

2. Hom transmission oil filler plug 12. 011 tank drain line
3. Voltage regulator 8. Transmission 011 level plug 1:. Ignition module
4. 011 tllter 9. Clutch access plug 14. Battery
S. Timing inspection hole plug 10. Transmission & chain case 15. Ignition/llght switch
Figure 1·24. XLS Left Side View - 1985 Model

1·14
".

2. Front tum signal lamp 7.011 tank fill plug & dipstick 12. Rear brake master cylinder
3. Front brake master cylinder 8. Rear tum signal lamp 13. Electric starter motor
4. Front brake hand lever 9. Tail/stop lamp 14. Rear brake pedal
Figure 1·25. XlS Right Side View - 1985 Model
''''
1. Ignition coli 7. Primary chain Inspection & 11. Jiffy stand

2. Hom transmission 011 filler plug 12. 011 tank drain line
3. Voltage regulator 8. Transmission all lavel plug 13. Ignition module
4.011 filter 9. Clutch accass plug 14. Battery
5. Timing inspection hole plug 10. Transmission & chain case 15. Ignition/light switch
Figure 1·26. XLH Left Side View - 1985 Model
1·15
2. Front turn signal lamp 7. 011 tank 1111 plug & dipstick 12. Rear brake master cylinder
3. Front brake master cylinder 8. Rear turn signal lamp 13. Electric starter motor
4. Front brake hand lever 9. Tall/stop lamp 14. Rear brake pedal
Figure 1·27. XlH Right Side View - 1985 Model
'"''
1. Ignition coli 7. Primary chain Inspection & 11 . Jiffy stand

2. Horn transmission 011 filler plug 12. 011 tank drain line
4. 011 IIlter 9. Clutch access plug 14. Battery
5. Timing Inspection hole plug 10. Transmission & chain case 15. Ignition flight switch
Figure 1·28. XLX Left Side View - 1985 Model
1·16
""

2. Front turn signal lamp 7. Oil tank fill plug & dipstick 12. Rear brake master cylinder
3. Front brake master cylinder 8. Rear turn signal lamp 13. Electric startef motor
4. Front brake hand lever 9. Tail /stop lamp 14. Rear brake pedal
Figure 1·29. XLX Right Side View - 1985 Model
1·17
STORAGE REMOVAL FRO M STORAGE
If the motorcycle wi ll not be ope rated for several
WARNING
months, such as during the winter season , there are
several things which should be done to protect parts
After extended periods of storage and prior to starting
against corrosion , to preserve the battery and to prevent
vehicle, place transmission in gear, disengage clutch
the build"up of gum and varnish in the carburetor.
and push vehicle back and forth a few ti mes to ensure
proper clutch disengagement.
This work should be performed by your local Harley-
Davidson dealer or other qualified mechanic following
1. Fi lilhe battery with water 10 the prope r level. Charge
Service Manual procedures .
and install i\'
WARNING
2. Remove and Inspect the spark plugs. Replace if
necessary.
Gasoline is flammable. Do nol store motorcycle having
gasoline in tank within the home or garage where open
3. Clean and oil the air cleaner element.
flames, pilot lights, sparks or electric motors are
present.
4. Remove the carburetor floal bow l. clean it and check
the f loat level .
1. Drain a ll fuel from the gas tank and carburetor Hoal
bowl and coat the ins ide of the float bowl w ith light 5. Fill fue l tank with fresh gaSO l ine.
oil. Spray the inside of the gas tank with one of the
commercially available rust preventatives. Follow 6. If oi l feed line was pinched off or plugged, unp lug it
the manufacturer's instructions . and reconnect.
2. Fill the oi l tank and pinch off or remove and plug the 7. Starl the engine and run until it reaches norma l
line leading from the bottom of the oil tank to the operating temperature .
feed fitting (marked F) on the oi l pump. This w ill
eliminate the possibi lity of oil seeping past the 8. Drain and flush the oi l tank. Install a new oi l filler
check ball into the oil pump and filling the engine and fill oi l tank w ith the proper grade oil. Check the
flywheel compartment with oil . transmission oil level.
3. Remove the spark plugs, inject a few squirts of 9. Perform all of the checks in the PRE-R IDING CHECK
engine oi l into each cylinder and crank the engine 5 LIST in the Owner's Manual .
or 6 revo lutions. Reinstall spark plugs.
4. Adjust the chains. FLUID REQUIREMENTS

5. Check tire inflation. If the motorcycle will be stored Harley-D avid son Oil
for an extended period of time, securely support the
motorcycle under the frame so that ali weight is off Use proper grade of oil for the lowest temperature ex-
the tires. pected before next oil change period as tollows:
6. Wash painted and chrome paint ed surfaces and ap-

p lya light film of oi l to exposed unpainted surfaces . Air Temperature Use
(Cold Engi ne Sta rting Harley·Davidson
Conditions) Oil Grade
WARNING 10° to 100¢ F. plus Power Blend
Norma l & severe Super Premium
Do not apply any oil to brake discs or brake pads. operating conditions
Below 40¢F. Special Light
Above 40¢F. Medium Heavy
7. Remove battery from vehicle and charge until the Above 60°F. Regular Heavy
correct specific gravity is obtained. Severe operating Extra Heavy
condit ions at air Grade 60
This should be done every other month for batteries temperatures
in winter storage, at temperatures below 60°F Above 80°F.
(16 QC), and once a month for batteries stored in a
warm area, above 60°F (16°C).
Harl ey-Davidson High Performance
8. If motorcycle is to be covered, use a material such Lu be Plus and Chain Spray
as light canvas, that will brealhe. Plastic materials
that do not breathe promote the formation of con- Designed especially as a chain lubricant. Penetrates in-
densation. ner bear ings tor a long chai n life.
1·18
Brake Fluid Gasoline
Use only O.O.T 5 HYDRAU LIC BRAKE FLUID. 1979·1981 models, use a good quality leaded or unlead·
ed premium grade gasoline (94 pump octane or higher).
1982 and later models, use a good quality regular grade
leaded gasoline (89 pump octane or higher).
WARNING
O.O.T. 5 HYDRAULIC BRAKE FLUID can cause eye Ir-
ritation. In case of contact with eyes, flush with plenty
of water and get medical attention. KEEP BRAKE FLUID PUMP OCTANE is the octane number usually shown on
OUT OF THE REACH OF CHILDREN! the gas pump.
1-19
METRIC CONVERSION TABLE
MILLIMETERS to INCHES INCHES to MILLIMETERS

(mm x 0.03937 '" Inches) (inches x 25.40 = mm)
mm mm mm in. mm m. in. mm m. mm m. mm mm
m. m. '"
.1 .0039 25 .9842 58 2.283 91 3.582 .001 .025 .6 15 .240 1 '~ 49.21 3 ~. 84.14
.2 .0078 26 1.024 59 2.323 92 3 .622 .002 051 , 15.875 2 50.80 3'. 85.72
.3 .0118 27 1.063 60 2.362 93 3.661 .003 .076 '~ . 462 39 3 4 86.36

17. 1 ". 52. 1 .
.4 .0157 28 1.102 61 2.401 94 3.701 .004 ,102 .7 17.780 2.1 53.34 3 U. 87.31
1
.127 19.050 2 '{ 53.97 3'1 88.90
.5
.6
,0197 29
.0236 30
1.142 62
1.181 63
2.441
2.480
95
96
3.740
3 .779
.005
.006 .152
"
8 20.320 ,., 55.56 3 y., 90.49
.7 .0275 31 1.220 64 2.519 97 3 .819 .007 .178 ''o, 20 .6 38 2 .2 55.88 3.6 91.44
.8 .0315 32 1.260 65 2.559 98 3 .858
3 .897
.008
009
.203
.229
"
.9
22.225 2 Y.
22.860 2.3
57,15
58.42 3'>;.
" 92.07
93.66
.9 .0354 33 1.299 66 2.598 99
1 .0394 34 1.338 67 2.638 lOa 3.937 1 .010 .254 ",. 23.812 2 ' i. 58.74 3.7 93.98
,
2 .0787 35 1.378 68 2.677 101
3.
976
i I x. .397 1 25.40 2 'i 60.32 3 'i 95 .25
3 .1181 36 1.417 69 2.716 102 4.0 161 .020 .508 1';. 26.99 2.4 60.96 3.8 96.52
4 .1575 37 1.456 70 2.756 103 4.055 , .030 .762 11 27.94 2 ',. 61 .91 3''(, 96.84
5 .1968 38 1.496 71 104 4 .094 .794 1'. 28 .57 63 .50 3 'c, 98.42
6 .2362 39 1.535 72
2.795
2.834 105 4 .134

"
040 1.016 1 '<, 30 .16
2 "
2 '{. 65 .09 3.9 99.06
I
7 .2756 40 1.575 73 2 .874 106 4.173 .050 1.270 ! 1.2 30.48 2.6 66.04 3 'X. 100.01
8 .3149 41 1.614 74 2 .913 107 4.212 060 31.75 66.67 4 101.6
9 .3543 42 1.653 75 2.953 108 4.252

1.524 i I "
1.588 1.3 33.02
"2 "(. 68.26 4 ~. 102.19
"
10 .3937 43 1.693 76 2.992 109 4.291 .070 U78 1'<. 33.34 1 27 68.58 41 104.14
11 .4331 44 1.732 77 3.031 110 4 .331 .080 2.032 1" 34.92 I" 69.85 H 104.77
12 .4724 45 1.772 78 3.071 111 4.370 .090 2.286 1.4 35.56 2.8 71 .12 4 70, 106.36
13 .5118 46 1.811 79 4.409 2.540 1 ';,
3 .110 112 .1 36.51
, 2'¥. 71.44 4.2 106 .68
14 .5512 47 1.850 80 3. 149 113 4.449 " 3 .175 1'" 38.10 I 2 " 73.02 4 Y- 107.95
15 .5905 48 1.890 81 3.189 114 4.488 \, 4 .762 ,.,. 39.69 1 29 73.66 4.3 109.22
16
17
18
.6299 49
.6693 50
.7086 51
1.929 1 82
1.968 83
2.008 84
3.228
3.268
3.307
115
116
117
4.527
4.567
4.606
.2
"
.3
5 .080
6.350
7.620
1.6
"
1 'X. 42.86
40.64
41.27
I
,
2 "1.
3
74.
76.20
61
77 .79 4.4
1
..
,", 109.54
111.12
111.76
19 .7480 52 2.047 85 3 .346 118 4.645 K. 7 .938 1.7 43.18
(' 31 78.74 4 ;(, 112.71
20 .7874 53 2.086 86 3 .386 119 4.685 ,
21 .8268 54 2.126 87 3.425 120 4.724 .4
9.525 1V.
10.160 18
44.45
45.72
"
3 ...
79 .37
"
80.96 4'4 11 5.89
114 .30
22 .866 1 55 2.165 88 3.464 121 4.764 li. 11.112 l 'K. 46.04 3.2 81.28 4.6 116 .84
23
24
.9055 56
.9449 57
2.205 89
2.244 90
3 .504
3.543
122
123
4.80:1
4.842 .," 1270~ I
14 .288
l Yo
1.9
47 .62
48.26
3 ';
I 3.3
825: 1 "
83.82 4 'x.
117,47
119.06
1·20
TORQUE SPECIFICATIONS
Torque specifications for specific components are listed In each repeclive section. For all other fasteners, use the
values listed in the table below. Torque figures are in ft -Ibs except those marked with an asterisk which are in in· n
Ibs.
I
FASTENER I TYPE
MINIMUM
TENSILE
STRENGTH
MATERIAL ! Body
2 , , , , •
Size or Outside Diameter
"
, ., " If, l l,
" '·1 '. , I
0 ' SAE 2 74,000 lOW I, Illro

STEn
-
PSI CARBON
I " " 961 m
32 206
'"--
MEDIUM
In'
" ", '" m
120,000
ED SAE 5
STEEL PSI CARBON
HEAT TREAT
14' 10 19 33 Ii '12
"
® SAt 7 133,000
MEDIUM
CARBON Il
" .. II 110 I" m
'" 110 .40
..
STEEL PSI AllOY
MEDIUM
150,000
@ SAE8
STEEL PSI
CARBON
AllOY
14 ~
" 18 119 I" 2~
'" 100
~
SOCKET
HEAD
CAP SCREW
160,000
PSI
HIGH CARBON
QUENCHED
TEMPERED "
I II
" .. "' I~ 2~ 400 .0 910
IJ SOCKET
SET
SCREW
212,000
PSI
HIGH CARBON
~U[NCHEO
EMPEREO
9'
'" " 10" 140' 18 ~ 4l 6J 100 '46
V1 STUDS Use SAt 2, 5 and 8 values when grade ,s known, w' th nut of SufflClcn t strength
1-21
TROUBLESHOOTING
The following check list wil l be helpful in locating most Starts But Runs Irregularly or Misses
operating t roubles . Refer to the appropriate sections in
this service manual for detailed procedures. 1. Spark plugs in bad condition or partially fouled.
2. Spark plug cables in bad condition and shorting .
3. Spark plug gap too close or too wide.
ENGINE 4. Defective ignition coil.
5. Defect ive ignition module.
Starting Motor Does Not 6. De/ective ignition sensor (1980 & later).
Operate or Does Not Turn Engine Over 7. Battery near ly discharged.
8. Damaged wire or loose connection at one 0/ battery
1. Engine run switch in OFF position . terminals or coil.
2. Ignition switch not on. 9. Intermittent short circuit due to damaged wire in·
3. Discharged battery, loose or corroded connections. sulation.
(Solenoid chatters.) 10. Water or dirt in fuel system and carburetor or filter.
4. Starter control circuit, relay or solenoid defective. 11. Gasoline tank cap vent plugged or carburetor vent
5. Electric starter shaft pinion gear not engaging or line closed off.
over·running clutch slipp ing . 12. Carburetor controls improperly adjusted.
13. Weak or broken valve springs.
Engine Turns Over But Does Not Start 14. Air leak at intake manifold or air cleaner.
15. Damaged intake or exhaust valve.
1. Gas tank empty. 16. Incorrect valve timing.
2. Gasoline valve turned off.
3. Gasoline valve or filter clogged. A Spark Plug Fouls Repeatedly
4. Discharged battery, loose or broken battery terminal
connections. 1. Incorrect spark plug.
5. Fouled spark plugs. 2. Piston rings badly worn or broken.
6. Spark plug cables in bad condition and shorting or 3. Fuel mixture too rich (see CARBURETOR TROUBLE
cable connections loose. CHART).
7. Ignition timing badly out of adjustment. 4. Valve guides badly worn.
8. Loose wire connection at coil or battery connection
or p lug between ignition sensor and,module. Pre· Ignition or Detonation
9. Defective ignition coil. (Knocks or Pings)
10. Defective ignition module.
11. Defective ignition sensor (1980 & later). 1. Excessive carbon deposit on piston head or com·
12. Sticking or damaged valve or tappets too tight. bustion chamber.
13. Engine flooded with gasoline as a result of over- 2. In correct spark plug for the kind of service.
choking . 3. Defective spark plugs.
14. Engine oil too heavy (winter operation). 4. Ignition timing advanced .
5. Fuel octane rating too low.
Starts Hard
Overheating
1. Spark plugs in bad condition, have improper gap or
are partially fouled. 1. Insufficient oil supply, or oil not circulating.
2. Spark plug cables in bad condition and shorting. 2. Leak.ing valves.
3. Battery nearly discharged. 3. Heavy carbon deposit.
4. Loose wire connection at one of the battery ter· 4. Ignition timing retarded.
minals, at coil or plug between ignition sensor and 5. Low power - timing advance weights sticking in
module. retarded position (1979 only).
5. Carburetor controls not adjusted correctl y.
6. Defective ignition coil. Valve Train Noise
7. Engine oil too heavy (winter operation).
8. Timing advance weights sticking in advanced posi- 1. Too much tappet clearance.
tion (1979 only). 2. Bent push rod.
9. Ignition not timed properly. 3. Cam, cam gears, or cam bearings or bushings worn.
10. Gasoline tank cap vent plugged, or carburetor fuel 4. Rocker arm binding on shaft.
line closed off restricting fuel flow. 5. Valve sticking in guide.
11 . Water or dirt in fuel system and carburetor.
12. Choke disc stuck in open position. Excessive Vibration
13. Air leak at intake man ifold.
14. Valves sticking. 1. Upper mounting bracket loose, broken or improperly
spaced .
1·23
2. Lower mounting bolts loose. ELECTRICAL SYSTEM
3. Broken frame.
4. Front chain badly worn or links light as a result of in· (Late 1984 . 1985)
sufficient lubrication.
5. Wheels and/or tires defective. Alternator Does Not Change
6. Internal engine problem.
1. Defective regu lator·rectifier modu le.
2. Module not grounded.
LUBRICATION SYSTEM 3. Engine ground wire loose or broken.
4. loose or broken wires in charging circuil.
Oil Does Not Return To 011 Tank 5. Defective stator.
6. Defective rotor.
1. Oil lank empty.
2. Scavenger pump gear pin sheared. Alternator Charge Rate Is Below Normal
3. Oil feed pump not functioning.
4. Restricted oil lines or fittings. 1. Defective regulator·rectifier module.
5. Restricted or plugged all filter (if applicable). 2. Defective stator.
3. Defective rotor.
Engine Uses Too Much Oil or 4. Weak or defective battery.
Smokes Excessively 5. loose connections.
1. Piston rings badly worn or broken.

2. Valve gUides worn. CARBURETOR
Engine Leaks Oil From Cases, Floods
Push Rods, Hoses, Etc. 1. Inlet valve sticking.
2. Inlet valve and/or valve seat worn or damaged.
1. Loose parts. 3. Dirt or other foreign matter between valve and its
2. Imperfect seal at gaskets, push rod cover, washers, seal.
etc. 4. Excessive "pumping" of hand throttle grip.
3. Restricted oil return line to tank. 5. Leaky or defective float.
4. Restricted breather hose to air cleaner. 6. Float misadjusted.
5. Plugged oil filter (if applicable).
TRANSMISSION
Shifts Hard
ELECTRICAL SYSTEM
(1979 . Early 1984) 1. Clutch dragging slightly.
2. Transmission oil too heavy (winter operation).
3. Shifter forks (inside transmisSiOn) damaged.
Generator Does Not Charge 4. Corners worn off shifter clutch dogs (inside
transmisSiOn).
1. Brushes badly worn.
2. Brushes Sticking in holders. Jumps Out of Gear
3. Voltage regulator not grounded.
4. Defectfve voltage regulator. 1. Shiiter forks (inside transmisSion) improperly ad·
5. Commutator dirty or ally. Justed.
6. Positive brush holder grounded. 2. Shifter engaging parts (Inside transmission) badly
7. Generator "A" terminal grounded. worn and rounded.
8. loose or broken wire in generator· battery circuit.
9. Broken field coil wire or loose terminal (both sides).
10. Commutator shorted. CLUTCH
11. Defective armature.
Slips
Charging Rate is Below Normal 1. Clutch controls improperly adjusted.
2. Insufficient clutch spring tension.
1. Broken field coil wire or loose terminal (one coil). 3. Worn friction discs.
2. Commutator worn or not turning true with shaft -
throws brushes at high speed. Drags or Does Not Release
3. Commutator dirty or oily.
4. Brushes gummy and sluggish in holders. 1. Clutch controls improperly adjusted.
5. Defective armature. 2. Clutch spring tension too tight.
1·24
3. Friction discs gummy. HANDLING
4. Clutch shell keys or hub studs badly worn (1979
·Early 1984). Irregularities
S. Clutch discs warped.
6. Transmission oil too heavy for air temperature. 1. Loose wheel axle nuts. Tighten front nuts to 50 ft·lbs
maximum. Tighten rear nuts t060-65ft·lbs.
Chatters 2. Excessive wheel hub bearing play.
3. Rear wheel out of alignment with frame and front
1. Friction discs or steel discs worn, warped, or dragg- wheel.
ing. 4. Rims and tires out-of true sideways (tire run·out
should not be more than 3/64 in.).
5. Rims and tires out·of·round or eccentric with hub
BRAKE (tire run-out should not be more than 3/32 in.).
6. Irregular or peaked front tire tread wear.
Does Not Hold Normally 7. Tires improperly inflated. Check TIRE DATA section.
Do not over·inflate.
1. Master cylinder Iowan fluid. 8. Tire and wheel unbalanced.
2. Brake line contains air bubbles. 9. Steering head bearings improperly adjusted. Correct
3. Master or wheel cylinder piston worn or parts defec- adjustment, and replace pitted or worn bearings and
tive. races. See FORKS.
4. Brake pads impregnated with grease or all. 10. Shock absorber not functioning normally.
5. Brake pads badly worn (1116 in. minimum lining 11. Heavy front end loading. Non-standard equipment
thickness). on the Iront end such as heavy radio receivers, extra
6. Brake disc badly worn or warped. lighting equipment or luggage tends to cause
7. Brake fades due to heat build up - brake pads drag- unstable handling.
ging or excessive braking.
8. Brake drags - insufficient brake pedal or hand lever
free play.
1-25
TOOLS
Part No. J·5586 Transmission Shaft Retaining Ring Pliers Part No. J·2690().14 Small Hole Gauge
Part No. HD·01289 Rim Protector Part No. HD·8062 Valve Spring Compressor
Part No. HD·S4Q4 Hose Clamp Tool Part No. HO ·20000 Tire RepaIr Kit
Part No. HD·21000 Tire Spreader Part No. HD·23433 Multiple Carburetor Synchronizer
Part No. HO·23738 Vacuum Pump Part No. HO·28700 Be.d Exp.nder
Part No. HO·33030 Piston Squaring Plate Part No. HO·33071 Wheel Be.rlng
Race Remover and Inst,lIer
Part No. H0-331H ACCfts Plug Remo'fal Tool Part No. HO·33223·1 Cylinder Compression G.uge
Part No. HO·33413 CarburetOlldle AdJustment Tool Part No. HO·33416 Unl'fersal Ori'fer Handle
1·28
Part No. HD·33418 Universal Puller Forcing Screw Part No. HD·33813 Inductive Tim ing Light
Part No. HD·33871 Valve Guide Tool Part No. HD·34190 Fork Seal Tool
~ ~~
~~ :::::::
~ ~~
~~
~~
Part No. HD·34198 Torque Plate Part No. HD·34723 Valve Guide Hone
q'-----
Part No. HD·34740 Valve Guide Driver Part No. HO·34761 Clutch Spring Compression Tool
1·29
Part No. HO·34810 Malnshatt Bearing Installation Tool Part No. HO ·34813 Rowe Flywheel RebUIlding Jig
Part No. HO·35102 Connecting Rod Bushing Hone

Part No. HO·34816 011 Pressu,. Switch Wrench
-~
Part No. HO·91042 Clutch locking Tool Part No. HD·94456-81 Ignition Test Adapter
Part No. HO·94546·41 Flywheel Shaft Nut Wrench Part No. HO·94547·80 Crankshaft Bearing,
Removal and Installation Tool
1-30
Part No. H D·94575·58A Spark Plug Wrench Part No. HD·94580·71 Clutch Adjusting Wrench
Part No. HD-94589·29A Cylinder Base Nut Wrench (9116,,) Part No. HD·9459().73 Cylinder Head Bolt Socket Handle
Part No. HD·94647·52 Clutch Hub Nut and Engine Part No. HD·94681·80 Spoke Nipple Wrench
Sprocket Locknut Wrench
n
I
~ ~
'--
Part No. HD-94752·77 Float Gauge Part No. HD·94800·26 Spiral Expansion Reamer
1·31
Part No. HO-94803·67 Rear Intake Part No. HD·94804·57 Rocker Arm Bushing Reamer
Camshaft Bushing Reamer
Part No. HO·94806·57 Idler Gear Bushing Reamer Part No. HD·94809·80 Expansion Reamer - Exhaust
Part No. HO·94810-80 Expansion Reamer· Intake Part No. HO·94812·77 Pinion Shaft Bushing Reamer
Part No. HD·94820·75 Spanner Wrench Part No. HD·94829·42 Clutch Gear Bushing Reamer
1·32
Part No. HD-95017·61 External lock Ring Pliers Part No. HD·95020·66 Rear Chain
Connecting link Press Tool
-
&
Part No. HD·95021·29A Chain Breaking Tool Part No. HD·95500·80 Wheel Trumg Stand
I o
I D
Part No. HD-9556Q.57 Transmlsslon Access Cover Puller - Part No. HO-95632·79 Gauge Pin Set
1979· early 1984
Part No. HD-95635·46 All Purpose Claw Puller Part No. HD·95637·46 Wedge Attachment
For Claw Puller
1·33
()))~
n
.J I
1·1/8 " 3/4 " 5/8 " 9/32 " 1/2 " 7116 "
Part No. HO-95715-19A Gear Puller Part No. HD·95760·69 Bushing and Bearing Puller
Tool Set (Includes items 1, 2, 3, and 4.) Item 9
(95768-69), 10 (95769·69), 11 (95770·69),
12 (95771·69) and 6 (95759·75) are optional extras
Part No. HD·95952·33 Connecting Rod Clamping Tool Part No. HD·95970·32A Piston Pin Bushing Tool
Part No. HD·96015·77 Sprocket Shaft Bearing, Part No. HD·96030·77 Pinion Shaft Bearing,
Inner Race Puller Inner Race Puller
Part No. HD·96137·52A Flywheel Support Plate Part No. HD·96215·49 Small Internal Lock Ring Pliers
'·34
Part No. HO·96216·49 Large Internal Lock Ring Pliers Part No. HD·96221 ·80 011 Filter Wrench
Part No. HD·96295·65B Timing Mark View Plug

Part No. HD·96333·51 B Ring Compressor
Part No. HD·96396-52 Malnshaft 3rd Gear Part No. HD·96550·36A Valve Lapping Tool
Retaining Ring Sleeve
Part No. HO·966SO·SO TNlng Stand Part No. HO·96710·40 Crankcase Main Bearing Lap
1·35
Part No. HD·96740·36 Connecting Rod Lapping Arbor Part No. HO·96796·47 Valve Spring Tester
Part No. HD·96810·63 Motorcycle Shop Stand Part No. HD·96910·35 Hydrometer
Part No. HD·96921·52 Oil Pressure Gauge Part No. HO·97010-52A Shock Absorber Tool
Part No. HD·97080·77 Pinion Shaft Inner Race Part No. HD·97081·54A Sprocket Shaft
Installation Guide Bearing Installation
1·36
=-
-
Part No. HD·97087·65A Hose Clamp Pliers Part No. HD·97178·71 Clutch Spring Compressor -
1979 . early 1984
Part No. HD·97200·55A Sprocket Locking Link Part No. HD·97273·60 Camshaft Needle Bearing
Installation Tool
Part No. HD·97292·61 Two Jaw Puller Part No. HD·97334·80 Connecting Link Assembly Tool
Part No. HD·97362·71 Pin Terminal Tool Part No. HD·97364·71 Socket Terminal Tool
1·37
CHASSIS
I
SUBJECT PAGE NO.
1. Specifications. . ......... • . . 2·1

2. Wheels ............ • . •• . . .2·5
3. Brakes. . .... 2·25
4. Front Forks. . ..... 2·47
5. Rear Fork . ..... 2-53
6. Rear Shock Absorber. .. .... 2·55
7. Handlebar Controls and Instru ments . .......... . . ....... ...... _.2·57
8. Fenders. . ... 2-65
9. Specifications(XR·l000j. . _ ........ ... _ ...... 2-69
10. Wheels (XR·1 000j . . .2·73
11. Handlebar Controls (XR· 1000j .2·77
SPECIFICATIONS
DIMENSIONS (in.) Oil Tank (U.S. Quarts)
1979-1981 . 4
1979·1981 1982 1982 and later ........... , ......... . 3
Transmission (U.S. Pints). , , . , . _.... _........... 1.5
XLCH
Front Forks (Ounces per Fork)
XlH XlS XlH XlS
Wei (1979-1983) Soz.
Wheel Base. 58.5 59.6 60 60.75 (1984-1985) . . ............. ... .... 5.4 oz.
Overall Length. 88.0 89.6 87.5 90 Dry(1979-1983) . Boz.
Overall Width. 33.8 29.2 33 33 (1984-1985) ..... ......... . . .. 6.4 oz.
Overall Height 46.5 42.5 48.5 50.5
Saddle Height 29.7 29.7 29 30.5
Road Clearance. 6 .• 6.8 6.75 7.5
ADJUSTMENTS
1983·1985
XlH XlS XlX
Wheel Base (1983) 60 60.75 60 Brakes
WheeI8a5e(1984·1985). 60 60 60
Overall Length 87.5 B7.S 87.5 Rear Brake Pedal Adjustment ...... ,1116 in.
Overall Width 33 33 35
Overall Height. 48.5 47.5 45
Road Clearance .. 6.75 6.75 6.75
WEIGHTS (Ibs.)
TORQUES
XLX XlS XlH XLCH
,-- Front axle nUl.
Weight as shipped . ...... ".50 ft-Ibs
from the factory (1979·1981) 527 522 513 Rear axle nuts. . .................... 60-6SIHbs
(1982) . 525 512 Sprocket mounting bolts (1979-1983) ..... 45 to 50 ft-Ibs
(1983) . 492 523 512 Sprocket mounting bolts
(Early 1984) . 481 491 489 (1984-1985 laced wheels) ... _........... 45-50 ft-Ibs
(Late1984·t985) . 468 478 476 Sprocket mounting bolts
- (1984.1985 cast wheels) . . .50·55 ft·lbs
Brake disc mounling front
VEHICLE WEIGHT RATINGS (Ibs.) wilhcasl wheels (1979·1983) .......... 1410 16 f1·lbs
with laced wheels ................... 1610 19 fHbs
The Gross Vehicle Weight Ratings (GVWR) and the
Gross Axle Weight Ratings (GAWA) are found on a label wilh cast or laced wheels (1984·1985) ... 1610 18 ft·lbs
on the frame steering head. Brake disc mounling rear ............... 23 to 27 ft·lbs
Caliper mounting bolls
1979 1980·1985 fronl (1979·1983) ................ . .. . 80 to 90 in·lbs
front (1984·1985) . . .............. 25 to 30 fI·lbs
XLH/XLS/XlCH XlHIXLS/XlX
rear ............................ 155 to 190 in·lbs
GVWA 960 900 Caliper clamping boll. . . . . . . . . . . . . .. 60 t065 It·lbs
GAWR - Front 340 320 Upper bracket pinch bolt. . ........... 21 to 27 ft·lbs
GAWR - Rear 620 580 Lower bracket pinch bolts .......... .... 30 to 35 ft·lbs
Slider cap nuts. .1 1 ft·lbs
Throttle conlrol clamp screws
CAPACITIES 1979 ·1981 ......................... 12 to 16 in·lbs
1982·1985 . . .............. 18·24 in·lbs
Fuel Ta nk (U.S. Gallons) Handlebar c la mp screws (1979·1983) ... . 20 It·lbs
Handlebar c la mp screws (1984·1985) . . . 12·15 ft·lbs
1979 1980 1982 1983 1984 Rear fork pivot shaft (1982· 1985) ............ 50 ft·lbs
1981 1985
XlH
Total 2.25 2.25 3.00 3.3 2.25
Reserve 0.25 0.25 0.25 0.8 0.25 BRAKE DISC
XlS
Tota l 3.6 3.6 3.6 3.8 3.8
Reserve 0.6 0.3 0.6 0.4 0.4 Front Rear Minimum Thickness
XlX Front Rear
Total 2.25 2.25 10 in . 11.5 in. .160 .205
Reserve 0.25 0.25 10 in. 11.5 in. .180 .205
2·1
TIRE DATA
Front Rear
Up to 300 lb.
load in·
cluding
rider with 26 30
Tire passenger
Pressure and cargo
(PSI)
(Cold) Up to
GVWW
max imu m 26 32
load
*Gross Vehicle Weight Rating (GYWA) is given on a

label located on the frame.
1981 and Later

Made in U.S.A.
Harley-Davidson
Heavyweight Motorcycle XLH CAH
MOd8IDesi g nation* - - - - - - - - - - - -- - - --j xLs CBH
CCH
II l I
En9ine Displacement- XLX
Regular Introduction Date XA-1000 CDH
Ch8Ck Digit (Factory user' ~-----~
MOd81 Year (1985)"
'1 HD CA H 1 F
r
Plant of Manufacture (York)
Y
-----.e....S..equential Number'
010000
(2)
Mid-year Introduction
* AbbreviatedVIN on Engine
·Varies - can be 0 thru 9 or X
*
Sample V.I.N. as it appears on the steering head - 1 HD 1CAH1 5 FY010234
Sample abbreviated V.I.N. as it appears on the engine· CAHF 010000
VEHICLE IDENTIFICATION TIRES

NUMBER (V.I.N.) WARNING
The full 17 digit serial, or Vehicle Identification Number Maximum cold inllation pressure of rear tires is 32 psi.
{V.I.N.) is stamped on the steering head and on a label Maximum cold inflation pressure 01 front tires is 40 psi.
located on the right front frame downtube. An ab-
breviated V.I.N. is stamped on the right side crankcase WARNING
near the front of the engine
For your own personal safety tires, tubes and tubeless
NOTE tires must be correctly matched to wheel rims. Tires and
tubes listed in the fitment chart must be used exclusive·
Always give one of these numbers when ordering parts
Iy for replacement. Mismatching tires, tubes and rims
or making any inquiry about your motorcycle.
may result in damage to the tire bead during mounting
or may allow the tire to slip on the rim, damaging the
1980 and Earlier tube, causing rapid tire dellation. In addition, using tires
MODEL and tubes other than those specified may adversely af·
LEITERS NO. SERIAL # MFR. YE . . R fect motorcycle stability. Use only tube type tires on
Harfey-Davidson laced wheels. Protective rubber rim
XLH 3A 10000 & UP H·1970's 0 strips must also be used on laced wheels.
XLS 4E {5 digils) J-1980's (1980)
XlCH 4A Harley· Tire sizes are molded on the tire sidewall. Tube sizes are
Davidson printed on the lube.
2·2
Tire Filmenl Chari
1979 XLH I XLCH I XLS
WHEEL SIZE WHEEL RIM HAALEY.oAVIDSON GOODYEAR GOODYEAR GOODYEAR
& POSITION TYPE CONTOUR- TIR E SERIES TUBe SIZE TIRE TYPE TIRE SIZE
Laced
lEarl v 1979)
2.50 eM N.A . v 18119 Sport Rib MM90-19T
19 Inch laced
Front (Late 1979)
2.50 TLA YYY V 18/19 Eagle AfT MJ90·19
Cast 2. 15 T L YYY V 18/19 Eagle ArT MJ90·19
Laced
2.50 eM N.A. W 18/19 All TRACTION 4.25·18T
18 Inch (Early 1979)
Rear Cast 2.50 TL N.A. V 18/19 Eag le AfT MN90-18
16 Inch Laced L 3.00 0 www I G 5.10-16 Eag le AfT MT90· 16
Rear Cast 3.00 0 WWW G 5.10-16 Eac le AfT MT90-18
1980·1985 XLH I XLS I XLX

WHEel SIZE WHEel RIM TUBe TIRE SIZE HARLEY.oAVIDSON
& POSITION TYPE CONTOUR · SIZE GOO DYEAR·EAGlE TIRE SIZE
AfT or DUNLOP K18t
19 Inch Laced 2.50 X 19 TLA MJ90-19 MJ90·19 yyy
Front Cast 2. 15 X 19 Tl MJ90-19 MJ90·1g yyy
Laced
16 Inch or 3.00 X 160 MT90· 16 MT90-16 WWW
Rear Cast
1985 XLH I XLS I XLX

WHEel SIZE WHEel RIM RIM VALVE TIRE SIZE HARLEY.{)AVlOSON
& POSITION TYPE CONTOUR· HOLE OIA. GOODYEAR·EAGlE TIRE SIZE
AfT or DUNLOP K181
19 Inch Tubeless 2.1 5 X 19 TL .45 in . MJ90·19 yyy
Front Cast
16 Inc h Tubeless 3.00 X 160 .34 in. MT90-l6 WWW
Rear Cast
19831984 XR 1000
WHEel SIZE WHEEl RIM RIM VALVE TIRE SIZE HARlEY.{)AVIOSON
& POSITION TYPE CONTOUR· HOLE OIA. GooDYEAR·EAGlE TIRE SIZE
AfT or DUNLOP K181
19 Inch Tubeless 2,15X19TL .45 in . 100/90V-19 RRR
Front Cast
16 Inch Tu beless 3.00 X 160 .34 In. 130/90V-16 ppp
Rear Cast
"Rim s ize and contour are cast or stamped into the exterior surlace of the rim. Example: T19 x 2.50 CM DOT. " T" in·
dlcates t hat t he rim con f orms to Tire and Rim Association standard s. 19 Is the norm al diameter of t he rim in inches,
meas ured at the bead seat diameter. 2.50 is the width of the bead seat measu red in i nches . CM designates the rim
contour. DOT means that the rim meets Department of Transportation Motor Veh ic le Safety Standards.
2·3
WHEELS
GENERAL WARNING
Maximum tife mileage and gOOd handling qualities are Riding with excessively worn tires is very hazardous
directly related to care given wheels and tires. Wheels and will adversely affect traction, steering and handl.
and tires should be inspected regular ly for wear. If ing.
handling problems occur, check the TROUBLESHOOT·
ING guide in Section 1 for possible causes.
Always keep lires in flated to the recommended pres· At regular intervals of 5000 miles, or at any time handl·
sure and balance the wheel whenever a tire or tube Is ing irregu larit ies are experienced, see t he chart below
replaced. for recommended service.
Check inflation pressure and inspect tread for punc- II tires are replaced, same as original equipment ti res
tures, cuts, breaks, etc., at least weekly. Check before must be used. Other tires may not fit correctly and may
going on trips, also. be hazardous to use.
Wheel Service Chart

CHECK FOR REMEDY
1. Loose axle nuts. Tighten front axle nut to 50 ft·lbs maximum torque. Tighten rear
axle nuts 10 60·65 ft·lbs maximum torque.
2. Excessive side·play or radial (up· Replace wheel hub bearings as described in INSPECTING AND
and·down) play in wheel hubs. REPAIRING WHEEL HUBS.
3. Loose spokes. Tighten or replace spokes as described under TRUING WHEELS

and LACING WHEELS.
4. Alignment of rear wheel in Irame Check wheel alignment as described in this sect ion or repair
and with Iront wheel. rear lork as described in REAR FORK.
5. Rims and tires out·ol·true sideways, True wheels, replace rims or replace spOkes as described under
(should nol be more than 3/64 in.). LACING WHEELS and TRUING WHEELS.
6. Rims and tires out·ol·round or ec· See Ilem 5, above.

centric with hub (should not be
more than 3{32 in.).
7. Irregu lar or peaked fronilire wear. Replace as described in REMOVING AND INSTALLING FRO NT
AND RE AR WHE EL, and REMOVING AND INSTALLING TIRE
AND TUBE.
8. Correct tire inflalion . Inflat e Ilres to correct pressure, as described in SPECIFICA·

TIONS .
9. Correct tire and wheel balance. Sialic balance may be satisfactory if dynamic balancing
lacllitles are not available. However, dynamic balancing is also
recommended.
10. Steering head bearing s. Correct adjustment and replace pitted or worn bearings. See
FORKS.
". Shock absorbers. Check damping action and mounllng stud rubbers . See FORKS.
12. Rear fork bearings. Check for looseness. See FORKS.
2·5
WARNING FRONT WHEEL
When repairing a flat tire or Installing a new tire:
Removal
Always locate and eliminate the cause of the original
lire failure.
1979·1983 MODELS IFigur. 2·1)
1. Support motorcycle undernea th frame with front
Do not patch or vulcanize a tire casing because this wheel raised off Ihe ground.
weakens the casing and may cause a blowout.
2. Remove brake caliper mounling hardware (3) and reo
An Inner tube should be patched only as an emer· move brake caliper assemblies (1 and 2).
gency measure. Replace the damaged lube as soon
as possible. 3. Remove axle nul (6) , lockwasher (7) and washer (8).
Loosen slider cap nuts (4).
Be sure the Inner tube Is the correct size for the Ure
casing to prevent stretching or wrinkling of the tube 4. Using a soft hammer, gently tap end of axle 10
which will weaken it . loosen ii, then pull axle free of fork assembly.
Remove fron t wheel and speedometer drive.
The use 01 tires other than those specified may ad·
versely affect handling. CAUTION
Because tires, lubes and wheels are critical safety Do not operate Iront brake lever when the front wheelis
items, the servicing of these items requires special removed because the brake caliper piston may be forced
tools and skills. Therefore, we recommend you see out of the bore, requiring disassembly of the brake
your dealer for these services . system to properly reseat brake caliper piston.
1. Right side caliper 6. Axle nut

2. Left sIde caliper 7. Lockwasher
3. Caliper mounting bolts 8. Washer
4. Slider cap mounting nuts 9. Speedometer drive
5. Axle 10. Brake disc
Figure 2·1 . Front Wheel Mounting - 1979·1983
2·6
1984·1985 MODELS (Figure 2·2) 2. Remove screws (7) securing brake discs (6) to hub
(8).
1. Support motorcycle underneath frame with front
wheel raised off the ground. 3. Remove lire and tube from wheel. See TIRES.
2. Remove brake caliper mounting hardware and 4. On laced wheels, if it Is necessary to remove the hub
remove brake cail::>er assembly (6). from the wheel, unscrew all the spoke nipples and
remove the rim and spokes.
3. Remove axle nut, lockwasher and washer. Loosen
slider cap nuts (7).
4 . Using a soft hammer, gently tap end of axle to 1984·1965 MODELS (Figure 2-4)
loosen It, then pull axle free of fork assembly.
Remove front wheel and speedometer drive. 1. Remove and discard oil seals (1), then remove spacer
(2), bearing cone (3), and spacer (5).
CAUTION
2. Remove screws (7) securing disc (6) to the wheel
Do not operate front brake lever when the front wheel is hub.
removed because the brake caliper piston may be forced
out of the bore, requiring disassembly of the brake
system to properly reseal brake caliper piston. NOTE
The brake discs on 'rant and resr wheel assemblies are

Disassembly attached with Torx screws. During removal or installa-
tion a special tool is required to fit the special recess in
1979·1983 MODELS (Figure 2·3) the screw head. The tool Is a T40 Torx driver or
equivalent.
1. Remove 011 seats (1), spacer (2) and bearing cones (3).
DIscard seals. For cast wheels use WHEEL BEAR· 3. Remove tire and, If applicable, the tube from the rim.
ING RACE REMOVER, Part No. HD·33071 to remove See TIRES.
bearing cups (4). Remove spacer (5) from the hub.
4. On laced wheels, if it Is necessary to remove the hub
2. Remove screws (7) securing brake discs (6) to hub from the wheel, unscrew all the spoke nipples and
(8). remove the rim and spokes.
1. 011 seal (2)

2. Spacer
3. Bearing cone (2)
4. Bearing cup (2)
•
S. Spacer
6. Brake disc (2)
7. Screw (10)
8. Cast wheel
.a.
mounting nuts
8. Axle
9. Washer
5. Caliper mounting screw 10. Lockwasher
6. Brake caliper 11. Axle nut
Figure 2-2. Front Wheel - 1984-1985 Figure 2-3. Front Wheel , 19 in. - 1979 - 1983
Cleaning, Inspection and Repair 5. Lightly coat the outside lip of oil seals (1) with
engine oil. Press one seal into each side of the hub
1. Clean all parts in solvent and inspect for damage or flush with outer surface.
wear.
2. If bearing cones or cups need replacing, replace as a 6. Install spacer (2) i n left side of the hub.
set.
7. If removed, install tire, and if applicable, the tube.
3. Replace brake disc if it is warped, scored or worn
Wheel and tire must be true. See applicable section
beyond the minimum thickness stamped on the
TRUING LACED WHEEL or CHECKING CAST RIM
disc. See SPECIFICATIONS.
RUNOUT.
4. Replace the oil seals.
5. On laced wheels, replace spokes, rim or hub if
damaged. 1984-1985 MODELS (Figure 2-4)
Assembly 1. If the hub and rim were disassembled, assemble the
hubs, spokes and rim as described in LACING
1979·1983 MODElS (Figure 2·3)
WHEELS.
1. If the hub and rim were disassembled, reassemble
the hub, spokes and rim as described in LACING 2. Make sure the brake disc is clean, then install it on
WHEELS. the hub, aligning the notch in the disc with the hole
in the hub. Secure the disc with Torx screws (7).
2. Make sure brake discs (6) are clean and then install Tighten screws to 16-18 ft·lbs torque using a T40
using screws (7). Tighten to proper torque. See Torx driver.
SPECIFICATIONS.
3. Apply a liberal amount of bearing grease to the bear·
3. Apply a liberal amount of bearing grease to bearing ing cups (4) and press the cups into the hub. Using
cups (4) and press one into each side of the hub, us- WHEEL BEARING RACE INSTALLER, Part No.
ing WHEEL BEARING RACE INSTALLER, Part No. HD·33071.
HD-33071.
4. Place the spacer (5) into the hub. Apply a liberal
4. Place the spacer (5) into the hub. Apply a liberal amount of bearing grease to the bearing cones (3)
amount of bearing grease to the bearing cones (3), packing the cavities around the railers. Install the
packing the cavities around the rollers. Install the cones in the matching cups (4).
cones in the matching cups (4).
5. Lightly coat the outside lip of oil seals (1) with
engine oii. Press one seal into each side of the hub
flush with outer surface.
1. Oil seal (2)
2. Spacer 6. Install spacer (2) on the right side of the hub op-
3. Bearing cone (2) posite the brake disc.
4. Bearing cup (2)
5. Spacer 7. If removed, install tire and, if applicable, the tube.
6. Brake disc Wheel and tire must be true. See applicable section
7. Screw (10) TRUING LACED WHEEL or CHECKING CAST RIM
8. Cast wheel RUNOUT.
Installation
1979-1983 MODELS
"-:::::~/ 1. Pack the cavity between the oil seals and bearing
/
/
/ cones with bearing grease.
/
/
/ 2. Place wheel between fork sides with brake disc(s)
/
centered between brake pads.
3. Apply LocHle ANTI-SEIZE to axle shaft and insert ax-

le from right fork side through speedometer drive,
wheel hub and left fork side.
CAUTION
Be sure speedometer cable Is routed outside brake line,

away from fender and tire. Speedometer drive gear must
Figure 2·4_ Front Wheel 19 in_ - 1984-1985 engage hole in right side of wheel hub.
2·8
4. See Figure 2·1. Install washer (8), lockwasher <n and WARNING
axle nut (6).
After proper tightening 01 axle nut, wheel bearing end
5. Initially, tighten slider cap nuts (4) only on nut side 01 play should be .004·.018 In. If wheel bearing end play Is
axle to 11 fI·lbs torque. Tighten axle nut to 50 fI·lbs not correct, a shorter or longer hub bearing spacer (5,
torque, then tighten the other slider cap nuts (4) to 11 Figure 2.4), Is required. Spacers (5) are available In three
fI·lbs torque. lengths, 2.564 (VIolet). 2.550 (Pink) and 2.536 (Gold) In.
NOTE 5. Reinstall brake calipers. Tighten brake caliper

mounting bolts to 25·30 It·lbs torque.
After tightening slider cap nuts, check to see that front
and rear gap between slider cap and fork leg Is equal.
REAR WHEEL
After proper tightening of axle nut, wheel bearing end
play should be .004·.018 in. If wheel bearing end play is
Removal (Figure 2·5)
not correct, a shorter or longer hub bearing spacer (5, t. Raise rear end of motorcycle high enough to permit
Figure 2·3) Is required. Spacers (5) are available In three removing wheel. Support motorcycle with suitable
lengths, 2.564 (Violet), 2.550 (Pink) and 2.536 (Gold) in. blocking underneath frame.
6. Reinstall brake calipers. Tighten brake caliper 2. Locate and remove chain connecllng link and dis·
mounting bolls to 80·90 In·lbs torque. Use new engage chain from rear sprocket.
locknuts.
3. Remove axle nut, axle nutlockwasher and washer.
WARNING
4. With a soft hammer, gently tap end of axle to loosen
Locknut threads are destroyed when nuts are removed . it, then pull axle free 01 frame assembly. Remove
Use new locknuts when reinstalling brake calipers. wheel.
CAUTION
1984·1985 MODELS Do not operate rear brake pedal when rear wheel is
removed because the brake caliper pi ston may be forced
out of the bore, requiring disassembl y of the brake
system to properly reseat brake caliper piston.
1. Pack the cavity between the 011 seals and bearing
cones with bearing grease.
2. Place the wheel between fork sides with the brake

disc centered between the brake pads.
3. Apply Loctlte ANTI·SEIZE to axle shaft, then Insert

ax le from the right fork side through the wheel hub,
speedometer d rive and left fork side. The
speedometer drive gear must engage Ihe hole in the
brake disc and hole in the left side of the hub.
CAUTION
Be sure the speedometer cable Is routed below the

brake caliper and parallel with the brake line hOle.
4. See Fig ure 2·2. Install washer (9), lockwasher (10)

and axle nut ( II ).
5. Ini tially, tigh ten slider cap nuts <n only on nut side 01
axle to 11 ft·lbs torque. Tighten axle nut 1050 It·lbs
torque, then lighten the other slider cap nuts <n to 11
fI·l bs torq ue.
NOTE
After proper tightening of slider cap nuts, check to see

that fron t and rear gap between slfdercap and fork leg is
equal. Figure 2·5. Rear Wheel Mounting
2·9
Disassembly 3. Remove bolts (12), washers (13) and sprocket (14).
CAST WHEElS (Figure 2-6)

1979·1983
CAST WHEELS (Figure 2·7)
1. Remove the two retaining rings (1), washers (2), oil 1984·1985
seals (3), spacers (4, 5), bearings (6), and spacer (8).
Discard oil seals. Use WHEEL BEARING RACE
1. Remove oil seals (3), spacers (4, 5), bearings (6), and
REMOVERIINSTALLER, Part No. HD·33071.
spacer (8), Discard oil seals, Use WHEEL BEARING
RACE REMOVER liN STALLER, Part No. HO-33071 to
2. Remove screws (10) and brake disc (11). remove bearing cups (7) from wheel (9).
1. Retaining ring (2)

2. Washer (2)
3. Oil seal (2)
4. Spacer
5. Spacer
6. Bearing cone (2)
7. Bearing cup (2)
8. Spacer
9. Wheel
10. Screw (5)
11. Brake disc
12. Bolt (5)
13. Washer (5)
14. Sprocket
15. Axle
16. Washer
17. lockwasher
18. Nut
14
Figure 2·6. Rear Wheel Cast - 1979·1983
2·10
2. Remove screws (10) and brake di sc (11). 3. Remove bolts (1 3), lockwashers (14), locknut s (15)
and sprocket (16).
3. Remove bolts (12), washers (13) and sprocket (14).
4. If it Is necessary to remove the hub from the wheel ,
LACED WHEELS (Figure 2 -8) unscrew all spoke ni pples and remove the rim and
1979·1983 spokes from the hub.
LACED WHEElS (Figure 2·9)
1. Remove the two retai ning ri ngs (1), washers (2), oi l 1984·1985
seals (3), spacers (4, 5), bearings (6), and spacer (7).
1. Remove the oil seals (3), spacers (4 , 5), bearings (6),
Discard all seals. Use a standard bearing puller to
and spacer (7). Disca rd oil sea ls. Use a standard
remove bea ring cups from hub (8). bearing puller to remove bearing cups from hub (8).
2. Remove screws (9), lockwashers (10), lockn uts (11) 2. Remove screws (9), lockwashers (10), lock nuts (11)
and brake di sc (12). and brake disc (12).
1. Nut
2. Lockwasher
3. Oil seal (2)
4. Spacer (short)
S. Spacer (long)
6. Bearing cone (2)
7. Bearing cup (2)
8. Spacer
9. Wheel
10. Screw (5)
11 . Brake disc
12. Bolt (5)
13. Washer (5)
14. Sprocket
15. Axle
16_ Washer
/
11
Figure 2·7. Rear Wheel · Cast - 1984·1985
2·11
3. Remove bolts (13), lockwashers (14), locknuts (15) 1. Clean al l pa rts in solven t and i nspect for damage or
and sp rocket (16). wear.
2. If beari ng cones or cups need repl acing, replace as a

4. If it is necessary to remove the hu b from the wheel, set.
unscrew al l spoke nipples and remove the rim and
spokes from the hub. 3. Replace brake disc it it is warped, scored or worn
beyond the mi nimum thickness stamped on t he
Cleaning, Inspection and Repair disc. See SPECIFICATIONS.
2.
/ 19 18
@I/
~@
17
1. Retaining ring (2) 11. Locknut (5)

2. Washer (2) 12. Brake disc
3. 011 seal (2) 13. Bolt (5)
4. Left spacer 14. Lockwasher (5)
5. Right outer spacer 15. Locknut (5)
6. Bearing (2) 16. Sprocket
7. Spacer 17. Axle
8. Hub 18. Washer
9. Screw (5) 19. Lockwasher
10. Loekwasher (5) 20. Nut
Figure 2·8. Rear Wheel, Laced - 1979·1983
2·12
4. Replace the all seals. using screws (10). Apply Loc tite STUD N' BEA RIN G
MOU NT and tighten screws to 23 to 27 ft·lbs torque.
5. On laced wheels, replace the spokes, rim or hub if
damaged. 2. Install the sprocket (14) using bolts (12) and washers
Assembly (13). Tighten bolts to 45·50 f1·lbs torque.
CAST WHEELS (Figure 2·6) 3. Apply a li beral amount of bearing grease to bearing
1979·1963 c ups and press one Into each side of the hub using
WHE EL BEARING RACE INSTALLER, Part No.
1. Make sure brake disc is clean and then Install disc HD·33071.
16
17
1. Lockwasher 10. Lockwasher (5)

2. Nut 11 . Locknut (5)
3. Oil seal (2) 12. Brake disc
4. Left spacer (short) 13. Bolt (5)
5. R~ht outer spacer (long) 14. Lockwasher (5)
6. Bearing (2) 15. Locknut (5)
7. Spacer 16. Sprocket
6. Hub 17. Axle
9. Screw 18. Washer
Figure 2·9. Rear Wheel · Laced - 1984·1985
2·13
4. Place the spacer (8) into the hub. Apply a liberal 3.lnstall the sprocket (16) using bolts (13),
amount of bearing grease to the bearing cones (6), lockwashe rs (14) and locknuts (15). Tighten bolts to
packing the cavities around the rollers. Install the 45-50 ft-Ibs torque.
cones in the matching cups.
4. Apply a liberal amount of bearing grease to bearing
5. Lightly coat the outside lip of new oil seals (3) with cups and press one into each side of the hub.
engine oil. Press one seal into each side of the hub
until it is 3/16 in. to 1/4 in. below outside edge of hub. 5. Place the spacer (7) into the hub. Apply a liberal
Fill the cavity between the bearing and seal with amount of bearing grease to the bearing cones (6)
bearing grease. packing the cavities around the rollers. Instal l the
6. Install the short spacer (4) on disc side and long
spacer (5) on sprocket side of hub. 6. Lightly coat the outside lip of the new oil seals (3)
with engine oil Press one seal into each side of the
7. Install washers (2) and retaining rings (1). hub until it is 3/16 in. to 1/4 in . below outside edge of
hub. Fill the cavity between the bearing and seal
8. Wheel and tire must be true. See applicable section, with bearing grease.
CHECKING CAST RIM RUN OUT.
7. Install the short spacer (4) on disc side and long
CAST WHEElS (Figure 2·7) spacer (5) on sprocket side of hub.
1984·1985
8. Install washers (2) and retaining rings (1).
1. Make sure brake disc is clean and then inst all disc
using screws (10). Apply Loctite STUD N' BEARING 9. Wheel and tire must be true. See applicab le section,
MOUNT and tighten screws to 23-27 ft·lbs torque. TRUING LACED WHEEl.
2. Install the sprocket (14) us ing bolls (12) and washers

(13). Tighten bolts to 50-55 ft·lbs torque.
LACED WHEELS (Figure 2·9)
3. Install a liberal amount of bearing grease to bearing 1984·1985
cups and press one into each side of the hub using
WHEEL BEARING RACE INSTALLER, Part No. 1.lf the hub and rim were disassembled, reassemble
HD·33071. the hub, spokes and rim as described in LACING
WHEELS.
4. Place the spacer (8) into the hub. Apply a libera l
amount of bearing grease to the bearings cones (6), 2. Make sure brake disc (12) is clean and then install
packing the cavities around the rollers. Install the disc using screws (9), lockwashers (10) and locknuts
cones in the matching cups. (11). App ly Loctile STUD N' BEARING MOUNT and
lighten screws to 23·27 ft-Ibs torque.
5. Lightly coat the outside lip of oi l seals (3) with
engine oil. Press one seal into each side of the hub 3. Install the sprocket (16) using bolts (13),
until it is 3/16 in. to 114 in . below outs ide edge of hub. lockwashers (14) and locknuts (15). Tighten bolls to
Fill the cavity between the bearing and seal with 45-50 fI-lbs torque.
bearing grease.
4. App ly a liberal amount of bearing grease to bearing
6. Install the spacers (4) and (5) in the hub. cups and press one into each side of the hUb.
7. Wheel and tire must be true. See applicable section, 5. Place the spacer (7) into the hub. Apply a libera l
CHECKING CAST RIM RUN OUT. amount of bearing grease to the bearing cones (6),
packing the cavities around the rollers. Install the
LACED WHEELS (Figure 2·8)
1979·1983 6. Lightly coat the outside lip of the new oil seals (3)
with engine oil. Press one seal into each side of the
1. If the hub and rim were disassembled, reassemble hub until it is 0.20 in. to 0.22 in. below outside edge
the hub, spokes and rim as described in LACING of hub. Fill the cavity between the bearing and seal
WHEELS. with bearing grease.
2. Make sure brake disc (12) is clean and then install 7. Install the spacers (4) and (5) in the hub
disc using screws (9), lockwashers (10) and locknuts
(11). Apply Loctite STUD N' BEARING MOUNT and 8. Wheel and tire must be true. See the section TRU-
tighten screws to 23-27 ft-Ibs torque. ING LACED WHEEl.
2·14
Installation Late Style Hub - See Figure 2-11. Pick any outside
spoke hole and sight straight across the hub. The
1. Place wheel centrally In the rear swing arm with the IIrst spoke hole to the right of the centerline Is an
brake disc In the caliper, and place the chain onlo outside spoke hole. Also, with the wheel assembled,
the sprocket. all Inner spokes on opposite sides of the wheel
cross and all outer spokes on opposite sides of the
2. Apply l octlte ANTI·S EIZE to axle shaft, then Insert wheet cross. See Figure 2-13.
axle through the left side 01 swing arm, through the 2. There are two thread patterns used on the spokes
rear caliper bracket, wheel and right side of swing and nipples. Align all the spokes next to each other
arm. on a table. Match the fine-threaded spokes with flne-
threaded nipples and coarse-threaded spokes with
3. Inslall lIatwasher, lockwasher and nut. Tighten axle coarse-threaded nipples. Do not Intermix the thread
nut to60-65 fI·lbs torque. patterns. Also, straighten or replace any bent
spokes.
WARNING
Wheel bearing end play should be .004 to .018 In. when

axle nulls tightened to 65·70 tt·lbs torque. It end play Is
.."
not correct, substitute a s1ighlly longer or shorter
spacer, (8, Figure 2·6 and 2·7) or (7, Figures 2·8 and 2·9)
as necessary. Spacers are available In three lengths,
3.937 (Red), 3.951 (Green), and 3.923 (Blue) in. for Inner rows
1979·1981 models and 4.420 (Orange), 4.434 (Yellow) and of spoke
4.448 (White) In. tor 1982 and later models. holes
4. Check for proper chain tension as described in Sec·

tlon 6, REAR CHAIN and align wheel as described in
this section under TIRES, Wheel Alignment.
LACING WHEELS - 16 INCH

1. There are two styles of wheel hubs and they are Inner spoke Outer spoke
Identified as follows: (clockwi se) (counterclockwise)
Line of
Earty Style Hub - See Figure 2-10. Pick any outside
sight
spoke hole anc! sight straight across the hub. The
first spoke hOle to the right of the centerline is an In-
ner spoke hole. Also, with the wheel assembled, all Figure 2·11 . Late Style Hub
Inner spokes on opposite sides of the wheel angle In
the same di rection and all ou ter spokes on opposite
sides of the wheel angle In the same direction. See
Figure 2-12.
.." Inner spokes on opposite
sides of wheel angle In
~~~:iE=~~ d irection
Outer rows
of spoke
holes
Inner rows
of spoke
holes
Outside spoke Inner spoke Ten groups 01

(clockwi se) (counterclockwise) four spokes
Figure 2·10. Early Style Hub Figure 2-12. Early Style Laced Wheel
2·15
11)40 Inner spokes on opposite
sides of wheel cross
.." First outside spoke -
cross four inside spokes
#~
fa~ :~
~;< A
c
Figure 2·14. Cross·4 Pattern
Ten groups of
tour spokes
spokes In the opposite direction as the other side so
Figure 2·13. Late Style Laced Wheel the inner spokes cross each other.
9. See TRUING LACED WHEEl.

3. Place the hub on the bench with either flange up.
4. See Figure 2-10 and 2-11.lns8rI10 spokes Into the

upper lIange inner spokes holes. Swing the loose
ends clockwise as far as they will go. LACING WHEELS - 19 INCH
NOTE
NOTE
The (Of/owIng procedure applies for both single and
When lacing an old style hub, inner spokes may be
started clockwise or counterclockwise because a1/ in- dual disc wheels.
ner spokes angle In the same direct/on.
1. See Figure 2-15. Divide spokes into 2 groups. Inner
spokes have long headS, outer spokes have short
5. See Figure 2-12 and 2-13. The rim Is divided Into len heads. There are also fine and coarse threaded
groups of spoke holes, 4 holes to a group. In each spokes and nipples. Match up fine·threaded spokes
group, only one hole will be angled toward each up- with IIne·threaded nipples and coarse·threaded
per flange inner spoke. Place the rim over the hub, spokes wi th coarse·threaded nipples . Do not inter·
either side up, and insert the spokes into these mix the thread patterns.
holes. Secure each spoke with a nipple screwed on
the end about 3 turns, just enough to hold II In place.
6. When all 20 inner spokes are Installed, Insert a

spoke into an outside spoke hole on the same flange Outer spoke Inner spoke
side. See Figure 2-10 and 2- 11 . (s hort·head) (Iong·head)
7. See Figure 2- 13. Swing the outer spoke In the op·

posite direction crossing over 4 inner spokes , and
secure the spoke in the nearest hole ang led towards
it. Repeat the procedure for all outer spokes.
NOTE
All Harley·Davldson laced wheels use a CROSS·4 pat·

tern, Figure 2·14. Each outer spoke must cross 4 inner
spokes before entering rim hole.
8. Carefully flip the hub and rim assembly over and

repe at the process. If lacing an earl y style hub, start
by swinging the Inner spokes in the same direction
as the other side. On late style hubs, swing the inner Figure 2·15. Spo«e Identification
2·16
2. See Figure 2-16. Place hub on bench either side up. 6. Center the rim over the hub assembly. Undo each
Insert one ouler spoke (short.head) into any bottom top bundle and fan the spokes out around the top
flange hole and swing it clockwise. Insert an inner rim edge.
spoke (Iong·head) in the next hole to the left of the
outer spake. Swing the inner spoke counter· 7. See Figure 2-17. The rim is divided into ten groups
clockwise over the outer spoke. of spoke holes, 4 holes to a group. Each group has
two holes on the left and two holes on the right,
3. Insert an inner spoke into the hole on the top flange angled inward towards each other. Only one hole in
that directly bisects the two spokes in the bottom each group will be angled toward the bottom flange
flange. Insert all remaining spokes in both hub inner spoke (Iong·head). Lace all bottom flange inner
flanges alternating the inner and outer spokes. spokes into these holes. Secure each spoke with a
nipple screwed on the end abOut 3 turns.
4. See Figure 2-18. With all 40 spokes inserted in hub, NOTE

group all spokes on top flange into 2 bundles. Se·
cure each group with throttle grips or tape to keep Hub and spoke assembly may have to be spun slightly
the spokes together. within the rim to aI/ow proper spoke·to·rim alignment.
Keep the bottom flange spokes crossed In correct pas;·
5. Swing all bottom flange outer spokes (short.head) tion when spinning the hub. Also, keep the top flange
clockwise. Swing the inner spokes (Iong.head) spokes fanned around the rim. If they fall off the rim and
counterclockwise, crossing over the outer spokes. become tangled in the bottom flange spokes, the hub
Angle all spokes as far as they will go without over· will not rotate and it might be necessary to unlace the
lapping the next LIKE spoke. For instance, swing an wheel to untangle them.
outer spoke (short.head) clockwise as far as it will
go before crossing another outer spoke. 8. Next lace the 10 bottom flange outer spokes (short·
head). Only one hole in each group of rim spoke
holes will be angled toward these spokes. Secure
each spoke with a nipple screwed on abOut 3 turns.
1~55
9. Lace all the top flange inner spOkes, one at a time

Inner spoke leaving the outer spokes resting on the rim. Swing
(Iong.head) the top flange inner spokes clockwise.
10. Now lace the top flange outer spokes. Swing them
counterclockwise and make sure each one crosses
4 inner spokes before securing it to the rim.
11. See TRUING LACED WHEEL.
TRUING LACED WHEEL

1. See Figure 2-19. Divide the wheel spokes into 4
groups of 4 and mark the center of each group with a
piece of tape. The groups should be directly across
Figure 2·16. Lacing'19 in. Wheel from one another and approximately 90 0 apart.
\ VI
Figure 2·17. Grouping The Spokes

2·17
('~~ on am
Figure 2·18. Bundling Top Spokes
;;L:::::=::::;==~-t""
;~ Straightedge
~ ~d~2340
LI
~ ~~ 2.400
Figure 2-20. Centering 16 In. Hub
Figure 2·19. Marking Spoke Groups
NOTE
All Harley·Davldson laced wheels use a cross·4 pattern.
Each outer spoke must cross four Inner spokes before
entering rim hole. TIghten the spokes In these four
groups finger tight, leaving al/ others loose.
2. Install truing arbor In wheel hub and place wheel In

WHEEL TRUING STAND, Part No. HD-99500·29A.
Tighten arbor nuts so hub will turn on its bearings.
.1.
3. See Figure 2-20 and 2-21. The hub must be centered T1
sideways with the rim. Lay a straightedge across the
hub brake disc flange and one of the marked spoke
J--'
groups. Measure the distance from the straightedge A Straightedge
to the rim as shown. If this dimension Is not equal on
both sides 01 the wheel, loosen and tighten the 4 Figure 2·21. Centering 191n. Hub
spokes accordingly. Use SPOKE WRENCH, Part No.
HD·94681-80. EXAMPLE
If the measurement on the rim right side is greater than
NOTE the teft side, loosen the two spokes attached to the hub
left side and tighten the two spokes attached to the hub
Dimension A (Figu re 2-20 and 2·21) must be maintaIned right side. Turn all 4 spokes an equal number of turns
to ensure centering of wheel on motorcycle. until dimension is equal to within 1132" for both sides.
2·18
CAUTION
Always loosen the appropriate spokes before tightening

the other two. Reversing this procedure will cause the
rim to become out·ol·round.
4. Repeat Step 3 for all four groups on the wheel.
5. See Figure 2-22. After rim has been centered

sideways it must be checked and trued radially. Ad-
just truing stand gauge to the rims tire bead seat as
shown. The ri m should be trued within 1132~.
6. Spin the rim slowly. If the rim contacts the gauge on

or near a marked group of spokes, loosen the spokes
in the marked group on the opposite side of the rim.
Now tighten the spokes In the group where the rim
makes contact. Loosen and tighten spokes an equal
number of turns.
If the rim contacts the gauge between two marked

groups, loosen the spokes in both opposite groups
and tighten the spoke groups on the side of the rim
that makes contact.
runout
7. When the wheel is centered and trued, start at the
valve hole and tighten the rest of the spoke nipples
one turn at a time until they are snug.
8. Seat each spoke head in the hub flange using a flat

nose punch and hammer. Then check wheel true·
ness again and tighten the nipples accordingly. Figure 2·23. Checking Cast Rim Lateral Runout
Gauge Spoke nipple Gauge

wrench
Figure 2·22. Truing Rim Radially Figure 2·24. Checking Cast Rim Radial Runout
2·19
CAUTION Some Ures have arrows molded Into the tire sidewall.
These ti res should be mounted on the rim with the arrow
Over tighten ing spokes may cause nipples to be drawn pointing in the direction of forward rotation. The colored
through rim, or hub fl anges to be distorted. Spokes left dot on the sidewall is a balance mark and should be
too loose continue to loosen when wheel is put into ser- located next to the valve stem hole.
vice.
WARNING
9. File or grind off ends of spokes protruding through
nipples to prevent puncturing tube when tire is Always check both tire sidewalls for arrows indicating
mounted. proper forward rotation. Some tires requlr. different tire
rotation depending on whether tire is used on front or
10. Check dimension A (Figures 2-20 and 2-21) and re- relr wheel.
true wheel if not within specifications,
Removal
CHECKING CAST RIM RUNOUT
1. Remove wheellrom motorcycle. See WHEELS.
The die-cast wheels should be checked lor lateral and
radial runout belore Installing a new Ure or tube. 2. let the air out of the tube or tire.
1. See Figure 2-23. Install arbor In the wheel hub and 3. See Figure 2-25. loosen both beads from rim flange
place wheel In the truing stand. To check rim lateral by stepping on sides of ti re or by using a Ure tool.
runout, place a gauge rod or dial IndIcator near the Stand or kneel on tire opposite valve and push bead
rim bead. II lateral runout exceeds 3/64 in., replace Into rim well. Repeat for other side.
the wheel.
NOTE
2. See Figure 2-24. Check lor radial runout as shown
here. Replace the wheel If runout exceeds 1/32 In. A bead breaker machine wffl be required to break the
bead on 16 In. wheels.
TIRES 4. Apply RIM PROTECTO RS, Part No. HD-01298 to the

rim. Using tire tools (not sharp Instruments), Figure
General 2·16, start upper bead over edge of rim at valve. Do
not use excessive force when starting bead over rim.
Tires should be Inspected for punctures, cuts, breaks Bead wires may be damaged ruining the tire. Repeat
and wear at least weekly. all around rim until first bead is over rim. Remove the
tube on tube type wheels.
Whenever a Ure Is replaced, the tube should also be
replaced. Inner tubes shou ld be patched only as an 5. Push lower bead inlo rim well on one side and Insert
emergency measure. Replace a damaged tube as soon lire tool underneath bead from opposite side. Pry
as possIble. bead over rim edge. Remove tire from rim.
Inner tubes must be used on all Harley·Davidson wheels

except cast wheels which are clearly marked for
tubeless tires. Rim bands must be used on all laced
wheels.
Flgur. 2·25. loosening Tlra Beads Figure 2·26. Starting Tire Oft Rim
2·20
6. On tubeless tire rims, remove the valve stem if it is 2. Thoroughly lubricate the rim flanges and both beads
damaged or leaks. of the tire with tire lubricant.
NOTE 3. See Figure 2-28. Starting at the valve stem hole,

start the first bead Into the rim well. Work the bead
On tube type wheels it is not necessary to completely on as far as possible by hand. Use the tire tool to pry
remove tire {rom rim. Removing one side allows the tube the remaining bead over the rim flange.
to be replaced and allows for inspection of tire.
4. Inflate tube just enough to round il out. Lubricate
thorough ly 360· around the tube base. Insert tube in
7. Mount the tire on TIRE SPREADER, Part No. tire with valve stem In hole.
HD·21000 for Inspection and repair procedures.
5. See Figure 2-29. Starting 180 · from valve stem, start
the second bead onto the rim. Work the bead onto
Cleaning, Inspection And Repair the rim with tire lools, working toward valve in both
directions. Remove the valve core from valve stem
1. Clean the inside of tire and outer surface of tube. before prying the remaining bead over the rim
flange.
2. If rim is dirty or rusty, clean with a stiff wire brush.
6. Make sure valve stem moves in and out freely, then
3. Inspect the tire and tube for wear and damage. inflate the tire 10 recommended pressure to seat the
Replace worn tires. Replace damaged tube. Use bead. See SPECIFICATIONS. Then deflate tire to
TIRE REPAIR KIT, Part No. HD·20000 for tire repair. allow inner tube to smooth out. Install the valve
Follow the kit manufacturer's instructions. core, then inflate to recommended pressure.
Installation TUBelESS TIRES
TUBE TYPE TIRES ,. If removed , Install a new valve stem.

WARNING 2. Thoroughly lubricate the rim flanges and both beads
of the tire with tire lubricant.
Use the correct Inner tube and tire as specified. See
TIRE DATA In SPECIFICATIONS. 3. Starling at the valve stem, start the first bead into
the rim well. Work the bead on as far as possible by
1. See Figure 2-27. On laced wheels, Install a rim strip hand. Use a tire tool 10 pry Ihe remaining bead over
into the rim well. Make sure no spokes protrude the rim flange.
through nipples and be sure to align the valve stem
hole in rim strip wilh hole in rim.
""
Figure 2·27. Installing Rim Strip Figure 2·28. Starting Bead On Rim
2·21
4. Start the second bead on the rim. Work the bead on· Checking Tire Radial Runout
to the rim with tire tools, working toward the valve in
both directions. 1. Check runout by turning wheel on axle, measuring
tread runout (see Figure 2-31).
5. Remove the valve core from the stem. Apply air to
the stem to seat the beads on the rim. It may be 2. Tire tread runout should be no more than 3/32 in. If
necessary to use a BEAD EXPANDER, Part No. tire tread runout is more than 3/32 in., remove lire
HD·28700 on the tire until the beads seal on the rim. from rim and check rim bead runout to see it rim is at
fault.
6. Deflate the tire, Install the valve core, then Inflate
the tire to recommended pressure. 3. If rim bead runout is less than 1/32 in., tire Is at fault
and should be replaced. If rim bead runout Is more
than 1132 in., correct by lightening selected spoke
WARNING nipples on laced wheels or replacing the cast rim.
Reinstall tire and recheck tire tread runout.
Do not Inflate over 40 psi to seat the beads. Inflating the
tire beyond 40 psi to seat the beads can cause the tire
rim assembly to burst with force sufficient to cause per· Wheel Alignment
sonal Injury. If the beads fall to seat to 40 psi, deflate
and relubrlcate the bead and rim and reinflate to seat NOTE
the beads but do not exceed 40 pSi.
Rims and tires must be true as outlined in the previous
paragraphs, before checking wheel alignment.
Checking Tire Lateral Runout
1. See Figure 2-32. Place a straightedge against the
1. Check runout by turning wheel on axle, measuring front and rear tire sIdewalls as far up as possIble.
amount of sideways displacement from a fixed point
near the tire (see Figure 2-30). 2. With the front wheel pointing straight ahead, both
front and rear wheels should be in perfect align·
2. Tire tread runout should be no more than 3/64 In. It ment.
lire tread runout is more than 3/64 In., remove tire
from rim and check rim bead side runout to see If rim Al18
is at fault.
3. Jt rim side runout is less than 1132 In., tire is at fault

and should be replaced. If rim side runout is more
than 1/32 In., correct by tightening selected spoke
nipples on laced wheels or replacing the cast rim.
I-
I
TI,. 'a'e,.,
mnou'
Reinstall old tire and recheck lire tread lateral
runout.
,
~ Gauge
Figure 2·30. CheckIng Tire Lateral Runout
AilS
pr=~
Gauge
"?~
9
~
j
!
-JL n
Tire radial runout

Figure 2·29. Starting Second Bead On Rim Figure 2·31 . Checking Tire Radial Runout
2·22
"111
Cast aluminum wheels require the special self·adheslve
Side view weights listed below.
Rear Front
Aluminum color Black
C@) ""r-..C@)
1 oz. weight 1 oz. weight
112 oz. weight 1/2 oz. weight
1. Sell adhesive wheel weights should be applied to

the flat surface of the rim. Make sure that area of ap·
Top view plication is completely clean, dry and free of 011 and
grease.
ShUt axle in rear fork
to correct misalignment
Rear J Front 2. Remove paper backing from weight and press firmly
: :
in place. If t oz. or more of weight must be added al
!
(1
~;f one localion, split Ihe amounl so thai half is applied
to each side of the rim.
Straightedge
3. Wheel should not be used for 48 hours to allow
Figure 2·32. Wheel Alignment Diagram
adhesive to cure completely.
Wheel Balancing 4. In most cases, static balancing using WHEEL TRU·

ING STAND, Part No. HD·95500-80 will prOduce
Wheel balancing is recommended to improve handling satisfactory results. However, dynamic balancing,
and reduce vibration, especially at high road speeds.
utilizing a wheel spinner, can be used to produce
Harley·Davldson has made available the following finer tolerances for besl high speed handling char·
spoke balance weights which press over the spoke acteristlcs. Follow the Instructions supplied with
nipple. the balance machine you are using. The maximum
1/2 oz. weight weight permissible to accomplish balance Is 3·1/2
3/4 oz. welghl oz. total weight applied to the rim. Wheels should be
1 oz. weight balanced to within 1/2 oz. at 60 mph.
2·23
BRAKES
GENERAL cylinder push rod free play. The push rod should have
1116 in. movement before contacting the piston
The Iront and rear brakes are fully hydraulic disc brake assembly.
systems, requiring little maintenance. The front brake
master cylinder is an integral part of the brake hand WARNING
lever assembly. The rear brake master cylinder is
located on the right side of the motorcycle near the Use a non·llammable cleaning solvent for cleaning com·
brake pedal. Every 2500 miles, check the master ponent parts. DO NOT use gasoline or other lIammable
cylinder reservoirs for proper fluid levels. With the reser- sUbstances.
voir In a level position, add O.O.T. 5 HYDRAULIC BRAKE
FLUID as needed. WARNING
Every 2500 miles, check brake pads and discs lor wear. Always clean brake components by washing In denat·
If brake pads are worn to 1116 in. or less they should be ured alcohol or brake lIuid. DO NOT use minerai base
replaced. Minimum brake disc thickness is stamped on cleaning solvents such as gasoline or paint thinner. Use
side of disc. of mineral base solvents causes deterioration of rubber
parts that continues after assembly and can result in
Also al 2500 mile intervals, check the rear brake master component failure.
TROUBLESHOOTING
Use the following troubleshooting guide to help in
determining probable causes of poor brake operation.
CONDITION CHECK FOR: REMEDY:

Ex.cessive lever or pedal travel or Air in system Bleed brake{s)
spongy feel Master cylinder low on lIuid Fill master cylinder with approved
brake fluid
Chattering sound when brake is Worn or defective pads Replace brake pads
applied Loose mounting bolts Tighten bolts
Warped disc Replace disc
Ineffective brake - Low fluid level Fill master cylinder with approved
lever or pedal travels to limit brake fluid
Piston cup defective Rebuild cylinder
Ineffective brake - Distorted disc Replace disc
lever or pedal travel normal Distorted or contaminated brake
pads Replace pads
Brake pads drag on disc - Cup In master cylinder not
will not retract uncovering relief port Inspect master cylinder
Rear brake pedal linkage out of
adjustment Adjust linkage
2·25
FRONT BRAKE MASTER CYLINDER 1. Open the bleeder screw on the front calipers and
drain the brake f luid by pumping the hand lever.
Removal and Disassembly 2. Disconnect hydraulic hose (20) from master cylinder.
1979·1981 MODELS (Figure 2·33) 3. Remove masler cylinder cover (2) and gasket (3), by
removing screws (4).
NOTE
4. Remove handlebar switch assembly and disconnect
The mas ter cylinder should only be disassembled if stoplamp wires.
problems are being experienced. When disassembling
master cylinder all seals should be discarded and a 5. Remove retain ing ri ng (6) and pivot pin (7), Pu llout
complete rebuild kit ins talled. brake lever (8), pin (9), pl unger (10) spring (11),
washers (12), and dust wiper (13),
CAUTION
6. Remove ret aining ring (14) with RETAI NING RING
When removing master cylinder cover, make sure that PLIE RS, Part No. HO-962 15-49.
all dirt Is removed to prevent dirt from entering reser-
voir. Master cylinders should be filled to the gasket sur- 7. Pull out piston (15), O-ring (16), piston cup (17),
face with the reservoir in a level position. spring cup (18), and piston return spring (19),
1. Master cylinder
2. Cover
3. Gasket
4. Screw (2)
5. Right angle fitting (2)
6. Retaining ring
7. Pivot pin
8. Brake lever
9. Pin
10. Plunger
11. Spring
12. Washer (2)
13. Oust wiper
14. Retaining ring
21 ~ 15. Piston
16. O-ri ng
1 17. Piston cup
18. Spring cup
19. Spring
20. Brake hose
_ 23
21 . Bolt and lockwasher
22. Tee
23. Brake hose
Figure 2·33. Front Hydraulic Mester Cylinder - 1979·1981

2-26
1982 Model (Figure 2·34) denatured alcohol or brake fluid. DO NOT use minerai
base cleaning solvents such as gasoline or paint
CAUTION thinner. Use of minerai base solvents will cause
deterioration of rubber parts that continues after
When removing master cylinder cover, make sure that assembly and can result In component failure.
all dirt is removed to prevent dirt from entering reservoir.
Master cylinders should be filled to the gasket surface 1. Inspect cylinder walls for scratches and grooves.
with the reservoir In a level position.
2. Make sure vent holes in master cylinder are open.
1. Open bleeder nipple on front caliper(s) and dra in 3. Inspect gasket (3) and replace if required.
brake fluid by pumping hand lever.
Assembly and Installation
2. Disconnect hydraulic brake line (7) from masler
cylinder, by removing bolt (5) and washers (6). 1979·1981 MODELS (Figure 2·33)
Discard washers (6).
1. Dip all internal parts in D.O.T. 5 HYDRAULIC BRAKE
3. Remove master cylinder screws (4), cover (2) and FLUID.
gasket (3).
2. install pislon return spring (19), spring cup (18),
4. Remove retaining ring (8), pivot pin (9), brake lever piston cup (17), new O·ring (16) and piston (15).
(10) and reacllon pin (23).
3. Using RETAINING RING PLIERS , Pari No.
5. Remove master cylinder from handlebar by removing HD·96215·49, install retaining ring (14).
screws (13) and clamp (14).
4. Assemble washers (12), spring (11), dust wiper (13)
6. Pull oul push rod (22), dust boot (21), piston and and plunger (10).
o·ring (19 and 20), back up disc )18), cup (17), stop (16)
and spring (15). 5. Coal pin (9) with Loctite ANTI·SEIZE and install pin
(9) inlo brake lever (8). Insert brake lever assembly in·
7. Remove sighl glass (11) and grommet (12). 10 master cylinder and align hole In pin (9) with
plunger. Insert pin (7) through lever assembly and
1983·1985 MODELS (Figures 2·37 and 2·38)
Ihe master cylinder. Secure pin (7) with retaining ring
(6).
CAUTION
6. Reconnect stop lamp wires and assemble handlebar
When removing master cylinder cover, make sure that
switch assembly.
all dirt Is removed to prevent dirt from entering the reser·
voir. Master cylinders should be filled to the gasket sur·
7. Connect hydraulic hose (20) to master cylinder.
face with the reservoir in a level position.
1. Open bleeder nipple on front calipers(s) and drain WARNING
brake fluid by pumping hand lever.
Before adding hydraulic fluid, check to see that relief
2. Disconnect hydraulic brake line (7) from master port In master cylinder is uncovered when brake lever Is
cylinder by removing bolt (5) and washers (6). Discard released and that there is no free play in lever.
washers (6).
8. Fill master cylinder with D.O .T. 5 HYDRAULIC
3. Remove master cylinder screws (4), cover (2) and BRAKE FLUID. Bleed brake system, using procedure
gasket (3). outlined in BLEEDING HYDRAULIC BRAKE
SYSTEM.
4. Remove retaining ring (8), pivot pin (9), brake lever
9. Install gasket (3), cover (2) and screws (4). Tighten to
(10) and reaction pin (22).
10-15 in·lbs torque.
5. Remove master cylinder from handlebar by removing
10. Test ride motorcycle. If brakes feel spongy repeat
screws (13) and clamp (14).
bleeding procedure.
6. Pullout push rod (21), dust boot (20), piston and O·rlng 1982 MODEL (Figure 2·34)
(18 and 19), cup (17), stop (16) and spring (15).
1. Dip all internal parts in D.O.T. 5 HYDRAULIC BRAKE
7. Remove sighl glass (11) and grommet (12). FLUID.
2. Install grommet (12), coated wilh D.O.T. 5 HYDRAUL·

Cleaning, Inspection and Repair IC BRAKE FLUID, and sight glass (11).
CAUTION 3. Inslall spring (15), stop (16), cup (17), back up disc
(18), piston and O·ring (19 and 20), dust boot (21) and
Always clean brake system components by washing in push rod and switch (22).
2·27
A,211
1. Master cylinder 20.0·ring

2. Master cylinder cover 21. Oust boot
3. Gasket 22. Push rod and switch
4. Screws (2) 23. Reaction pin
5. Bolt 24. Brakehose
6. Washers (2) 25. Lockwasher 13
7. Hydraulic line 26. Lockwasher
8. Retaining ring 27. Bolt
9. Pivot pin 28. Brake hose
10. Brake lever
11. Sight glass
12. Grommet
13. Screws (2)
14. Clamp
15. Spring
16. Stop
17. Cup
18. Back up disc
19. Piston
o
28
Figure 2·34. Front Hydraulic Master Cylinder - 1982
4. See Figure 2·35. Lightly coat reaction pin (4) with 5. Install master cylinder to handlebar by installing
Loclite ANTI·SEIZE and insert into large hole in clamp (14, Figure 2·34) and screws (13). Tighten
brake lever (5). Assemble brake lever (5) to master screws to 70-80 in·lbs torque.
cylinder assembly (2) using pivot pin (1) and retain·
ing ring (6). Make sure push rOd (3) fits into hole in
reacllon pin. (4). Check front brake for proper oper· 6. Install new washers (6), bolt (5) and hydraulic brake
atlon. line (7) Into master cylinder. Tighten bolt to 30-35 ft·
CAUTION Ibs torque.
See Figure 2·36. Push rod (1) must be inserted into hole
in reaction pin (2). There must not be any binding of CAUTION
brake lever when depressed. If brake lever does bind,
push rod switch activator Is hitting the inside master Make sure washers (6), bolt (5), hydraulic brake line (1)
cylinder casting wall. and master cylinder bore (1) are free of hydraulic fluid,
dirt and metal chips before assembly. to avoid leakage.
NOTE
If master cylinder Is mounted on the handlebar, 7. Fill the master cylinder with D.O.T. 5 HYDRAULIC
assembly of the brake lever is simplified by using a BRAKE FLUID. Bleed brake system using pro·
piece of strIng or wire to hold push rod stationary while cedure outlined In BLEEDING HYDRAULIC
aligning react/on pin. SYSTEM .
2·28
AU7
INCORRECT
2-----;V;
3--f'--L:: ~
@--6
1. Pivot pin
2. M.. ter cylinder assembly
3. Puahrod
4. Reaction pin
1. Push rod
5. Brake lever
2. Reaction pin
6. Ret.lnlng ring
Figure 2·36. Handlever
Figure 2·35. Front Brake Handlever
WARNING 4. See Figure 2·35. Lightly coat reaction pin (4) with
Loct;te ANTI·SEIZE and insert into large hole in
Before adding hydraulic fluid check to see that relief brake lever (5). Assemble brake lever (5) to master
port In masler cylinder Is uncovered, when brake lever Is cylinder assembly (2) using pivot pin (1) and retain·
released and that there Is no free play In the lever. ing ring (6). Make sure push rod (3) lits into hole in
reaction pin (4). Check front brake for proper opera·
8. Install gasket (3), cover (2) and screws (4). Tighten tion.
screws 10·15 In·lbs torque.
CAUTION
9. Test ride motorcycle. If brakes feel spongy, repeat
bleeding procedure.
See Figure 2·36. Push rod (1) must be inserted into hole
In reaction pin (2). There must not be any binding of
NOTE
brake lever when depressed . If brake lever does bind,
push rod switch activator Is hitting the Inside master
The master cylinder assembly is equipped with. sight
cylinder casting wall.
gl.ss to visually check fluid level without removIng
cover. When full, the sight glass will be dark. When fluid
NOTE
level drops. glass will lighten.
If master cylinder Is mounted on handlebar. assembly of
1983·1985 MODELS (Figures 2·37 and 2·38) the brake fever Is simp/med by using a piece of string or
wire to hold push roo stationary while aligning reacl/on
1. Dip all internal parts in D.O.T. 5 HYDRAULIC pin.
BRAKE FLUID.
5. Install master cylinder to handlebar by Installing
2. Install grommet (12), coated with D.D.T. 5 clamp (14, Figures 2·37 and 2·38) and screws (13).
HYDRAULIC BRAKE FLUID, and sight glass (11). Tighten screws to 70-80 in·lbs torque.
3. Install spring (15), stop (16), cup (17), piston and 6. Install new washers (6), bolt (5) and hydraulic brake
D·ring (18 and 19), dust boot (20) and push rod and line (7) into master cylinder. Tighten bolt to 30-35 ft·
switch (21). Ibs torque.
2·29
A216
1. Master cylinder 20.0·ring

2. Master cylinder cover 21. Dust boot
3. Gasket 22. Push rod and switch
4. Screws 23. Reaction pin
5. Bolt 24. Brake hose 13
6. Washers (2) 25. Lockwasher
7. Hydraulic line 26. Bolt
8. Retaining ring
9. Pivot pin
10. Brake lever
11. Sight glass
12. Grommet
13. Screws (2)
14. Clamp
15. Spring
16. Stop
17. Cup
18. Back up disc
19. Piston
13
o
/'
/'
'®"
if'1154 0
o
CAUTION 8. Install gasket (3). cover (2) and screws (4). Tighten
screws 10·15 in-Ibs torque.
Make sure washers (6), bolt (5), hydraulic brake line (7)
and master cylinder bore (1) are free of hydraulic fluid,
dirt and metal chips before assembly to avoid leakage. 9. Test ride motorcycle. If brakes feel spongy, repeat
bleeding procedure.
WARNING
Before adding hydraulic fluid, check to see that relief

port in master cylinder Is uncovered when brake lever is NOTE
released.
The master cylinder assembly is equipped with a sight
7. Fill the master cylinder with O.O.T. 5 HYDRAULIC glass to visually check fluid level without removing
BRAKE FLUID. Bleed brake system using proce- cover. When full, the sight glass will be dark. When fluid
dure outlined in BLEEDING HYDRAULIC SYSTEM. level drops, glass will lighten.
2·30
A216
1. Master cylinder 14. Clamp

2. Master cylinder cover 15. Spring
3. Gesket 16. Stop
4. Screws 17. Cup
5. Bolt 18. Piston
6. Washers (2) 19. O·rlng
7. HydrauliC line 20. Dust boot
8. RetalnlnQ ring 21. Push rod and switch
9. Pivot ring 22. Reaction pin
10. Brake lever 23. Brake hose
11. S~ht glass 24. Lockwasher
12. Grommet 25. Bolt
13. Screws (2)
'it'14
II§' 15
REAR BRAKE MASTER CYLINDER 3. Remove two bolts and lockwasher (12) securing
master cylinder to sprocket cover.
4. Remove cover screws (6), cover (7) and gasket (5)
Removal and Disassembly and dra in I luid from cylinder (8).
1979 MODELS (Figure 2·39) NOTE
1. Disconnect brake line (9) at master cylinder (8). The master cylinder should only be disassembled if
2. Remove retaining ring (10), clevis pin (11) and push master cylinder aI/ seals should be discarded and 8
rod (2) from master cylinder (8). complete rebuild kit Instal/ed during assembly.
2·31
5. Remove rubber boot (13), retaining ring (14), piston 2. Make sure vent ho les in the master cylinder are
assembly (15), wafer (17), piston cup (18), spring open.
seat (19) and spring (20). Remove O-ring (16) from
piston (15). 3. Inspect gasket (5) and replace if required.
1980·1981 MODElS (Figure 2·40) Assembly and Installation

1. Disconnect brake line (9) at master cylinder (3). 1979 MODElS (Figure 2·39)
2. Remove two bolts (1) and lockwashers (2) that secure 1. Dip all internal components in D.O.T. 5 HYDRAUL-
master cylinder to sprocket cover. Pull master IC BRAKE FLUID before assembly.
cylinder free of push rod (16) and remove cupped
washers (14), spring (15) and boot (13). 2. Push spring seat (19) into spring (20) and slide into
cylinder bore.
3. Remove master cylinder cover screws and cover (4)
and gasket (5). Drain fluid from cylinder (3). 3. Slide piston cup (18) into bore, over spring seat
(19), place wafer (17) against piston cup (18).
NOTE
4. Carefully install new O-ring (16) over piston (15).
The master cylinder should only be disassembled if
problems are being experienced. When disassembling 5. Push piston assembly into cylinder bore and
master cylinder a/l seals should be discarded and a secure with retaining ring (14). Use INTERNAL
complete rebuild kit installed during assembly. LOCKRING PLIERS, Part No. HD·96215-49, to in·
stall retaining ring (14).
4. Remove retaining ring (12), piston (10), wafer (25),
piston cup (8), spring seat (7) and spring (6). Remove 6. Install boot (13) over master cylinder assembly.
O-ring (11) from piston (10).
7. Carefully slide push rod (2) through boot assembly,
to piston assembly . Align master cylinder assem·
1982-1985 MODElS (Figure 2-41) bly with outer sprocket cover mounting holes and
secure with bolts and lockwashers (12). Tighten to
1. Disconnect brake line (9) at master cylinder (3). 155·190 in·lbs torque.
2. Remove two bolts (1) and lockwashers (2) securing 8. Connect brake line (9) to cylinder (8).
master cylinder to sprocket cover. Pull master
cylinder free of push rod (16), and remove cupped 9. Fill the master cylinder with D.O.T. 5 HYDRAULIC
washer (14), spring (15) and boot (13). BRAKE FLUID. Bleed brake system using proce-
dure outlined in BLEEDING HYDRAULIC SYSTEM .
3. Remove master cylinder cover screws and cover (4)
and gasket (5). Drain fluid from cylinder (3).
WARNING
NOTE
Always lest motorcycle braking at low speeds after
The master cylinder should only be disassembled if
completing repairs or bleeding procedure. We recom-
mend all brake repairs be performed by a Harley-
master cylinder all seals should be discarded and a
Davidson dealer or other qualified mechanic.
complete rebuild kit installed.
4. Remove retaining ring (12), piston (10), piston cup (8), 1980·1981 MODElS (Figure 2·40)
spring seat (7) and spring (6) . Remove seal (II) from
piston (10). 1. Dip all internal components in D.O.T. 5 hydraulic
brake fluid before assembly.
Cleaning, Inspection and Repair 2. Push spring seat (7) into spring (6) and slide into
cylinder bore.
CAUTION
3. Slide piston cup (8) into bore and over spring seat (7).
Always clean brake system components by washing in Place wafer (25) against piston cup (8).
denatured alcohol or brake fluid. DO NOT use mineral
base cleaning solvents such as gasoline or paint 4. Carefully install O-ring (11) over piston (10).
thinner. Use of mineral base solvents causes deteriora·
tion of rubber parts that continues after assembly, and 5. Push piston assembly into cylinder bore and secure
can result in component failure. with retaining ring (12). Use INTERNAL LOCKR1NG
PLIERS, Part No. HD-96215-49, to install retaining
1. Inspect cylinder walls for scratches and grooves. ring (12).
2·32
42
r Inl
7·5116
~ (7.3 in.)
I c
1. Brake pedal 16. a·ring 31. Lockwasher

2. Push rod 17. Wafer 32. Inner pivot arm
3. Jamnul 18. Piston cup 33. Pivot shaft
4. Pedal stop bolt 19. Spring seat 34. Retaining ring
5. Gasket 20. Spring 35. Clevis pin
6. Cover screw (2) 21. Acorn nut 36. Brake rod
7. Master cylinder cover 22. Lockwasher 37. Clevis
8. Master cylinder 23. Washer 38. Spring clip
9. Brake line 24. Outer pivot arm 39. Jamnut
10. Retaining ring 25. Outer sprocket cover 40. Brake pedal shaft
11. Clevis pin 26. Return spring 41. Clamp screw
12. Bolt and lockwasher (2) 27. Inner sprocket cover 42. Brake fee
13. Rubber boot 28. Retaining ring 43. Brake hose
14. Retaining ring 29. Clevis pin 44. Stoplight switch
15. Piston 30. Acorn nut 45. Bushing
Figure 2·39. Rear Brake Master Cylinder and Rear Brake Linkage - 1979
2·33
6. Push cupped washers (14) and spring (15) into boot 9. Fill the master cylinder with D.O.T. 5 HYDRAULIC
(13). Assemble to master cylinder assembly, boot BRAKE FLUID. Bleed brake system using procedure
drain hole down. outlined in BLEEDING HYDRAULIC SYSTEM.
7. Carefully slide push rod (16) through boot assembly

to piston assembly. Align master cylinder assembly
with cover mounting holes and secure with bolts (1) WARNING
and lockwashers (2). Tighten bolts to 155·190 in-Ibs
torque. Always test motorcycle braking al tow speeds after
completing repairs or bleeding procedure. We recom·
mend all brake repairs be performed by a Harley-
8. Connect brake line (9) to cylinder (3). Davidson dealer or other qualified mechanic.
O~ 22
,~~/
~
'4 . ~®~ 11921~ -
4 ~~;7 ,.
~.,;;.-- . r
_ ~ 16
---1
~ I
I 15 _-- "
--
I ~'\\)')
5_~ i / / / - 2\ ~'l~~~
I __ ~~
, \ \;J 12 13
"
'
- .. ~
" 6 a",C)Ilff\-"
... -.•
\ \ 10 '\ \
c ,-" 7 •
~ ' \!~
..
9 1
"2, Bolt
Lockwasher
9.
10.
Brake line
Piston
17, Locknut
18, Rod end
3, Master cylinder 11. O-ring 19, PI"
4, Cover and screws 12. Retaining ring 2., Retaining ring
.,
5, Gasket
Spring
7, Spring seat
13.
14.
15.
Boot
Cupped washer (2)
Spring
21,
22.
Retaining ring
Brake pedal
23. Adjusting screw
8. Piston cup 16. Push rod 24. Locknut
25. Wafer
Figure 2·40. Rear Brake Master Cylinder and Rear Brake Linkage - 1980·1981
2-34
1982·1985 MODELS (Figure 2·41) 1. Remove rlghllootrest assembly.
1. Dip all Internal components In D.O.T. 5 HYDRAULIC

2. Remove retaining ring (10), clevis pin (11) and push
BRAKE FLUID before assembly.
rod (2). Remove bolts and lockwashers (12). Lilt
master cylinder up out of the way without discon-
necting the brake tine.
2. Push spring seat (7) into spring (6) and slide Into
cylinder bore.
3. Remove acorn nut (21), lockwasher (22) and washer

3. Slide piston cup (8) into bore and over spring seat (7). (23). Pull off pivot arm (24).
4. Carefully install seat (11) over piston (10). 4. Remove sprocket cover mounting nuts and screws,
remove outer sprocket cover (25).
5. Push piston assembly into cylinder bore and secure

with retaining ring (12). Use INTERNAL LOCKRING
PLI ERS, Part No. HD-96215·49, to install retaining
NOTE
ring (12).
It may be necessary to loosen the right side exhaust
system to remove sprocket cover.
6. Push cupped washer (14) and spring (15) into boot
(13). Assembly to master cylinder assembly, boot
drain hole down.
5. Unhook return spring (26) from stud on inner

7. Carefully slide push rod (16) through boot assembly sprocket cover (27). Remove Inner sprocket cover
to piston assembly. Align master cylinder assembly (27).
wit h cover mounting holes and secure with bolts (1)
and lockwashers (2). Tighten bolts to 155-190 In·lbs
torque.
Remaining parts need not be disassembled unless
they are worn or damaged.
8. Connect brake line (9) to cylinder (3).
9. Fi ll the master cylinder with D.O.T. 5 HYDRAULIC 1980·1985 MODELS (Figures 2·40 and 2-41)
BRAKE FLUID. Bleed brake system using procedure
outli ned In BLEE DING HYD RAU LI C SYSTEM.
1. Remove rear cylinder exhaust pipe.
2. Remove screw and clamp securing the rear brake

line to the sprocket cover.
WARNING
Always test motorcycle braking at low speeds after 3. Remove footrest assembly.
completing repa irs or bleeding procedure. We ,acom·
mend all brake rapairs be performed by a Harley-
Davi dson dealer or other qualified machanic.
4. Remove master cylinder mounting bolts (1) and
lockwashers (2), pull master cylinder (3) free of push
rod (16).
BRAKE LINKAGE AND 5. Remove retaining ring (21) and brake pedal (22).
SPROCKET COVER
6. Remove the locknut attaching the adjusting screw
Removal bracket (Integral part of exhaust system), then
remove the cover screws and free the sprocket
1979 MODELS (Figure 2·39) cover.
2·35
~
_3 1 24 .----
----- .'
.-
0' .-----
-----20.-1
1. Bolt (2) 9. Brake line 17. Locknut

2. Lockwasher (2) 10. Piston assembly 18. Rod end
3. Master Cylinder 11 . Seal 19. Pin
4. Cover and screws 12. Retaining ring 20. Cotter pin
5. Gasket 13. Boot 21. Retaining ring
6. Spring 14. Cupped washer 22. Brake pedal
7. Spring seat 15. Spring 23. Adjusting screw
8. Piston cup 16. Push rod 24. Locknut
Figure 2.. 1. Rear Brake Master Cylinder and Rear Brake linkage - 1982 and Later
Installation Retighten jamnut to 90·110 in-Ibs torque.
1979 MODELS (Figure 2·39) 2. Install inner sprocket cover (27) and hook return
spring onlo stud.
1. Carefully measure the brake rod assembly (36), from 3. Carefully Install outer sprocket cover (25), aligning
center line to center line of clevis pin holes, length pivot shaft (33) to pass through cover hole. Install
must be 7·5/16 in. Loosen jam nut (39) and adjust sprocket cover mounting screws and nuts. Tighten
clevis (37) as required to attain correct length. screw to 90·110 In-Ibs torque.
2·36
4. Install outer pivot arm (24), in a vertical position and 2. Depress brake pedal (1) slightly until reSistance, as
secure with flat washer (23), lockwasher (22) and the push rod (2) contacts piston (15), is encountered.
acorn nut (21). Tighten nut to 155·190 in·lbs torque. Measure the distance the outer pivot arm (24) has
traveled. Turn the pedal stop bolt (4) in or out of the
bracket until 1/16 in. pivot arm travel is obtained.
5. Position master cylinder assembly (5) over mounting
holes in sprocket cover (25). Secure with bolts and
lockwashers (12). Tighten bolts to 155·190 in·lbs 3. Secure the pedal stop bolt with the jamnut. Tighten
torque. the jamnut to 155-190 in·lbs torque.
6. Adjust brake pedal free play. Refer to BRAKE PEDAL

ADJUSTMENT.
1980 and Later Models
(Figure 2·40 and 2·41)
1980·1985 MODELS (Figures 2·40 and 2·41)
1. Hold sprocket cover in place and install the cover Proper free play between push rod (16) and piston (10) is
mounting screws. Tighten the screws to 90-110 in· critical to ensure proper rear brake operation. Adjust as
Ibs torque. follows:
2. Install the adjusting screw bracket (integral part of

the exhaust system), and secure with a new locknut. 1. Loosen locknut (24) and adjust brake pedal (22) with
Tighten the nut to 50-50 ft·lbs torque. adjusting screw (23) until desired pedal height is ob·
tained. Tighten locknuts to 90-110 in-Ibs torque.
3. Install brake pedal assembly (22) and secure with a
new retaining ring (21).
2. Depress brake pedal (22) slightly until reSistance, as

4. Position master cylinder assembly (3) over mounting the push rod (16) contacts piston (10), is en-
holes in sprocket cover. Secure with screws (1) and countered. Measure the gap between the brake
lockwashers (2). Tighten screws to 155-190 in-Ibs pedal and the adjusting screw. Gap should be 1/16
torque. in. Refer to Figure 2·42. Turn the push rod (16, Figure
2-40 and 2-41) in or out until the desired gap is ob·
5. Reinstall footrest assembly. tained. Tighten push rod locknut (17) to 12-15 ft·lbs
torque.
6. Install the brake line clamp and secure with screw.
7. Install the rear cylinder exhaust pipe.
8. Adjust brake pedal free play. Refer to BRAKE PEDAL

ADJUSTMENT.
BRAKE PEDAL ADJUSTMENT
1979 Models
(Figure 2·39)
Proper free play between push rod (2) and piston (15) is
critical to ensure proper rear brake operation. Adjust as
follows:
1. Loosen locknut (3) securing pedal stop bolt (4). Figure 2·42. Rear Brake Pedal Adjustment
2·37
DISC BRAKE CALIPERS - 3. Remove bolt (4) and washer (5) to separate caliper
halves (13) and (14).
FRONT 1979 to 1983 AND
REAR 1979 to 1981 4. Remove seal (16), piston boot (7), piston (8), outer
plate (9), brake pad set (10), and inner plate (11)
Removal and Disassembly from pins (12).
(Figures 2·43 and 2·44)
5. Pull pins (12) from inner caliper (13) for complete
If the brake disc must be replaced, it wi ll be necessary disassembly.
to remove the wheel. See WHEEL section . To remove
and disassemble one caliper assembly, use the follow-
ing procedure. Cleaning, Inspection and Repair
1. Remove the two mounting screws (1) and nuts (2) (Figure 2·43 and 2·44)
to release the caliper from the front fork or rear
mounting bracket.
1. Clean all metal parts in a non-flammable cleaning
2. Disconnect brake line fitting at the brake caliper. solvent. Blow dry with compressed air. Rubber
On 1979-1982 models be careful brake hose seal (3) parts must be cleaned in denatured alcohol or
is not misplaced. brake fluid.
v',,S
Wheel rotation
'4
1. Mounting Screws (2) 9_ Outer plate
2. Nut (2) 10. Brake pad set
3. Brake hose seat 11. Inner plate
4. Bolt 12. Pins
5. Washer 13. Inner caliper
6. Seal 14. Outer caliper
7. Piston boot 15. Bleed fitting
8. Piston 16_ Foam tape
Figure 2-43. Front Brake Caliper (Left) - 1979-1983

2·38
WARNING Assembly
Always clean brake system rubber parts by washing in (Figures 2·43 and 2·44)
denatured alcohol or brake fluid. DO NOT use mineral
base cleaning solvents such as gasoline or paint thin· 1. Place the two pins (12) in the inner caliper (13).
nero Use of mineral base solvents causes deterioration Slide the inner plate (11), brake pad set (10) and
of rubber parts that continues after assembly and can outer plate (9) onto the pins. Make sure the outer
result In component failure. plate (9) is positioned between the caliper piston
and the ouler brake pad so the direction of wheel
2. Inspect ali components carefully for excessive
rolalion is into the notch.
wear or damage. Discard old seal (6) and replace
with a new one.
2. Dip the seal (6), piston boot (7) and piston (8) into
brake fluid before assembly. Use silicone base
3. Inspect brake discs and replace if warped or badly
D.O.T. 5 HYDRAULIC BRAKE FLUID. Place the
scored. See WHEELS for disassembly procedure.
seal, boot and piston into Ihe ouler caliper (14).
4. Inspect brake pads for wear and damage. If pads
are worn to 1/16 in. or less replace them as a set.
NOTE
WARNING
Piston assembly must be pressed a/l the way into the
The front brake and the rear brake pads must be reo bore when new brake pads have been installed to
placed only In sets for correct and safe brake operation. assure proper clearance when calipers are reassembled
to motorcycle.
5. When replacing brake pads, sand the surface of
the pads with 60 or 80 grit emery cloth on a flat sur-
face to break up the surface glaze. Also, use emery 3. Posilion the outer caliper on the pins (12) and
cloth to slightly round off the leading edge of the secure to inner caliper assembly with washer (5)
brake pads. After the brake pads are installed, they and bolt (4). Tighten bolt to 60 to 65 fI-lbs torque.
should be burnished by making several hard stops
from approximately 55 mph. 4. Install bleed fitting (15), if removed, and brake hose
seat (3) inlo ouler caliper. Connect brake hose to
6. Replace any parts that appear worn or damaged. caliper. Install wheels, if removed. See WHEELS.
9
IIfI) Wheel rotoHon
14
,
16.........
6;;/
>
/
3-<>
1. Mounting screw (2) 6. Seal 11. Inner plate 16. Caliper mounting bracket
2. Nuts (2) 7. Boot 12. Pin (2) 17. Rubber bumper
3. Brake hose seat 8. Piston 13. Inner caliper
4. Bolt 9. Outer plate 14. Outer caliper
5. Washer 10. Pad set 15. Bleeder fitting
Figure 2·44. Rear Brake Caliper - 1979·1981

2·39
5. Mount the caliper assembly to the fork or caliper FRONT BRAKE CALIPER
mounting bracket with two mounting screws (1)
and locknuts (2). Coat mounting screws (1) with
Loctite ANTI·SEIZE. Torque screws to proper tight. Removal and Disassembly
ness. See SPECIFICATIONS.
1984·1985 Models
NOTE
(Figure 2·46)
New locknuts (2) should be used as this type of nut 1. Remove the upper mounting bolt (1) and the lower
tends to lose its holding power when reused. If new mounting pin (2) to release the caliper assembly
locknuts are not available, Loctile LOCK N' SEAL from the vehicle.
should be used on threads.
2. Disconnect the brake line at the caliper fitting.
6. With master cylinder nearly level, fill reservoir with 3. Move the caliper assembly to a clean bench area
D.O.T. 5 HYDRAULIC BRAKE FLUID. Reservoir and remove the retainer screw (15), pad retainer
may be filled with bladder type pressurized equip· (14) and inside pad (9).
ment, see BLEEDING HYDRAULIC SYSTEM.
4. The outer pad (9), pad holder (7) and spring clip (8)
NOTE are then removed as an assembly. Remove pad (9)
from pad holder (7) by pushing the pad free of the
Check for leaks. If leaks persist at hydraulic fittings, pad hold down spring clip (8).
coat surfaces with Loctite hydraulic sealant. Use only
Loctite hydraulic sealant to avoid contamination of 5. Pry out the retaining wire (13) by inserting a small
hydraulic system. Bleed brake to purge system 01 air. screwdriver into the notched groove at the bottom
of the piston bore.
6. Remove the piston dust boot (12). Then remove the

FRONT CALIPER FOAM piston by applying air pressure to the hydraulic
brake line inlet.
TAPE INSTALLATION
(Figure 2·45) WARNING
1. Remove the upper caliper mounting screw and
When removing the piston with air pressure, wear heavy
rotate the caliper away from the slider. Clean the
gloves or hold piston with heavy towel to prevent per·
caliper body with Loe1ile CLEANING SOLVENT
sonal injury. Be sure piston is not dropped on hard sur·
and allow to dry.
face.
2. Remove the paper backing from the foam tape and
apply to the front of the outer caliper body as 7. Pull threaded bushing (4) out of bushing bore, then
shown. Do not remove the protective Mylar from remove pin boot (5) from groove in caliper.
the foam. Apply a thin coating of Loctite ANTI·
SEIZE to the mounting screw and reinstall the 8. Seal (10) and the three O·rings (6) can be removed
caliper using a new locknut. Tighten the screw to 80 by prying them out of their respective grooves.
to 90 in·lbs torque.
",152 Cleaning, Inspection and Repair

Upper mounting
hole 1. Clean all metal parts with alcohol. Do not use
.56 In. gasoline. Blow dry with compressed air.
Outercaliper 2. Clean all rubber parts in denatured alcohol or
body brake fluid.
.10in. Foam tape WARNING
Always clean brake system rubber parts by washing in

denatured alcohol or brake fluid. DO NOT use minerai
base cleaning solvents such as gasoline or paint thin·
nero Use at mineral base solvents will cause deterlora·
tion at the rubber parts, which will continue alter
assembly, resulting In component tailure.
3. Inspect all components carefully for excessive

Figure 2·45. Foam Tape Installation wear or damage. Discard seal (10) and O·rings (6).
2·40
"'235
1. Upper mounting bolt 10. Seal piston
2. Lower mounting pin 11. Piston
3. Flat washer 12. Piston dust boot
4. Threaded bushing 13. Retaining wire
5. Pin boot 14. Pad retainer
6.0·ring 15. Retainer screw
7. Pad holder 16. Caliper
8. Spring clip 17. Bleed fitting
9. Pad set
Figure 2·46. Front Brake Caliper
4. Inspect brake disc and replace if warped or badly lightly coat the cavity of pin boot (5) with Dow Cor·
scored. Minimum acceptable disc thickness is ning Moly 44 grease. Insert the flanged end of pin
stamped on the disc. boot (5) into the internal groove of the threaded
bushing bore.
5. Inspect the brake pads for wear and damage. If
pads are worn to 1/16 in. or less, replace them as a 2. Push the piston dust boot (12), with the open side
set. downward, over the top of the piston. Push
downward on the boot unti l the inner lip seats in
WARNING the groove at the top of Ihe piston .
Brake pads must be replaced only In sets for correct 3. Coat the outside circumference of piston (11) with
and safe brake operation. D.0.T. 5 HYDRAU LIC BRAKE FLUID and push the
piston with dust boot into the piston bore. If
6. After the brake pads are i nstalled, they should be necessary, press the piston in with a " C " c lamp.
burnished by making several hard stops.
NOTE
7. Replace any parts that appear worn or damaged.
Piston must be pressed al/ the way into the bore when
new brake pads have been installed to assure proper
Assembly clearance when calipers are installed on vehicle.
After the parts have been inspected and any worn or 4. POsition the gap of the retainer wire at the lop of
damaged parts replaced , the caliper is reassembled as the caliper and compress the retainer wire (13) into
follows: the piston bore. Push the retainer wire firmly
against the piston dust boot.
1. Apply a coating of D.O.T. 5 HYDRAULIC BRAKE
FLUID to Ihe exterior surfaces of seal (10). Inslall 5. lightly coat the bores of the caliper mounting lugs
seal (10) and O·rings (6) in thei r respective grooves. with Dow Corning Moly 44 grease.
2·41
6. Push the threaded bushing into the pin boot and tapping retainer screw (15) through the hole in the
through the bushing bore in the mounting lug. center of pad retainer (14) and thread into the hole
Keep pushing until the free end of the pin boot in the pad. Tighten screw (15) to 55·70 in-Ibs.
seats in the grooved shoulder next to the hex-
agonal head of the threaded bushing .
Installation
7. Lay the pad holder (7) down on a firm flat surface
with the upper mounting bolt hole positioned at Mount the caliper on the vehicle as follows:
the upper right.
1. Coat t he outside diameter of the mounting pin (2)
8. Instatt the spring c li p (8) at the top of pad holder (7) with Dow Corning Moly 44 grease.
as shown in Figure 2-47.
2. Position the caliper with the disc between the fric-
9. Take pad (9, Figure 2-46), the pad that has the in- tion pads and the two mounting holes in the
sulator backing, and place it on top of the spring caliper aligned with the mounting lugs on the fork.
clip with the lower end of the pad slightly entering See Figure 2-48.
the opening of the pad holder. With the pad 3. Place a flat washer on bolt (1, Figure 2·46). Insert
centered within the pad holder and the insulated the upper mounting bolt through the fork lug, and
back facing downward, push down on the pad untit pad holder (7), then thread the bolt into threaded
it is against the flat surface and is held firmly by bushing (4).
spring tension from the spring clip.
4. Insert the lower mounting pin (2) through the
10. Insert the outer pad (9), pad holder (7) and spring caliper, and the fork lug and then thread into the
clip (8) assembly into place with the backside of tapped hole at the lower end of pad holder (7).
the pad against the face of the piston . Tighten the pin to 25-30 ft-Ibs torque.
NOTE 5. Tighten upper mounting bolt (1) to 25·30 f1-lbs

torque.
The spring clip loop and friction material must always
face away from the piston. If it is wrong, the pad must be 6. If the bleeder screw was removed, it should be in·
removed, the pad holder reversed and the parts stalled and tightened to 32-40 in-Ibs torque .
reassembled.
7. Using new banjo washers (6), connect the brake
line (23) to the caliper. Tighten banjo bolt to 30-35
11. Place the inner pad (9) (Without insulator) in the
ft-Ibs torque.
recessed seat machined into the caliper.
12. Position the pad retainer (14) within the counter·

bore at the inside end of the caliper. Insert self·
''''
Figure 2-47. Spring Clip Installation Figure 2·48. Front Brake Caliper Mounting
2·42
reservo irwith Actuate the master cylinder an d check for leaks.
H~ri~~UllC ty~~t,c~~~sU~ized
. der nearly leve,J 1"11
I 10 Reservoir 11.
With master BRAKE equip.
8. D.O.T. '. with btadde, SYSTEM.
may be fllle DING HYDR
men!. See BlEE b sure there is a
REAR BRAKE CALIPER
9.
Actuate the bfr~I~~~~::~k~~~~~~~IU~ surface when
small spurt 0 brake lever.
1982·1985
actuating the (Figure 2·49)
10. .
Relnsta II the master cy rnder
I cover.
Disassembly
1. Remove screws (2) and lift caliper body (5) off
1 . Cap
2. Screw (2)
3. Frame
4 Pad (2)
s' Caliper body
6: Upper p~n
7 lower pin
S' Boot (2)
. Pad spring
1~: Retaining wire
11. Boot
12. Piston
13 Seal
.. Bleed valve
15.. Abutment shim
1
Figure 2·49. Rear Brake Caliper - 1982·1985
2·43
bracket (3). Remove brake pads (4). Cleaning, Inspection and Repair
NOTE 1. Clean all metal parts in a non·flammable cleaning
solvent and blow dry with compressed air.
Brake pads may now be replaced without further disas·
sembly. WARNING
Always use a non·flammable solvent for cleaning metal

2. Remove upper and lower pins (6 and 7) and boots (8). parts. DO NOT use gasoline or other flammable
Remove pad spring (9) from caliper body. substances.
2. Clean all rubber parts in denatured alcohol or brake

NOTE fluid.
Do not remove the pistons from the caliper unless there WARNING
are signs of hydraulic fluid leakage or if the piston is not
operating properly. If the piston must be removed, pro· Always clean brake system rubber parts by washing in
ceed to the following steps. denatured alcohol or brake fluid. DO NOT use mineral
base cleaning solvents such as gasoline or paint thin·
nero Use of minerai base solvents will cause deteriora·
tion of rubber parts, which will continue after assembly,
3. Remove retaining wire (10) and piston bOot (11). resulting in component failure.
Remove piston (12) and seal (13). If piston cannot be
easily removed, use the fOllowing method:
3. Inspect brake disc and replace If warped or badly
scored.
a. Pump brake lever until piston reaches its lull level.
4. Inspect the brake pads for wear and damage. If
b. Remove brake line (1). pads are worn to 1/16 in. or less, replace them as a
set.
c. Place the caliper on a workbench with the pistons
facing downward. Place a shop towel under the pis' WARNING
tons and apply low air pressure to the inlet hole
until piston is forced out of the caliper. II piston Is Brake pads must be replaced only In sets for correct
tight in bore, tap lightly around caliper while ap· and safe brake operation.
plying air pressure.
5. After the brake pads are installed, Ihey should be
burnished by making several hard stops.
WARNING
6. Replace any parts that appear worn or damaged.
Always replace seal (13) if piston is removed.
Piston may develop considerable force from pressure
bulld·up and care should be taken to keep hands out
7. Check the abutment shims in the caliper mounting
from under to prevent personal Injury.
bracket for damage. Replace missing or badly
damaged shims as follows:
a. Remove all the existing adhesive Irom the

mounting bracket surface where the abutment
shim is located . The surface should be scraped
with a knife and if required, lightly sanded with
fine emery cloth.
b. Clean the surface seraped and sanded in Step

'a' above with denatured alcohol.
c. Apply a silicone sealant to the bracket surface

and install the abutment shim. To hold the shim
in position, install the brake pads in the
bracket.
d. Allow the silicone sealant to dry.
e. Check thaI the brake pads slide freely in the

Figure 2·50. Caliper Pin Alignment bracket.
2·44
Assembly and Installation 1. Slip a length of appropriate size plast ic tubing Over
wheel cylinder bleeder valve with other end In a
1. If piston was removed Instal l new seal (13) into clean container.
caliper bore. Install piston (12) all the way into
caliper bore and install boot (11) and retaining wire 2. Turn handlebars so that bleeder valve is near ly ver·
(10). tical. Open bleeder valve by rotating counter-
clock wise about one-half turn.
2. Place pad spring (9) into top of caliper with long
tab extending above piston. Hook shorl lab op· 3. With master cylinder full of fluid at ali times, slow-
posite piston above ridge on caliper casting to ly depress brake pedal or lever once until fluid
hold spring i n place. stops lIowing from tubing. Close the b leeder valve.
Allow pedal or lever to return slowly t o release
3. Instal l p in boots (8) on upper and lower pins (6 and position.
7) and coat pins and pin bores with silicone grease.
Insert pins into pin bores (pin with nylon sleeve 4. Repeat operation unlil brake system is free of air
goes into top hole) making sure boots are properly bubbles.
seated on boss around holes. Turn pins so flats are
parallel with opening In bracket as shown in Figure 5. Add f luid to master cylinder to bring to or ig inal
2·50. level. Do not reuse fluid unless it is clear and free
from sediment and bubbles.
4. Install pads (4, Figure 2·49) on bracket and place
cal iper body (5) on bracket making sure pins (6 and NOTE
7) do not turn.
Hydraulic brake fluid bladder type pressure equipment
5. Install screws (2) and tighten to 11-14 ft-Ibs torque. can be used to fill brake master cylinder through the
Pins (6 and 7) should sti l l be in same position as bleeder fitting, prolllding master cylinder cover Is re-
described in slep 3. mOiled so that system cannot pressurize. Do not use
pressure bleeding equIpment when the hydrauliC sys·
6. Bleed brake system as described under BLEEDING tern is sealed with master cylinder cover and gasket in
HYDRAULIC BRAKE SYSTEM. place.
BRAKE DISCS STOPLIGHT

FRONT BRAKE SWITCH
Removal And Installation To replace stoplight switch in right handlebar
assembly, remove cover screw securing switch halves.
The brake discs have a minimum thickness stamped on
Disconnect wires and discard switch . Replace switch
their sides. Replace any brake disc that is worn beyond
as a unit. Reassemble switch and hous ing and test
this limit.
operation of brake li ght.
BLEEDING HYDRAULIC SYSTEM

Alter servicing hydraulic brake system where any STOPLIGHT REAR BRAKE SWITCH
hydrau lic line or cyl inder is opened, it is necessary to
bleed the system to expel the air. The rear stoplight switch is screwed into the rear
hydraulic brake filling. The stoplight switch is an open
WARNING type switch which closes with hydraulic pressure. The
switch pa rts are not serviceable and switch must be
Brake fluid can cause irritation of eyes and skin and replaced as a unit. After switch is replaced, check fluid
may be harmful If swallowed. If fluid is swallowed, in· level in master cylinder and operat ion of rear brake. It
duce vomiting by administering two tablespoons of salt may be necessary to bleed rear brake_
In a glass of warm water. Call a doctor_ In case of can·
tact with skin or eyes, flush with plenty of water_ Get
medical attention for eyes _ KEEP BRAKE FlUID OUT
OF THE REACH OF CHILDREN .
2·45
FRONT FORKS
GENERAL 3. On all models except XR·l000, remove two screws (1)
so cover (2) can be slid up out of the way, exposing
The front fork is made up of two telescoping tubes work- the fork stem and bracket (12). The XR-l000 does not
ing against springs, with an oil 'illed damping have a cover.
mechanism to control the action.
4. Loosen the fork tube pinch bolls (3), then loosen
screw (9) in the upper fork bracket (5).
5. Unscrew the fork tube cap (6) from Ihe fork tube, Ihen
remove fork side (7) completely by sliding down and
CHANGING THE FORK OIL out of both upper and lower fork brackets. Drain oil
from fork side.
1. Remove the lork lube cap from one fork side.
2. Remove the drain plug from the bottom of the fork Disassembly
and drain the oil by compressing the front suspen-
sion. 1983 and Earlier Models (Except XR-l000)
(Figure 2·52)
1. Remove O-ring (3) from inner groove in tube cap (1)

NOTE and slide off washer (4). Pull spring (5) out of fork
tube (2).
If the fork oil Is emulsified, aerated or light brown In co/-
or, then It has been contaminated by water and the oil 2. Using an allen wrench, remove screw (6) along wilh
seals in the fork must be replaced. See steps 1 and 2 of washer (7) from bottom end of fork slider (8). This
the DI$A$SEMBL Y procedure. will free shock absorber tube (9) so that It can be
removed from fork tube (2). Remove both fiber wear
3. Install the drain plug. rings (10) from slots in shock absorber tube.
4. On 1983 and earlier models, fi ll the fork side with 5 3. Separate fork tube (2) and fork slider (8) by pulling
oz. (wet) or 6 oz. (dry) TYPE E FORK OIl. the two apart. Slip fork boot (II) off end of fork
slider (8).
On 1984 and 1985 (including XA·l000) models, !llIthe
fork side with 5.4 oz. (wet) or 6.4 oz. (dry) of TYPE E 4. Remove damper tube sleeve (12) from inside fork
FORK OIl. slider (8) by carefully pulling out past seal (14).
Remove seal (14) only If it is to be replaced.
NOTE Remove lock ring (13) and they pry out seal (14),
discarding the damaged seal.
When the fork has been disassembled, cleaned and re-
assembled It Is considered a DRY fork and requires more
oil than a WET fork. The difference In the amount of all re- 1984 and 1985 Models (Including XR·l000)
quired between a WET and a DRY fork is due to oil cling. (Figure 2·53)
5. Install the fork tube cap. 1. Remove O-ring (5) from the groove in the tube cap
and slide off washer (4). Pull spring (10) out of fork
6. Repeat steps 1·5 for the other fork side. tube (1).
2. Remove dust seal (6) then compress internal circle

clip (7) and remove the clip from the internal groove
at the top of slider (2).
FORK SIDES
3. Using an allen wrench, remove socket head bolt
(14) along with washer (15) from the bottom end of
Removal fork slider (2). This will free shock absorber tube
(Figure 2·51) (11) and slider (1) so that they can be removed from
fork tube (2).
1. Remove front wheel and brake assembly as described
under WHEElS in this section, then remove front
fender. NOTE
2. Remove bracket attaching head lamp to the upper Since there Is //tte resistance to rotation when removing
fork bracket and allow head lamp to hang loose by socket bolt (1 4), the job Is best done with an air Impact
wiring harness. wrench.
2·47
12
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1. Screw (2) 10. Upper bearing shield

2. Cover 11. Bearing cone
3. Pinch bolt (2) 12. Fork stem and bracket
4. Screw (2) 13. Bearing cone
5. Upper bracket 14. lower dust shield
6. Fork tube cap (2) 15. Upper bearing race
7. For1o; side (2) 16. Lower bearing race
8. Fork stem nut 17. Screw Insert (2)
9. Pinch screw 18. Brake caliper bushings (4)
Figure 2-51. Front Fork Assembly
2-48
.,,,
11-§ ~,
I
1 2<8'~"'""
1 3 - -0 " "
I "
"1 ,
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1 2-~
,-8 I
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-'
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g----14 I
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1. Tube cap
2. Fork tube
3. 0·rlng
9. Shock absorber tube
10. Wear rings
11 . Boot
I
I
1
I
I 17--9
,, I
"
I
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4. Was her 12. Damper tube sleeve
5. Spring 13. lock ring
6. Screw 14. Seal -'--."
7. Washer 15. Drain plug 1_Tube 11. Shock absorber tube
8. Fork slider 16. Washer 2. Slider 12. Piston ri ng
3. Cap bolt 13. Oil lock
Fig ure 2·52. Front Fork Shock Absorber 4. Washer 14. Socket bolt
(1979-1983) 5. 0 ·rlng 15. Washer
4. The upper bushing (16) is a slight interference lit in 6. Dust seal 16. Bushi ng upper
slider (2). The upper bushing (16) together with 7. Internal circle clip 17. Bushi ng lower
spacer seal (9) and oil seal (8) are removed by light- 8. 0 11 seal 18. Rebound spring
ly hitting the upper bushing w ith the lower bushing 9. Spacer seal 19. Bolt drai n
as the fork lube is pulled free of the slider (2) in a 10. Spri ng 20_ Washer
quick continuous stroke. Continue this slide ham-
Figure 2-53. Front Fork Shock Absorber
mer type action until the components are freed.
(1 984·1985)
5. Remove shock absorber tube (11) by pushing the lion shows Ihal any parts are bent, broken or dam-
tube and spring assembly free of fork tube (1) by in- aged, those parts should be either repaired or re -
serting a small diameter rod through the opening placed.
in the bottom of tube (1).
2. Inspect all seals for wear. If seals were removed,
6. Remove sleeve (13) from the lower end of shock abo new seals must be installed.
sorber tube (It) and slide off rebound spring (ta).
3. Inspect both wear rings on damper tube and replace
7. Piston rings ('2) can now be removed from the If worn excessively or damaged.
grooves at the top end of shock absorber tube (' 1).
Lower bushing (17) should not be removed unless 4. Check boot or dust seal where it rubs on fork tube.
It is to be replaced. The tube should show a bright, shining surface, free
of scoring or abrasions. The boot or seal should pre-
sent a good continuOUS seal and not show excessive
Cleaning, Inspection and Repair wear.
1. Thoroughly clean and inspect each pari. If Inspec- 5. Replace shock absorber spring If broken.
2·49
6. Inspect small hole in groove in lower end 01 fork 4. Assemble fork tube (1) and shock absorber tube
tube and see that it is not obstructed. (11) into slider (2). Hold the assembly in place by
exerting pressure on the spring and install socket
7. Make sure tube cap a-ring is in good condition,
bolt (14) with washer (15).
without irregularities, and that it provides proper
sealing.
5. Place upper bushing (16), seal spacer (9) and seal
(8) (in that order) over fork tube (1). Be sure that the
8. Check drain bolt washer and shock absorber
concave or dished surface of the seal spacer is
washer to see that they provide a good seal when
downward and lettered side of the seal is facing
used with their respective bolts to prevent oil
upward . Place FORK SEAL AND BUSHING TOOL,
leakage.
Part No. HD·34190 over fork tube. Push the
bushing (16), spacer (9) and seat (8) into place by
9. Replace bent or damaged fork tube.
lightly ramming the components with the installa·
tion tool.
Assembly Installation (Figure 2·51)
1983 AND EARLIER XL MODELS 1. Slide the fork sides (7) through the lower and upper
(Figure 2·52) brackets (12) and (5). Tighten the fork pinch bolt (3)
to 30·35 ft-Ibs. Tighten pinch screw (9) to 21-27 ft.
1. Carefully slide damper tube sleeve (12) into fork Ibs torque.
slider (8).
2. Pour 6 oz. (1983 and earlier XL models) or 6.4 oz.
(XR·l000 and 1984-1985 XL models) of Harley-
2. If removed, install a new seal (12) and retaining ring Davidson TYPE E FORK OIL into each fork side
(13). and replace tube caps (6).
3. Install the head lamp bracket on the upper fork

3. Slide the fork tube (2) into slider (8), then install bracket.
boot (11) on the slider.
4. Install the front fender, then install the front wheel
4. If removed, install fiber wear rings on shock abo and brake assembly. See WHEELS in this section.
sorber tube (9) and insert the tube into tube (2).
Secure shock absorber tube with socket head
screw (6) and washer (7).
FORK STEM
5. Install spring (10) in tube (1). Install washer (4) and
o·ring (3) on tube cap (1) and assemble tube cap to Removal
tube (1).
1. Remove the fork side as described in FORK SIDES
REMOVAl.
6. Fill the fork side with 6 oz. of TYPE E FORK OIl.
2. Remove the fork stem nut (8, Figure 2-51) and
loosen the fork upper bracket pinch bolt (9). Lift the
handlebar assembly from the steering head with
fork upper bracket (5) attached. Carefully position
XR·l000 AND 1984·1985 XL MODELS
the assembly away from the work area, being
(Figure 2·53)
careful not to bend control wires more than
necessary.
1. If removed, install new lower bushing (17), expand·
ing the bushing only enough to fit over tube (1).
Slide the bushing into its groove.
NOTE
2. Place rebound spring (18) on shock absorber tube It is not necessary to disconnect clutch and brake hand-
(11). Insert shock absorber tube (11) into fork tube levers, wiring harnesses or control cables from
(1). handlebar unless the handlebar assembly is to be
removed 'rom the motorcycle.
3. Insert spring (10) into fork tube (1), taper side 3. Remove the upper bearing shield (10) and upper
toward piston, and push the shock absorber tube bearing cone (11). Drop fork stem and bracket
through the opening at the bottom end of the fork assembly (12) and remove bearing cone (13) and
tube. lower dust shield (14).
2·50
NOTE Assembly
On 1979·1981 models the steering head bearing races 1. II removed, press new bearing races (1982 and
are press lit in cupS which in turn are press fit in the later) or bearing race and cup assemblies (15 and
Ira me. On 1982 and later models the bearing races are 16) (1979·1981) into the frame.
press fit in the Irame.
2. Liberally coat the bearing cones (11 and 13) with
4. If replacement of bearing races is necessary, drive grease. Work the grease into the rollers.
cup and race assemblies or races (15 and 16) from
the frame with a drift. 3. Assemble the lower dust shield (14) and bearing
cone (13) on the fork stem and bracket (12).
4. Insert fork stem and bracket (12) through the steer·

ing head and install the upper bracket bearing (11)
and dust shield (10) on the slem .
Cleaning, Inspection and Repair
5. Install the upper bracket (5) including the
handlebar assembly and loosely install fork stem
1. Clean the bearing shields (10 and 14), bearing nut (8).
cones (11 and 13), fork stem and bracket (12) and
frame with solvent. 6. Install the fork sides {71 and secure with pinch
bolts (3).
2. Carefully Inspect bearing races and cones for pil.
tlng, scoring, wear and other damage. Replace 7. Install the front fender and front wheel, including
damaged bearing as a set. Do not replace an in· the front brake assembly.
dividual cone or race.
8. Tighten the fork stem nut (8) until the bearings
3. Check the fork stem and bracket (12) lor damage. have no free play. Make sure the fork stem turns
Replace damaged fork stem. freely, then t ighten the pinch screw (9).
2·51
REAR FORK
DISASSEMBLY 1982 and Later
(Figure 2·55)
1979·1981 NOTE
(Figure 2·54)
Mark all hardware, as it Is removed, so it may be returned
Remove the rear wheel as described under REAR to orlginal/oeat/on.
WH EEL, REMOVAL. Free brake assembly from fork and
remove from motorcycle. II is not necessary to discon- 1. Remove rear wheel as described under REAR
nect brake lines or drain brake fluid. Disconnect lower WHEEl, REMOVAl.
rear shock absorber bolts from rear fork. Remove chain
guard. 2. Remove rear brake caliper assembly as described
under REAR BRAKE CALI PER.
3. Remove rear shock absorber bolts from rear fork.

See Figure 2·54. Remove pivot bolt (1) from rear fork (2).
Rear fork can now be pulled from frame (3) assembly. 4. Remove rear chain guard. Remove forward chain
Remove screw and lockwasher (4), bearing lockwasher Quard on 1982 mOdels.
(5), right bearing locknut (6) and bearing outer spacer (7).
Using a punch, turn ou l left bearing locknut (8) from fork 5. Carefully loosen pivot bolt (l), support rear fork and
hub and remove spacer (7). From Inside of fork, press or pull fork assembly from frame.
drive out bearings (9) and bearing spacers (10) by apply-
ing pressure against spacer. Press or drive out bearing
shields (11) from fork inner side. CAUTION
Carefully mark all bearing components as they are

removed, so components may be returned to their
original locations. Bearing components must not be In·
termlxed.
NOTE
Bearing race (8), or pivot bushing (4) should only be

removed if replacement is required. The complete bear·
Ing assembly must be replaced, as a unit, if replace·
ment is required. Bearing components must not be In·
termlxed.
3
\
1. Pivot bolt
2. Rear fork
3. Frame
4. Screw and lockwasher 1. Pivot bolt
5. Bearing lockwasher 2. Rear fork
6. Right bearing locknut 3. Frame
7. Outer spacer (2) 4. Pivot bushing
8. left bearing locknut 5. Pivot plug
9. Bearing (2) 6. Dust shield (2)
10. Inner spacer (2) 7. Inner race (2)
11. Shield (2) 8. Outer race (2)
9. lock ring
10. Bearing spacer
Figure 2·54. Rear Fork - 1979·1981 Figure 2·55. Rear Fork - 1982 and Later
2·53
7. Carefully press bearing outer races (8) from fork. 8. Take scale reading and tighten locknut (6) sufficient
Remove lock ring (9). amount to provide from one to two pounds drag on
the bearing. For example, if rear end of fork weighs
8. Press pivot bushing (4) from fork assembly. three and one·half pounds with bearings free, bear·
ings should be adjusted tight enough to increase
weight of fork to tour and one-half or five and one-
half pounds as fork is lifted to horizontal position.
CLEANING AND INSPECTION
9. Assemble screw and washer (4), and lockwasher (5).
1. Carefully inspect all bearing components for wear
and lor corrosion. Replace complete bearing assem-
10. Install shock absorbers, brake assembly and rear
bly if any component is damaged.
wheel.
2. Clean all components in solvent and blow dry.
11. Install chain guard.
3. Dimensionally check rear fork to ensure it is proper-
Iyaligned.
1982 and Later
(Figure 2-55)
ASSEMBLY 1. If necessary, install new lock ring (9) and press new
outer races (8) into position.
1979-1981 NOTE
(Figure 2-54)
RoJ/er bearing assemblies are shipped assembled as a
1. From outside of fork, press or drive bearing shield unit, do not Intermix components. Mark all components
(11) into position, flush with inner fork side. From so they may be correctly installed.
outside of fork insert bearing spacers (10), shoulder
facing in. Apply a heavy coating of bearing grease to 2. Coat bearing components with bearing grease and
bearings (9). assemble.
NOTE CAUTION
Repack the two rear fork pivot bearings with fresh Bearing spacer (10) must be Installed between Inner
grease at 10,000 mile intervals. races (7) or bearing failure can result.
2. With side of bearing outer race facing out, tap bear- 3. Press dust shields (6), lip side in, over bearing inner
ing into fork until flush with inner fork side. Insert races (7).
bearing outer spacer (7), shoulder facing in.
4. Press new pivot bushing (4) into rear fork (2), if re-
3. Assemble and lighten bearing locknut (6), and then quired.
back off one full turn.
5. Insert pivot plug (5) into pivot bushing (4), as shown.
4. Insert left spacer (7), shoulder facing in, and left
bearing locknut (8). With a punch, tighten bearing 6. Align pivot plug (5) ears with slots in frame and slide
locknut until snug. Slake lock in three places. rear fork assembly into posJtlon.
5. Position rear fork in place on motorcycle. 7. If rear fork pivot boll does not have a reusable lock
patch, apply four drops at Loctite 271, High strength
6. Coat pivot bolt (1) with grease. If rear fork pivot bolt threadlooker, to the pivot bolt threads.
does not have a reusable lock patch, apply four
drops of Lootite 271, High Strength Threadlooker, to Holding fork assembly in pOSition, ~nstall pivot bolt
the pivot bolt threads. Insert pivot bolt in rear fork (1). Tighten to 50 ft-Ibs torque.
assembly and tighten to 50 ft-Ibs torque.
8. Install chain guards.
NOTE
9. Assemble shock absorbers to fork.
Before instalflng locknut (5), tighten bearings as de-
scribed in fof/owing paragraph. 10. Install rear brake caliper assembly, see REAR
BRAKE CALIPER (1982 and Later).
7. Weigh the extreme rear end of fork by attaching spr·
ing scale and raising fork to horizontal position with 11. Install rear wheel as described in REAR WHEEL, IN·
centerline of frame. STALLATION.
2·54
REAR SHOCK ABSORBER
REMOVAL
(Figure 2·56)
1. Raise rear end of motorcycle with stand or suitable
blocking underneath frame. If blocking is not
available, remove one shock absorber at a time, the
remaining one will hold the rear fork and frame in
lat.
3~-'~;;e~,_~~8' place.
~~ Ea",
F31-' 1979
II rer r
2 1
2. On 1979 to Early 1984 models, remove top and bot-
tom mounting bolts (1) and nuts (2), and remove
shock assembly.
I 3. On late 1984 to 1985 models, remove nut (10) and
C~>,-
washer (11) from top mounting stud. Remove bottom
I nut (2) and bolt (1), and remove shock assembly.
7 I
6
I
I
DISASSEMBLY
(Figure 2·56)
I
I 1. Place shock absorber in SHOCK ABSORBER TOOL,
Part No. HD-97010·52A, with retainer (3) up. Com-
I 9 press spring (5) far enough to remove reta iner (3) and
I
cover (4).
e-----7
~ ___ J
I
2. Release spring compression and remove shock abo
sorber (6) from tool. Remove remaining items.
1. Bolt 7. Spring seat (2)

2. Nut (1979· Early 1964) 8. Cam
3. Retaining ring 9. Cam stop CLEANING AND INSPECTION
4. Cover 10. Nut (late 1984·1985)
5. Spring 11. Washer Clean and inspect all parts for wear and damage.
6. Shock absorber (Late 1984·1985) Especially check rubber components for signs of wear
and stiffness. Exam ine shock assembly for signs of
Figure 2·56. Rear Shock Absorber
leakage. Unit should compress slightly easier than it ex·
tends. If possible, compare with new shock absorber.
Faulty shock absorber assemblies must be replaced.
ADJUSTING SPRING
(Figure 2·56)
ASSEMBLY
The rear shock absorber springs can be adjusted for the
weight the motorcycle is to carry. The average weight Assembly of the rear shock absorber is the reverse of
solo rider would use the extended spring position, A disassembly.
heavy solo rider might require the position with springs
in slightly compressed spring position. When reassembling, be sure to position cam lobes (8)
on cam stop (9) as shown. Apply a thin coat of grease to
To adjust the rear shock absorber springs, use SPAN· cam surface. Place assembly in tool and compress
NEATOOL, Part No. HD·94820·75. Adjust both shock abo spring enough to insert split retainer halves. Slowly
sorber cams the same. release spring compression.
2·55
HANDLEBAR CONTROLS
AND INSTRUMENTS
THROTTLE CONTROL
General
The throttle control must operate freely without binding.
With the friction adjusting screw backed off, the throttle
must return to the closed (idle) position.
Removall Disassembly
1979 TO 1980 (Figure 2·57)
1. Remove the two screws (1) and separate the upper

clamp (2) from the lower clamp (3),
2. Unhook the ferrule (4) and cable (5) from the throttle
grip (6) and clamp (3). Disconnect the other end of
the cable from the carburetor.
3. Remove the friction spring (7), sel screw (8), spring
\
(9) and adjusting screw (10) from the lower clamp (3).
1981 to 1985 (Figure 2-58)
1. Remove the two screws (1) and separate the upper

clamp (2) from the lower clamp (3). 1. Screw (2) 8. Set screw
2_ Upper throttle clamp 9. Spring
2. Unhook the ferrules (4) and cables (5) from the throt- 3. Lower throttle clamp 10. Adjusting screw
tle grip (6) and clamp (3). Disconnect the other end of 4. Ferrule 11. Handlebar
the cables from the carburetor. 5. Control cable assembly 12. Grip plug (2)
6. Throttle 13. Adjusting nut
3. Remove the friction spring (7), spring (8), retaining 7. Friction screw
ring (13) and adjusting screw (9) from the lower
clamp (3). Figure 2·57. Handlebar Throttle Control - 1979·1981
Cleaning, Inspection And Repair

1. Clean all parts in a non-flammable cleaning solvent 2. Attach the cable assembly (5) to the lower clamp (3).
and blow dry with compressed air. Install the set screw (8), adjusting screw (10), spring
(9) and friction spring in the lower clamp. Be sure the
2. Replace the cable assembly (5) if it is frayed, kinked hole in the spring (7) engages the set screw.
or bent.
3. Position the throttle (6) on the handlebar. Place the
1979 TO 1980 MODELS ONLY: lower clamp (3) on the throttle. Position the ferrule
(4) over the cable ball and seat it in the throttle notch.
3. Lubricate pivot points of lever. Use Loctite ANTI-
SEIZE on pin and a teflon or silicone base lubricant
on cable end. 4. Fasten the upper clamp (2) to the lower clamp (3) us-
ing the screws (1). Tighten the screws to 12-16 in·Jbs
torque.
Assembly Iinsiallation
5. Route throttle cable down right side of motorcycle
1979 TO 1980 (Figure 2-57) along underside of fuel tank to carburetor.
1. Apply a light coating of graphite to the handlebar

and inside surface of the clamps (2 and 3). 6. Fasten the cable to the carburetor.
2·57
1981 TO 1985 (Figure 2·58) grip travel lim it. To adjust for grip travel limit, turn
throttle to open position and adjust set screw (8)
with a 2mm (Allen) wrench. The throttle grip should
1. Apply a light coating of graphite to the handlebar and
be in fully open position as the carburetor lever
inside surface of the clamps (2 and 3).
reaches fully open position.
2. Attach the cable assemblies (5) to the lower clamp

(3). The throttle cable has a 5116 x 18 in. threaded ad-
juster and should be assembled to the right side of
the throttle grip. The Idle cable has a 114 x 20 in.
threaded adjuster and should be assembled to the
left side of the throttle grip. Install adjusting screw
(9), spring (8), friction spring (7) and retaining ring (13)
in the lower clamp.
3. Position the throttle (6) on the handlebar. Place the

lower clamp (3) on the throttle. Position the ferrules (4)
over the cable balls and seat them in the throttle not-
ches.
4. Fasten the upper clamp (2) to the lower clamp (3) us·
ing the screws (1). Tighten the screws to 12·16 ft·lbs
torque.
5. See Figure 2-59, 2-60, 2-61 and 2-62. Route throttle

cables down right side of motorcycle, as shown.
1. Screw 8. Spring
6. See Figure 2·63. Install the idle cable (1) and spring 2. Upper throttle clamp 9. Spring
into the longer of the two support sleeves on the car- 3. Lower throttle clamp 10. Handlebar
buretor. The idle cable has a 114 x 20 threaded ad- 4. Ferrule (2) 11. Grip plug (2)
juster at the throttle end. 5. Control cab&e assembly (2) 12. Adjusting nut (2)
6. Throttle grip 13. Retaining ring
7. Friction spring
Install the throttle cable (2) into the other support
sleeve on the carburetor. The throttle cable has a Figure 2·58. Handlebar Throttle Control - 1981 and Later
5116 x 18 threaded adjuster at the throttle end.
Adjustment
1979 TO 1980
1. When turned by hand and then released, the throttle

lever must return throttle grip (6) to the closed or idle
position. If throttle grip (6) does not return to idle
position freely, back off of adjusting screw (10) until
this is accomplished. If the throttle grip turns stiffly,
it should be disassembled, cleaned and inspected
thoroughly.
WARNING
Do not overtighten the fnctlon screw. Operation with

the friction screw overtightened is not recommend·
ed because of the possible hazard involved when the
engine will not return to idle position automatically
in an emergency.
2. Adjust throttle cable FREE PLAY by turning adjust-

ing nut (13) to desired position. The cable should not
put pressure on the carburetor lever when handle-
bars are turned to left and right stops.
3. With handlebar in straight ahead position, adjust Figure 2·59. Throttle Cable Routing - 1981
2-58
Figure 2·62. Throttle Cable Routing - 1983·1985 XLS
Figure 2·60. Throttle Cable Routing - 1982
CAUTION
This adjustment Is necessary to prellent excess stress
and potential failure of the throttle cable.
1981 TO 1985 (Figure 2-64)
CAUTION
Thi s adjustment is necessary to prellent excess stress
and potential failure to the throttle cables.
NOTE
The throttle cable has a 5116 x 18 threaded adjuster and

;s assembled to the right side of the throttle grip. The
idle cable has a 114 x 20 threaded adjuster and ;s
assembled to the left side of the throWe grip.
2125
Figure 2·63. Cable Installation
1. Turn the cable adjusters and locknuts clock wise as

far as they will go. Both cables should halle zero ad·
justment to start this procedure.
2. Poi nt the fron t wheel straight ahead. Turn the throt-

tle grip so the throttle is wide open (fully cou nter-
clock wise) and hold it there. Now turn the throttle
cable adjuster (1) counterclockwise until the throttle
cam stop (3) just touches the stop boss on the car-
buretor. Tighten the locknut (2) against the throttle
cable adjuster and release the throttle.
Figure 2·61. Throttle Cable Routing - 1983·1985 3. Turn the Iront wheel full right. Tu rn the idle cable ad·
XLH and XLX juster (4) counterclockwise until the cable housing
2·59
""
1. Throttle cable adjuster

2. Locknut
3. Cam stop
4. Idle cable adjuster
5. Locknut
6. Cable housing
7. Spring
Figure 2·84. Throttle Cable Adjustment
(6) just louches the spring (7) in the cable support NOTE
sleeve. Work the throttle grip to make sure throttle
cable returns to idle position when released. II the On 1979 models It wlff be necessary to remove the ex·
cable does not return to idle, continue to turn ad· haust system components on the left side of the motor-
Juster (4) counterclockwise to achieve the correct ad· cycle.
justment. Tighten the locknut (5) against the idle
cable adjuster.
2. On late 1984·1985 models, remove access plug (7)
from the front chain cover using ACCESS PLUG
REMOVAL TOOL, Part No. HO·33186. Remove the
NOTE spring (8) and lockplate (9). Remove the clutch ad-
justment nut (10).
On 1982 and later models the throttle clamp com-
ponents (2 and 3) are Integrated Into the push button
assembly. AI/adjustment procedures remain unchanged. 3. Loosen the locknut and back off the primary chain
shoe adjuster. Drain and remove the primary chain
case cover.
The throttle control must operate freely without binding.
4. See Figure 2-65 and 2-66. Disconnect clutch cable by
With the friction adjusting screw (9) backed off, the car·
rotating the cable coupling (4) 90 * from installed
buretor throttle must return to the closed (idie) position.
position in lever (5) (Coupling has a flat which locks
it in place in the lever (5).) Unhook cable end (3) from
coupling (4) loosen locknut (1) and unscrew ad-
justing sleeve (2) from cover.
CLUTCH HAND CONTROL
5. See Figure 2-67. Remove the clutch cable and an-
Removal chor pin from the handlever. On 1982 and later
models It is necessary to remove the pivot bolt in
order to remove the anchor pin.
WARNING
Disconnect the battery cables (negative cable first) to

prevent accidental start·up of vehicle and possible per·
sonal injury. Installation
1. Lubricate pivot pOints of lever. Use loctlte ANTI·
SEIZE on pin and a lei Ion or silicone base lubricant
1. Remove foot shift lever, and left footrest assembly. on cable end.
2-60
6
1. Locknut
2. Adjusting sleeve
3. Cable and coli assembly
4. Cable coupling
S. Release ramp and lever
6. Washer
Figure 2·65. Clutch Cable Removal and Installation, Primary Chaincase - 1979· Early 1984
1. locknut
2. Adjusting sleeve
3. Cable and coil assembly
4. Cable coupling
5. Release ramp and lever
6. Washer
7. Plug
8. Spring
9. lockplate
10. Nut
3
----'<~
~ 5
~6
Figure 2·66. Clutch Cable Removal and Installation, Primary Chaincase - late 1984-1985
''''
Pivot bolt
Figure 2·67. Clutch Cable Removal and Installatlon
Figure 2·68. Clutch Cable Routing - 1981 and Earlier

2. See Figure 2·67. Install the clutch cable and anchor
pin to the clutch handlever. On 1982 and later
models, install pivot bolt and retaining ring.
3. See Figure 2-68. On 1981 and earlier models, route

the cable along the left side downtube and through
the clip as shown.
See Figure 2·69. On 1982 models, route the cable

along the left side downtube as shown and through
the cable guide on the upper engine mount.
See Figure 2-70. On 1983·1985 XLH models, route the

cable outside the left fork tube as shown and
through cable guide on the upper engine mount.
See Figure 2·71. On 1983-1985 XLS models, route the

cable between the upper triple clamp and headlight
housing, between the steering head and left fork
tube as shown and through cable guide on the upper
engine mount.
See Figure 2-72. On 1983·1985 XLX models, route the

cable between the turn signal lamp and left fork tube
as shown and through the cable guide on the upper
engine mount.
4. See Figure 2-65. Install adjusting sleeve (2), washer

(6), locknut (1) and cable (3) into cover.
5. Attach cable end (3) to cable coupling (4).

Figure 2·69. Clutch Cable Routing - 1982
6. Replace gasket and install primary chain case
cover. Tighten chain case cover screws to 90 to 110
in-Ibs torque. 8. On Late 1984 and 1985 models, install clutch ad·
justing nut (10).
7. Adjust primary chain tension. See FRONT CHAIN,
section 6. 9. Adjust clutch cable. See CLUTCH, section 6.
2-62
2137
Figure 2·72. Clutch Cable Roullng - 1983·1985 XLX
10. On Late 1984 and 1985 models, Install the lockplate

(9), spring (8) and access plug (7).
11.lnslall gear shift lever, tightening pinch bolt to

90·'10 in·tbs torque. Install left footrest assembly,
lightening mounting nut to 24-36 ft·lbs torque. In·
stall exhaust components If removed.
Figure 2·70. Clutch Cable Routing - 1983·1985 XLH

SPEEDOMETER/TACHOMETER
General
The Instruments are non·repalrable and must be replac·
ed II they are not working properly. Before replacing an
Instrument, check to see If the problem Is caused by a
faulty connection.
Lubricate the cables with graphite grease every 5,000

miles, If applicable.
Replacement
Use the following procedures to replace an instrument
or instrument bulb.
Remove mounting hardware and lift instrument up.
Remove instrument by disconnecting cable.
Replace any burnt out bulb by pulling bulb housing from

Instrument.
HANDLEBAR SWITCH ASSEMBLY

Figure 2·71 . Clutch Cable Routing - 1983·1985 XLS
The left handlebar switch assembly contains a rocker
arm switch (head lamp hl·to beam) and two pushbutton
switches (horn and left turn signal). The right handlebar
switch assembly contains a rocker arm switch
(emergency engine cut·off) and two pushbutton
switches (engine start and right turn signal). Individual
rocker arm and pushbutton switches can be replaced II
not functioning.
2·63
1. Screw 7. Retainer
2. Switch housing cover 8_ Pushbutton switch
3. Screw 9. Rubber cap
4. Rocker switch (Hi-Lo) 10. Stoplight switch
5. Rocker switch (Run·Off) 11. Washer
6. Screw 12. Button cap
/
/
C)
LEFT ",2 RIGHT
Figure 2·73. Handlebar Switch Assemblies - 1981 and Earlier
A166
Switch Replacement - 1979·1981

(Figure 2·73)
1. Remove four screws (1) and pull off each switch
housing cover (2).
2. Remove screws (3) and rocker switches (4 and 5) or

screws (6), reta iner (7) and pushbutton switch (8) as
needed.
3. Reassembly is the reverse of disassembly.
Switch Replacement - 1982 . 1985

(Figure 2·74)
1. Remove screws (1) from switch housing (2).
2. To replace switch(es) (3) remove screws (4).
3. Replace switch(es) (3) screws (4) and screws (1).

Tighten to 18·24 in-Ibs torque.
NOTE
See BRAKE Section for front brake switch.
4
1. Screw 3. Switch
2. Switch housing 4. Screw
Figure 2·74. Handlebar Switch Assemblies -

1982·1985
2·64
FENDERS
FRONT FENDER ,0,113
Removal (Figure 2·75)

1. Remove front wheel. See WHEEL section. Remove
speedometer cable from speedometer drive and For1c:
feed cab le through guide on fender.
2. On 1983 and earlier XL models, remove four 5116-18

in. x 5/8 in. bolls and lockwashers securing fender to
lorks. On XA-l000 and 1984·1985 XL models, remove
four 5116·18 x 1-114 in. socket head screws and
locknuts.
3. Remove fender.
Installation
1. Carefully remount fender using lour bolts removed.
Tighten bolts to 19 f1·lbs torque on 1983 and earlier head cap screw
Xl models. Tighten nuts to 33 ft-Ibs on XR·1QOO and
1984-1985 XL models. Figure 2-76. Front Fender Mounting
XR·1000 and 1984·1985 XL Models
... 112 All models except XlX
2. Feed speedometer cable through cab le guide on
fender, if applicable. Reattach speedometer cable to
speedometer drive. Reinstall front whee1. See
WHEEL section.
REAR FENDER
Removal and Inslallation 1979·1981
1. Remove 1/4 in. screw securi ng seal to fender,

remove passenger strap, if applicable, and l ift off
seat.
XLX
2. See Figure 2·77. Unplug tall la mp and rear signal
lights. Cut cable straps if applicable. Push wires be·
tween the oil tank and frame cross bar under rear
fender. It may be necessary to loosen the two rear oil
tank mounting bolts to gain clearance needed for
wire plugs.
3. See Figure 2·78. Remove the 3/8-24 bolts, under

fender, securing turn signal assemblies. Carefully
pull wires through fender support assemblies.
NOTE
Take note as to the location of spacers used between

Washer, 5/16 in.
fender and fender supports, so they may be properly
I reinstalled. XLH motorcycles use spacers in conjunc-
tion with all mounting bolts and signal lights. XLS
Figure 2·75. Front Fender Mounting - 1983 and Earlier motorcycles use spacers only in conjunction with rear
Xl Models mountfng bolts.
2-65
4. Remove four 5116·24 acorn nuts securing fender sup·
ports. Push bolts through fender and remove. Lilt off
fender supports.
5 . Remove 5116·24 bolt securing fender, and passenger

strap and carefully remove fender.
6. Carefully place rear fender into position and secure

front with the 5116·24 bolt removed In Step 5. Tighten
bolt to 19 fI·lbs torque.
7. Carefully place fender supports Into position on

motorcycle. Align mounting holes and push moun·
tlng bolts, removed in Step 4, through holes from in·
side fender.
NOTE
Install spacers into the same locations they were

removed (rom.
Figure 2·77. Tail and Signal light Wiring
8. Use 5116·24 x 1 In. bolts in rear holes and 5116-24 x
1·1i2 In. bolts In front countersunk holes. Loosely
secure with 5116·24 acorn nuts, plain washers and
lockwashers.
Hex head bolt, 3/8-24
9. Push turn signal wires through holes with half boss
and route them under wire clips to front of fender.
Using two 318 x 24 bolts removed in Step 3, secure
turn signal assemblies. Tighten bolts to 33 1I·lbs tor·
que.
10. Tighten four fender mounting bolts to 19 fl-lbs

torque.
Removal and Installation - 1982 and Later

1. Remove 114 in. screw securing seat to fender and
hardware securing passenger strap, if applicable,
remove seal.
Figure 2·78. Rear Fender Disassembly
2. See Figure 2·80. Unplug terminal block. Use a PIN
TERMINAL TOOL, Part No. HD·97362·71 , to remove
pins from terminal housing .
""
3. Snap circuit breakers from clips.
4. See Figure 2·81 . Remove 318·24 bolts, under fender,

securing turn signal assemblies.
Carefully pull signal wires through fender and sup·

port assemblies.
NOTE
Take note as to the location of any spacers used be·

tween fender and fender supports, so they may be prop·
erly reinstalled.
5. Remove 114·28 hex socket screw and lockwasher

securing plastic fender extension to lower bracket.
FJgure 2·79. Tail Light and License Plate Bracket
6. See Figure 2-80. Remove 1/4·20 screw and hardware,
securing fender to frame.
2·66
,."
5/ 16- 18. 1-114 In.
with torque petch,
lockw.. her end locknut
5/16-18 .'In. with
Figure 2·80. Tall and Signal light Wiring -

1982 and later
Figure 2-81. Reer Fender Disassembly
7. Remove lour 5116·18 hex socket screws securing

fender and fender supports. Carefully lift off fender.
NOTE
13. See Figure 2-81 . Install fender supports and hard·
Complete following steps If 8 new, replacement lender ware, use 1· 114 in. long hex socket screws in the for·
is to be Installed. ward mounting holes. Tighten to 19 It·lbs torque.
8. Carefully drill out pop rivels securing circuil breaker 14. Push turn signal wires through holes with half boss
clips with a 114 In. diameter drill. Rivet clips to the and route under wire clips to front of fender. Use a
new fender. 318·24 bolt to secure signal light assembly. Tighten
to 33 ft·lbs torque.
9. See Figure 2·77. Remove and discard two 1/4 in.
speed nuts securing taillight assembly, transfer 15. See Figure 2-80. Reinstall connector pins, into the
assembly to new fender and install it using new 1/4 same locations they were removed. Reconnect
In. speed nuts. Route wiring harness to Ironl of socket/plug.
fender, securing It under wire clips.
10. See Figure 2·78. Remove three 114-28 nuts securing CAUTION
license plale bracket and transfer assembly to new
fender. Tighten screws to 6 1I·lbs torque. Check for proper tellllght end slgne' light operetlon,
before operating motorcycle.
11. Carefully drill out pop rivets securing plastic fender
extension with a 114 in. diameter drill. Rivet fender
extension to new fender.
16. Install 114-28 screw and hardware securing plastic
12. See Figure 2-80. Carefully place fender Into pOSition, lender extension to lower bracket.
secure with 114·20 screw, washers and new locknut.
Tighten to 10 ft·lbs torque. 17. Install seal and passenger strap, If applicable.
2-67
SPECIFICATIONS
(XR·1000)
DIMENSIONS (in.) TORQUES
Wheel Base .. 60 Axle nuts. . ......... 50 ft-Ibs
Overallength . .... .. 87.75 Sprocket mounting bolts. . ...... 45-50 ft-Ibs
Overall Width. . .. 35 Brake disc mounting - front .... 16-18 ft-Ibs
Overall Height .... 45 - rear .. _.. _. __ .. _.. 23·27 ft·lbs
Road Clearance .. ........ 6.75 Caliper mounting bolts - front. .40-45 ft-Ibs
- rear. _.. _155-190 In-Ibs
Upper bracket pinch bolt. . _.. _.. 20·25 ft-Ibs
Lower bracket pinch bolt. . .30·35 ft·lbs
WEIGHT (Ibs.) Slider cap nuts. . ........ 11 ft-Ibs
Weight as shipped Throttle control clamp screws. . . .18-24 in-Ibs
from the factory . . ... 495 Handlebar clamp screws. . .. _. _12-15 ft-Ibs
Rear l ark pivot shaft ....... 50 ft·lbs
VEHICLE WEIGHT RATINGS (Ibs.) BRAKE DISC

The Gross Vehicle Weight Ratings (GVWR) and the
Gross Axle Weight Ratings (GAWA) are found on a label
on the frame steering head. Diameter Minimum thickness
Front I Rear Front I Rear
11.5 in. I 11.5In. I
GVWA ...... 900 Ibs. _205 In .
.180 in.
GAWR·Front ......... . .. . 32Slbs.
GAWR·Rear. . ..... 575Ibs.
TIRE DATA
CAPACITIES Front Rear
Fuel Tank (U.S. GallOns) Up to 300 lb.
Standard - Total. . ..... 2.25 load including
Reserve ....... .. • .. ...... 0.25 rider with 26 30
Optional - Total .3.00 Tire passenger and
Reserve. . .............. . ..... 0.25 Pressure cargo
Oil tank (U.S. Quarts) ... ..... 2.75 (PSI)
Transmission (U.S. Pints) . . ....... 1.5 (Cold) Up to gross
Front Forks (ounces per fork) GVWR"
Wet. ...... 5.4 maximum 26 32
D')' . .6.4 load
Gross VehIcle Weight Rating (GVWR) IS gIven on a

label located on the frame.
ADJUSTMENTS WARNING
Brakes Maximum cold pressure of rear tires is 32 pSi. Maxi mum
Rear Master Cylinder Plunger Free Play . . . . 1/16 in. cold pressure of front tires Is 40 pSi .
2·69
WHEELS
(XR·1000)
FRONT WHEELS REAR WHEELS
Disassembly and Reassembly Installation

The brake discs on the front and rear wheel assemblies The XR·l000 has a debris deflector welded to the spacer
are attached by Torx screws. See Figure 2-82. These at the sprocket side of the wheel assembly. The deflec-
screws replace the socket head screws identified as tor must be rolated during Installation so that the
item (7) in Figure 2-3 and 2-4 and lIem (10) in Figure 2-6 U·shaped end 01 the deflector straddles the top 01 the
and 2-7 in the Service Manual. During removal or in- swing arm as shown in Figure 2-83.
stallation, a special tool is required to fit the special
lorx recess in the head of the screw. The tool is iden-
tified as a T·40 socket adapter or equivalent. When in·
stalling, apply Locktite Stud'n Bearing Mount to threads
and lighten to 16·18 fHbs torque.
@-
(Torx) Screw
Figure 2·82. Brllke Disc Fllstener
Figure 2·83. Debris Deflector
2·71
BRAKES
(XR·1000)
as a piston modification accomp lished the same pur·
FRONT BRAKE pose. See Figure 2-84. Any reference to the removal or
MASTER CYLINDER installat ion of th e flapper valve is to be ign ored.
WARNING
Disassembly and Assembly
Installation of a flapper valve disc on master cylinders
The fron l hydraulic master cylinder no longer has the where it is not required may cause brake drag or lockup.
flapper valve which was Installed on earlier vehicles. Always after servicing the master cylinder actuate the
The hexagonal nylon flapper valve is no longer needed brake lever with the reservoir cover removed. While ac-
... 216
1. Master cylinder
2. Mastsr cylinder cover
3. Gasket
4. Screws
14. Clamp
15. Spring
16. Stop
H. Cup 13 /11
~i ~
,1
~3
2
5,~
5.Bolt 18. PI ••on ~ (3 I~ 6 ~
6. Washers (2) 19. 0·,;n9 "11~ u / ~
7. Hydraulic line 20. Dust boot ~' ~
8. Retaining ring 21. Push rod and switch ~ Al J

9. Pivot ring 22. Reaction pin 14- I, 1
10. Brake lever 23. Brake hose
11. Sight glass 24. Lockwasher ~ 'c
12. Grommet 25. Bolt
13. Screws (2)
o
13
o
r-14
8'25 o

2·73
tuating the brake lever a small spurt of fluid will break Inspect al l components carefully for excessive wear or
through the fluid surface if all internal components are damage.
working satisfactorily.
Clean all meta l parts with alcohol. Do not use gasoline.
Clean all rubber parts in denatured alcohol or brake
fluid.
FRONT BRAKE CALIPER
WARNING
(Figure 2·85 and Figure 2·86)
Always clean brake system rubber parts by washing in
denatured alcohol or brake fluid. 00 NOT use mineral base
Disassembly cleaning solvents such as gasoline or paint thinner. Use of
mineral base solvents will cause deterioration of the rubber
To disassemble the XR-l000 front brake caliper for ser· parts, which will continue after assembly, resulting in com-
vicing do the following: ponent failure.
1. Remove the upper mounting bolt (1) and the lower

mounting pin (2) to release the caliper assembly Reassembly
from the vehicle.
After the parts have been inspected and any worn or
2. Disconnect the brake line at the caliper fitting. damaged parts replaced, reassemble the caliper as follows:
3. Move the caliper assembly to a clean bench area

and remove the retainer screw (15), pad retainer 1. Apply a coating of D.O.T. 5 HYDRAULIC BRAKE
(14) and inside pad (9). FLU ID to the exterior surfaces of sea l (10). Install
seal (10) and O·rings (6) in their respective grooves.
4. The outer pad (9), pad holder (7) and spring clip (8) Lightly coat the cavity of pin boot (5) with Dow
are then removed as an assembly. Remove pad (9) Corning Moly 44 grease. Insert the flanged end of
from pad holder (7) by pushing the pad free of the pin boot (5) into the internal groove of the threaded
pad hold down spring clip (8). bushing bore.
5. Pry out the retaining wire (13) by inserting a small 2. Push the piston dust boot (12), with the open side
screwdriver into the notched groove at the bottom downward, over the top of the piston. Push down·
of the piston bore. ward on the boot until the inner lip seats in the
groove at the top of the piston.
6. Remove the piston dust boot (12). Then remove the
piston by applying air pressure to the hydraulic 3. Coat the outside circumference of piston (11) with
brake line inlet. D.0.T.5 HYDRAULIC BRAKE FLUID and push the
piston with dust boot into the piston bore. If neces·
WARNING sary, press the piston in with a "C" clamp.
When removing the piston with air pressure, wear heavy NOTE
gloves or hold piston with heavy towel to prevent person·
al injury. Be sure piston is not dropped on hard surface. Piston must be pressed all the way into the bore when
new brake pads have been installed to assure proper
7. Pull threaded bushing (4) out of bushing bore, then clearance when calipers are reassembled to vehicle.
remove pin boot (5) from groove in caliper.
4. Position the gap of the retainer wire at the top of
8. Seal (10) and the three O-rings (6) can be removed the caliper and compress the retainer wire (13) into
by prying them out of their respective grooves. the piston bore. Push the retainer wire fi rmly
against the piston dust boot.
Cleaning, Inspection and Repair 5. Light ly coat the bores of the cal iper mounting lugs
with Dow Corning Moly 44 grease.
If brake pads are worn to 1116 in. or less, replace entire
set (9). After the brake pads are installed, they should be 6. Push the threaded bushing into the pin boot and
burnished by making several hard stops. through the bush ing bore in the mounting lug.
Keep push ing unti l the free end of the pin boot
WARNING seats in the grooved shoulder next to the hex-
agonal head of the threaded bushing.
For correct and safe brake operation, all brake pads (left
and right hand calipers) must be replaced at the same 7. Lay the pad holder(7) down on a firm flat surface. If
time. Rear brake pads must also be replaced in pairs. the caliper is right hand, the upper mounting bolt
2-74
.... 235
er mounting bolt 10. Seal piston
1. Upp
2 lower mou nting pin
wda.sdh:~shlng
11. Piston dust boot
3: Flat 12. Piston re
4. Threa 13 Retaining wi
5. Pin boot 4· Pad retainer
8. 0 ·rlng ~s:
Retainer screw
7 Pad holder 16 Caliper
8: Spring clip 17:
Bleed titt lng
9. Pad set
17
l
------------------------~~. IF:;~ 9~ u' :re :2;-'8 :5,;. the.,~~c~a~lI~p:.~r:(I.~It~)
hole mus I be paSI ndToned
I Ihe uppe
at the
r moun
UPPt.ng
. hiI bolt hole
k:
Front Bra •
____ ~~~~~;;~~
lett handd opposite)
shown
. _
cal iper is le'.1 .ha ed' al the upper rig er. lelL If ( R·ght
0 han Pad holder
must be pOSition f pad ho lder (7)

. cl ip (8) al the top a
Install the .sP,,~gu,e 2-86. .
B. as shown on Fog lator backong,
th~
~'9htl'
ad thai has the i~SUWith the lower
9_
Take pad (9),
and place II on entering th~
Pp of the spring clip opening of the
wlth'n the pad
~ad holder. Wo th·~=ul:.ed

nd of the pad. S e ad centere.
back lac~s~downward,
the flal sur-
pu
face an d is held firm
I,
holder and the I ad until It Is agal .on from the
sh down on the ~ by spring lenSI
spring clip. (7) and spri ng
10. ~~~pe~~)t a:sei~~tl~~;~~t~a~fethe

h outer pad (9), pad with
the pad aga
holder
the bac kslde of
piston.
NOTE
nd 'riction m8 te(f~. Ihtmust always

The spring clip :%:~i:ton regard/~s~:~;~oved,
or left hand
the pad
sides.a7,ar,
'ace
holder
';;:rong,
reverse d and the
thep~a:s7:asssembled. Figure 2·86. Spring Clip Installation
2-75
11. Place the inner pad (9) (without insulator) in the caliper, the fork lug and then thread into the
recessed seat machined into the caliper. lapped hole at the tower end of pad hOlder (7).
Tighten lower mounting pin to 40·45 ft·lbs torque.
t2. Position the pad retainer (14) within the counterbore
at the inside end of the caliper. Insert self·tapping 5. Tighten upper mounting bolt (1) to 40·45 ft·lbs
retainer screw (15) through the hole in the center of torque.
pad retainer (14) and thread into the hole in the pad.
Tighten screw (15) to 55·70 in·lbs. 6. If the bleeder screw was removed, it should be in·
stalled and tightened to 32·40 in·lbs.
Inslallation 7. Using new banjo washers (6), connect the brake

line (23) to the caliper. Torque banjo bolt to 30·35 ft·
Mount the caliper on the vehicle as follows: tbs torque.
8. With master cylinder nearly level, fill reservoir with
1. Coal the outside diameter of mounting pin (2) with D.C.T. 5 HYDRAULIC BRAKE FLUID to 1/8" below
Dow Corning Moly 44 grease. top. Reservoir may be filled with bladder type
2. POsition the caliper with the disc between the frlc· pressurized equipment. See BLEEDING
tion pads and the two mounting holes in the HYDRAULIC SYSTEM.
caliper aligned with the mounting lugs on the fork.
9. Actuate the brake lever. Check to be sure there is a
small spurt of fluid breaking the fluid surface when
3. Place a flat washer on boll (1), then insert the up· actuating the brake lever.
per mounting boll through the fork lug, through the
pad holder (7), then thread Ihe boll into the thread· 10. Reinstall the master cylinder cover. Be sure the
ed bushing (4). longer screw is installed at the end of the cover
with the thicker section. Actuate the master
4. Insert the lower mounting pin (2) through the cylinder and check for leaks.
2·78
HANDLEBAR CONTROLS AND INSTRUMENTS
(XR·1000)
THROTTLE CONTROL CLUTCH HAND CONTROL

The throttle control on the XA·1000 vehicle has a single The clutch control cable is routed through a cable guide
control cable which is connected to a dual control drum. on the XA·l000 vehicle. The cable guide can be removed
Two control cables extend from the drum to the throttle or installed without disconnecting the clutch cable. The
valve at each Individual carburetor. An idle cable is not cable is held by open coils at one end 01 the guide and
required with the XA·1000 carburetors. The single con· the other end Is attached to the generator through bolts
trol cable Is disconnected and installed at the throttle at the generator end cover. See Figure 2-88. The guide
grip In the same manner as previously described In the will have no effect on the removal or reassembly 01 the
Service Manual. The cable connection 10 the drum is cable however, It is important that it is in place, with the
carried out by leading the cable down the light side of cable running through the guide, after assembly.
the vehicle and Inserting the cable stop through the
threaded hole in the drum mounting bracket. The con·
duit end Is then firmly pressed into the bracket hole. The
metal cable stop al the end of the cable is led around
the underside of the drum sleeve and anchored In the
slot in the side 01 the steeve groove. See Figure 2-87.
After assembly, loosen the locknut at the bottom side of

the adjuster. Adjust the cable length so that the spring
loaded drum has full rotation to Its full throttle off posi·
tion. Be sure the throttle cable drum may rotate, caus·
ing the throttle cables to lose their adjustment.
Flgu ... 2-88. Clutch C.ble Guide
2·77
ENGINE
I
SU BJ ECT PAGE NO.
1. Specifications . . ........... . . ..... . .. . .. . . . 3-1

2. Generallnformalion . . .. . 3-5
3. Cyl inder Head .. . .. . ...... . .. . . ..... 3·15
4. Cyl inder and Piston . .. . .......... . ..... . .... . ....•. . . 3-25
5. Gearcase . . . .. . .. . .... . ........ . .... .. .... . . . .3-31
6. Crankcase ..... . 3-43
7. Specifications (XA·1000) . . ...... . ... 3-55
8. Engine (XA-l000) .. . .. . ...... . ... . .. . ..• . . . . 3-57
9. Cylinder Head (XR-l000) .... . .. . .. . . . . . . ... 3-63
10. Cylinder and Pistons (XA·l000) . . .......... . ... • ........... .. . .. . ..... 3-69
11 . Gearcase(XA·l000) . . 3-71
12. Crankcase (XA-l000) . . ... 3-77
SPECIFICATIONS
GENERAL CONNECTING ROD
Numberofcylinders. . .. 2 Piston pin/bushing clearance. .0008 in. - .001 n.
Type . .. . ............. ..... 4·cycle, 45 degree V-type End play between flywheels .005 in. - .025 n.
Bore................... . . ......... 3.188in. Crank pin/rod bearing clearance .001 in.-.0015 n.
Stroke. . . ............. . ...... 3.8125 in.
Piston displacement ... SO.9 cu. in. (997.5 ee)
Compression ratio 1979 ·1981 . . ....... 9.0 to 1 OIL PUMP
1982 ................................... 8.0101
1983·1985. . ........ 8.8to 1 Pressure (oil hot)
Minimum (al idle). 4Ibs./sq. in.
Maximum (al 3500 rpm) . 10-20 Ibs./sq. in.
VALVES Feed and scavenge Inner/outer gerolor
clearance. .000 In.
Fit in guide Shaft/bushing clearance .0005 in.
Exhaust. .0025 in. - .0045 In. Feed gear height in pump cover. .011 in.
Intake. .0015 in. · .0035 in.
Outer spring load - Early 1983 and earlier TAPPETS
Valve closed. 50-66Ibs. at '-9/32 in.
Valve open ................. 152·168Ibs. at 15/16 in. Fit in guide (lOOse). .001 in.
Ouler spring load - Late 1983 and later Roller fit . . . . . . . . . . . . . . . . .0005 in. - .001 in.
Valve closed.......... . .52-67Ibs at 1-3/8 in. Roller end clearance. .008 in. - .010 in.
Valve open .............. 171.6-194.4lbs. at 31132 In. Tappet clearance. . Just free (no lash) - engine cold
Inner spring load - Early 1983 and earlier
Valve closed. 30-36Ibs. at 1-3/32 in.
Valve open .......... ........... 76-88Ibs. at 3/4 in. VALVE TIMING
Inner spring load - Late 1983 and later
Valve closed. . .20.9-29.1 Ibs. at 1-13/64 in.
(@O.050 in. tappet lift)
Valve open. . .. 79.7-90.3 Ibs. at 25/32 in.
Spring free length - Early 1983 and earlier 1979
Outer. 1-112 in. Intake
Opens. . .. 35.4°±3"BTDC
Inner. . ... 1-23164 in.
Closes .......... . . . . .. ......... 41.2 " ±3° ABDC
Spring free length. Late 1983 and later
Exhaust
Outer............... . .............. 1-9/16 In.
Opens. . .. 44.3°±4° BBDC
Inner ................................. 1-11/32In.
Closes. . ... 20.2°±4"ATDC
1980 and later

ROCKER ARM Intake
Opens. ..7.5°±3°BTDC
Shaft fit in bushing (loose) . .0005 in. - .0025 In.
Closes .. 42.5°±3"ABDC
Exhaust
Opens....... . . . . . . . . ..... . 36" ±4" BBOC
CYLINDER HEAD Closes. ...... . . • . . .. 8"±4"ATOC
Valve guide to cylinder head (press fit) . .0022 in.
PISTON GEARCASE
Fit in cylinder (loose) Idler gear shaft
197910 Early 1985. .003 to .004 in. in bushing ... .0005 in. - .001 In.
Late 1985 . .0025 to 0.0035 in. Cam gear shaft in bushing. .6005 In. - .002 In .
Ring gap - 1982 and earlier Cam gear shaft
Top compression ... . .010 In. in needle bearing .0005 in. - .003 In.
2nd compression ......... . .010 in. Cam gear shaft end play ............ minimum .005 In.
Oil control ............ . .010 in. except rear intake which Is ..................004 in.
Compression ring side clearance .0035 in. Cam gear backlash. . . . . . . . . . . . . . .0000 in. - .0005 in.
Ring gap - 1983 - 1985
Top compression. .008 in.
2nd compression. . .008 in. FLYWHEEL ASSEMBLY
Oil control .015In.
Oil control ring side clearance. . .003 In. Runout al rim (flywheels) .. .003 In.
Compression ring side clearance .004 In. Shaft runout at flywheel end ............... .001 In.
Piston pin ............... Light hand press fit at 70 "F End play ........... . .001 - .007 In.
3·1
SPROCKET SHAFT BEARING Valve stem taper .0015 in.
Valve stemlface eccentricity .. .002 in.
Cup fit in crankcase (light). .0004 in. - .0024 in. Valve seat width. .062 in .· .100 in.
Cone fit on shaft (tight). .0002 in.· .0015 in. Valve stem protrusion from guide .. 1.420In.
Outer spring load· Early 1983 and earlier
Valve closed. . .. 40-66Ibs. at 1-9132 In.
PINION GEAR SHAFT Valve open. . ............. 140·168 Ibs. at 15/16 In.
Outer spring load· Lale 1983 and later
Fit in roller bearing (tight). .0005 in. - .0015 in. Valve closed. . ....... 43-69Ibs. all-3/8In.
Fit In cover bushing (loose) . .0005 In. - .0015 in. Valve open. . ...... 150-172lbs. at 31132 in.
Inner spring load - Early 1983 and earlier
Valve closed. 25-36Ibs. at '·3132 in.
IGNITION Valve open. . ...... 65-88Ibs. at 314 in.
Inner spring load - Late 1983 and laler
1979 Valve closed . . ... 17-29 lbs. all·3/16 in.
Ignition timer air gap. .004 - .006 in. Valve open. . . . ........ 68-90 Ibs. a125/32 in.
Retarded 10-BIDC (1/3 2" BTDC) Spring free lenglh . Early 1983 and earlier
Automatic advance 40 -BToC (17132" BlOC) Outer 1·7/16 in.
Spark plug gap setting (NO.4 plug) . .060 in. Inner. . ........... . . . . . 1·19/64 in.
Spring free length . Late 1983 and later
1980-1982 Ouler .. . ..... 1-112 in.
Ignition timer air gap ......... .. .... . not adjustable Inner .............. . . ....... 1·5116 in.
Retarded ................. . BO BTOC
Idle advance (600·1600 rpm). 26° BTDC
Full advance (above 1600 rpm) 40° BlOC Rocker Arm
Spark plug gap setting (No. 4·5, 4AS) . .038-.043 in.
Shaft ftt in bushing ... .... . .• • ..... 0005 in. - .0035 in.
1983·1985
Range ............ . • . • . 10 0 .55° BTDC
Start . 10° BTDC Cylinder Head
Fast idle.. . ........... . 40· BlOC
1800·2800 rpm ..... ....... .... . 55° BTDC Valve guide to cylinder head .001 in.
Spark plug gap setting (No. 4R5) . .038 to .043 in. Warpage .......... . .005 in.
TORQUES Cylinder
Taper. .002 in.
Gear shaft nut ...................... 100 to 120 ft-Jbs
Out-of-round .............. . .001 in.
Sprocket shaft nut ............. 100 to 120 ft-Ibs
Warpage head and base gasket surfaces. .003 in.
Crank pin nuts ...................... 150 to 175 ft·lbs
with commonized tapers. . 150 to 185 ft·lbs
Oil pump mounting screws. . .90 to 110 In·tbs
Cylinder head bolts .......... ..... .... 55 to 65 ft-Ibs
Piston
Cylinder base nut ............ 25 to 35 ft-Ibs
Fit in cylinder (loose)
Rocker arm cover nut. . . .... 14 to 19 ft·lbs
1979to Early 1985 .003 to.OO6 in.
Tappet adjusting locknut. ...... 6 to 11 ft·lbs
Late 1985 .. . . . 0055 in.
Rear motor mounting bolt-nut. . ... 16 to 24 ft·lbs
Ring gap - 1982 and earlier
Top compression. .010 In. to .031
2nd compression. .010 In. to .031
SERVICE WEAR LIMITS Oil control .010 In. to .050
Compression ring side clearance .0035 in. to .006
NOTE
Ring gap - 1983·1985
Top compression .. .008 in. to .022
Wear limits are given as a guideline for measuring
2nd compression. .008 in. to .030
engine components that are not new. For new com·
Oil control .015In. to .055
ponents or for measurements not given under WEAR
Oil control ring side clearance. .003 In. to.OO6
LIMITS, see the foregoIng. .004 In. to .006
Compression ring side clearance
Valves Connecting Rod

Fit In guide Piston pin /bushlng clearance. .0008 In. - .002 in .
Exhaust ...... . • •• • .•..•••...... 0025 in.· .007ln. End play between flywheels .005 In. - .030 in.
Intake. .. _. . . . . . •. . ...•....... 0015 in.· .006 In. Fit on crank pi n (loose) .. .001In.-.0017In.
3·2
011 Pump Cam gear shaft in bushing. . ...0005 in. · .003 In.
Cam gear shaft
Feed and scavenge Inner/outer in needle bearing .......... ,0005 in.· .0031 In.
gerolar clearance .004 in. Cam gear shaft end play. . ..... minimum .005 in.
Shaft/bushing clearance ......... . .0005 in. except rear intake which is ................ .. 004 in.
Feed gear height in pump cover. .001 In.
Flywheel Assembly
Tappets
Runou! al rim (flywheels) .......... • • •.. . .006 In.
Fit in guide (loose) .001 in.· .(X)2 in.
Shalt runout at flywheel end .002 In.
Rollerfil, .0005 in.· .0012 in.
End play ............ . .007 In.
Roller end clearance. . ......008 in. - .012 in.
Gearcase Pinion Gear Shaft

Idler gear shaft Fit in roller bearing (tight). .0005 In .•. 002In.
in bushing .0005 in. - .003 in. Fit in cover bushing (loose) .. .0005 in.· .0035 in.
3·3
GENERAL INFORMATION
DESCRIPTION Most other engine components function similar to

usual internal combustion engine design. For further
The engine is a two-cylinder, four-cycle, air cooled, over- description 01 part 'unction, see pertinent manual sec·
head-valve V·type engine with 1000cc (61 cu. in.) dis- tions.
placement. It has three major component assemblies:
cylinder, crankcase and gearcase. GASOLINE
The CYLINDER assembly includes cylinder head, 1979-1981 models use a good quality leaded or unlead·
valves, rocker arms and piston . Cylinders mount on the ed premium grade of gaSOline (94 pump octane or
engine crankcase in a 45 degree V, with both connect· higher). 1982 and Jater models use a good quality
ing rods connected to a single crank pin. regular grade leaded gasoline (89 pump octane or
higher).
The up and down motion of the piston in the cylinder is
converted to circular motion in the CRANKCASE. The LUBRICATION
built-up crankshaft consists of an offcenler crank pin
mounted between two counterweighted flywheelS
which rotate on two end shafts, which are supported by General
anti-friction roller bearings. The lower end of the rear
cylinder connecting rod is forked to fit around the The engine has a force-feed (pressure) type Oiling
single-end front cylinder connecting rod, allowing a system incorporating oil feed and return in one pump
single connecting rod-crank pin connection to the body, with one check valve on the oil feed side. The feed
flywheel. pump forces oil to the engine, lubricating lower con-
necting rod bearings, timing gears and bUShings,
Flywheel rotation is clockwise, viewing engine from generator drive gear (1979-early 1984) rocker arm
right side. Using the front cylinder firing position as a bush ings, valve stems, valve spring, push rods and tap-
starting point, the rear cylinder fires at 315 degrees rota- pets. Cylinder walls, pistons, piston pins and main bear-
tion (360 degrees minus the 45 degrees between ings are lubricated by oil spray thrown off from connec-
cylinders). The front fires at 405 degrees (360 degrees ting rods and crankshaft, and oil draining from rocker
plus the 45 degrees between cylinders). This completes arm boxes through two holes in the base of each
the 720 degrees of flywheel rotation necessary for the cylinder. The oil scavenging section of the pump returns
four piston strokes. oil to the tank from the engine.
The GEARCASE is located on the right side of the Checking and Changing Oil
crankcase and houses a gear train which operates and
times the valves and ignition. The generator (1979-early Oil mileage normally varies depending on the nature of
1984) is also driven from the gear train. service, fast or moderate driving, and how well the
engine is kept tuned.
A cam gear train consisting of four cam shafts with one
cam lobe on each shaft is gear driven. The engine valves See Figure 3-1. Remove tank cap and dipstick located
are opened and closed through the mechanicatlinkage behind side cover on right side of motorcycle. Check oil
of tappets, push rods, and rocker arms. Tappets serve to supply at least every 500 miles or more frequently
transmit the cam action to the valve linkage. Valve tim- depending on the condition of the engine. The oil tank
ing is obtained by meshing gearcase gears with timing capacity Is 4 quarts for 1979, 1980 and 1981 and 3 quarts
marks aligned. 1982 and later. The dipstick has two marks. One quart
Ignition spark Is produced by the operation of an elec-

tronic ignition module, ignition coil and spark plugs.
Spark timing is determined by a trigger rotor and a
magnetic sensing unit. On 1983 and Jater models spark
timing is determined by a trigger rotor, a magnetic sens-
ing unit and vacuum operated electric switch.
On 1979 models, the trigger rotor has two lobes. The

narrow lobe times the front cylinder and the wide lobe
times the rear cylinder. On 1980 and later models the Upper mark (full)
trigger rotor has two openings of equal size that time
the cylinders. Lower mark (add 011)
Both spark plugs fire each crankshaft revolution.

However, the spark in one cylinder occurs ineffectually Figura 3·1. 011 Tank Dipstick
during its exhaust stroke.
3·5
should be added when oil level is at the lower mark.
Push cap all the way in to prevent leakage. Oil runs
cooler and oil mileage is somewhat higher when oil tank
is kept full. Check the oil level at regular intervals to
avoid running dry.
NOTE
Oil level should be measured with motorcyle held

upright and oil at operating temperature ..
See Figures 3-2 and 3-3. 1980 and 1981 models come
equipped with an oil filter, located on a bracket between
oil tank and engine. On 1982·early 1984 models, the oil
filter Is mounted on the lower left front engine bracket.
On late 1984 and 1985 models, the oil Ii Iter is mounted
on the right crankcase and extends to the left side of
the vehicle (Figure 3·4). Change the oil filter with the oil
at the recommended 2500 mile interval or if oil is
changed more frequently, it is recommended the filter
be replaced also.
Figure 3·3. Oil Filter Mounting - 198~· Early 1984
after system has been drained and refilled with 011. Be

sure oil pressure signal light goes out within 1 minute
with engine operating at fast Idle. It light does not go
out, loosen all pressure switch at front of 011 pump and
011 tank filler plug enough to allow about 2 oz. of 011 to
flow from threaded connection while engine is running .
Retighten switch and oil tank filler plug. Add engine all
at tank to correct level.
Figure 3·2. Oil Filter Mounting - 1980-1981 Models
Alter a new engine has run lis first 500 and 2500 miles,
and, at 2500-mlle Intervals thereafter, completely drain
all tank of used oil and refill with fresh oil. If the engine Figure 3-4. Oil Filter (late 1984 - 1985)
is driven extremely hard or used on dusty roads or in
competition, drain and refill at shorter Intervals. Drain-
Winter Lubrication
ing should be done while ollis hot. It Is not necessary to Combustion in any engine produces water vapor. When
drain the crankcase as it does not accumulate used all. starting and warming up in cold weather, much of the
Always change the oil filter when changing oil. vapor that gets Into the crankcase condenses to water
before the crankcase is hot enough to exhaust the vapor
Use proper grade of oil for the lowest air temperature through the breather system. If engine Is driven enough
expected before the next oil change period. to get the crankcase thoroughly warmed up, most of
this water is again vaporized and blown out through the
CAUTION breather. However, a moderately driven engine making
short runs, does not thOroughly warm up and is likely to
Oil pump may lose prime because of air trapped in line accumulate water in the oil tank.
3·6
In freezing wea ther, this water wi ll become slush or ice, 4. When adequate pressure is produced, the all
and, if allowed to accumulate too long, may block the pressure indicator light sending unit is activated
all lines and cause damage to the engine. Water mixed and the check valve opens.
with oil for some time also forms sludge that is harmful
to the engine and causes undue wear of working parts. 5. With check valve- open, oil flows into the right
crankcase through a hole located in the all pump
In winter the oil change Interval shou ld be shorter than gasket surface. 011 enters gearcase passage
normal, and any engine used only for short runs must through hole in gearcase cover gasket.
have oil drained frequently along with a thorough tank
flushout before new oil is put in tank. The further below 6. Oil flow is then routed to both the crankshaft and
freezing the temperature drops, the shorter the oil the cylinder head areas. Oil enters a hole in the end
change intervat should be. of the pinion gear shaft and travels to the right
flywheel where i t is rOuted through the flywheel to
the crank pin. 011 Is forced through the crank pin to
011 Pressure Signal light properly lubricate the rod bearing assembly.
The OIL signal light, when on, ind icates that oil is not 7. Oil which does not enter the pinion gear shaft travels
circ ulating through the engine or that oil pressure is abo upward through the gearcase cover to the right
normally low. Proper operation Is indicated when the crankcase. Oil flow continues through a channel in
light is off. The OIL signal will light when the ignition Is the crankcase to the overhead oil lines to both front
turned on preparatory to starting engine. The light and rear intake rocker arm shafts. The oil provides
should be off when engine speed is approximately 1200 lubrication to the rocker arm shafts, bushings, In·
rpm. If the oil pressure signal light fails to go off at take valves and push rods.
speeds above idl ing, it is usually due to one of the
fal lowing causes: empty oi l tank; oil feed line clogged 8. Oi l flow continues around a groove machined in the
with ice and sludge (freezing weather); air bound; outside diameter of the large end of the rocker arm
grounded oil signal switch wire; malfunctioning signal shaft and through the rocker arm cover to the ex·
switch; gear pin sheared In all feed pump; diluted oil, or haust rocker arm shall. The exhaust rocker arm
oil pump check valve is not functioning. bushings and push ro ds are lubricated in the same
manner as described for the intake shafts. The ex·
II the oil pressure signal light does not work when ignl. haust valves are l ubricated and coo led by a hole drill·
tlon is turned on preparatory to starting engine, it Is ed in the rocker arm. For this reason, the intake and
usually due to one of the following causes: signal exhaust rocker arms are not interchangeable.
switch; wiring; burned-out signal bulb, or dead battery.
9. Oil col lected in the push rod area of the cylinder
heads flows down the push rod covers to lubricate
the tappets. Tappet rollers are lubricated by oil drain·
Oil Pressure Signal Light Switch ing into gearcase through two drain holes in tappet.
The oil pressure signal light sw itch is a pressure ac·

tuated diaphragm·type switch. The diaphragm is spring. 10. Oil collected in the intake and exhaust valve spring
loaded and held against Its contact point by spring ten· pockets drains to the flywheel compartment through
sian when oil is not circulating through the system, or holes drilled in each cylinder. Oil returning from the
when oil pressure is abnormally low. This closes the clr· heads, rod assembly and gearcase collects in the
cuit and causes the indicator light to go ON. sump area below the flywheels.
11. Oil collected in the sump area returns to the

Oiling System (Figure 3·5) scavenge section of the oi l pump through a passage
located in the rear section of the sump. Oil flow to
1. Oil is supplied to the gerotortype oil pump by gravity the pump 'is accomplished by the scavenging effect
feed from the oil tank. Oil enters the feed section of the pump and by the pressure created by the
and fills a cavity located under the feed pump. downward st roke of the pistons.
NOTE 12. Return oil fills a cavity just above the scavenge
pump . The pump transfers return oil to the outlet
A complete explanation of the gerolor pump is given in side of the pump and back to oi l tank.
GEARCASE section. See OIL PUMP.
13. All engine breathing is accompl ished through the
2. The feed pump transfers oi l from the inlet cavity to gearcase breather system. On 1979 to early 1984
the check valve located in the oullet line. models, oil carried by the crankcase exhaust air is
centrifugally separated from the air by an oil slinger
3. The one way check valve is pre·set to open at 4 to 6 on the end of the generator drive gear shaft. On late
psi oil pressure. Th is valve prevents grav ity oil 1984 and 1985 models, oil carried by the crankcase
drainage from tank to engine and acts as a re st ric· exhaust air is separated by the breather baffle at the
tion to activate oil pressure switch . front of the gearcase.
1979-1981
Late 1984 & 1985
Figure 3·5. Oiling System - Part I
3·8
Figure 3·5. Oiling System - Part II
3·9
14. On the piston downstroke, exhaust air escapes Symptoms indicating a need for engine repair are often
through a one way check valve and is routed into the misleading, but generally if more than one symptom is
rear of the air cleaner housing. present, possible symptom causes can be narrowed
down to make at least a partial trouble diagnosis. An
15. Any oil that condenses in the breather hose, drains above normal consumption of 011 for example, could be
into the gearcase from drain hole below breather caused by several mechanical lau lts. See TROUBLE-
valve. SHOOTING , Section 1. But, when accompanied by a
blue-gray smoke from the exhaust, and when low com-
16. Scavenge pump. pression is present , it indicates the rings need replac·
ing . Low compression by itself, however, indicates 1m·
17. Return oi l to tank. properly seated valves, not worn rings.
18. Vent line to air cleaner. A noisy engine is usually caused by loose bearings.
Main bearings are generally more durable than rod bear-
ings or bushings so that the latler should be suspected
Oil Pressure first. Certain knocking noises may be caused by loose
bearings, others by piston slap, a condition where
The oil pump is non-regulatory and delivers its entire piston or cylinder or both are worn out of round and
volume of oil under pressure to the engine. When a cold loose fitting, allowing the piston to slap from front to
engine is started, engine oil will be thick restricting cir· rear of the cylinder as it moves up and down.
culation through the oiling system and causing high oil
pressure. As engine becomes hot and oil thins, pressure Most frequenlly, valves, rings, pins, bushings and bear-
will correspondingly drop. Similarly, when an engine Is ings need attention at about the same time. If the symp·
operated at high speeds, the volume of oil circulated toms can be narrowed down through the process of
through the oil ing system increases, resulting in higher elimination to ind icate anyone of the above com·
oil pressure. As engine speed is reduced, volume of oil ponents Is worn, it is best to give attention to all of the
pumped is also reduced, resulting in lower oil pressure. cylinder head and cylinder parts.
To check oil pressure, use OIL PRESSURE GAUGE, Part

No. HD-96921 -52. Remove oil pressure switch from all
pump and insert pressure gauge hose fitting in oil pump
Compression Test Procedure
opening .
Satisfactory engine performance depends upon a
Run the engine until oil becomes hot. Under normal mechanically sound engine. In many cases, unsatisfac·
riding conditions, oil pressure will vary from 4-15 pSi. tory performance is caused by combustion chamber
Idle down and check the gauge. Oil pressure will vary leakage. A compression test can help determine the
from 4 to 7 psi. To ensure that the oil is hot prior to source of cylinder leakage. Use CYLINDER COMPRES-
checking, motorcycle should be driven ?O miles at or SION GAUGE, Part No. HD-33223·1.
above 50 mph.
A proper compression test should be performed with
the engine at normal operating temperature when possi·
REPAIR PROCEDURE ble. Proceed as follows:
1. Disconnect spark plug wires, clean around plug
base and remove plugs.
General
2. Connect compression tester to front cylinder.
When an engine needs repair, It Is not always possible
to determine definitely beforehand whether repair can 3. With choke and carburetor thrott le plates in wide
be made with only cylinder head, cylinders and pistons open position, crank engine continuously through 5
removed from engine or whether engine must be to 7 tull compression strokes.
disassembled completely for crankcase repair.
4. Note gauge readings at the end 01 the first and last
Most commonly, only cylinder head and cylinder repair compression strokes. Record test results.
is needed (valves, rings, pistons, etc.) and it is "recom-
mended procedure to service these units first, allowing 5. Connect compress ion tester to rear cylinder per
eng ine crankcase to remain in frame. Follow the pro- manufacturer's instructions.
cedure under STRIPPING MOTORCYCLE FOR ENGINE
REPAIR, Steps 1-11 to strip motorcycle for removal of 6. Repeat Steps 3 and 4 on rear cylinder.
cylinder head, cylinder and pistons.
CAUTION
After disassembling "upper end " only, it may be found
that crankcase repair is necessary. This requires Make sure that throttle plate 18 In the closed position
removal of engine cra nkcase from chassis, outlined before starting engine.
under STRIPPING MOTORCYCLE FOR ENGINE RE·
PAIR, Steps 12-25. 7. If the final readings are 120 psi or more and it the
3-10
final readings do not indicate more than a 10 psi a cylinder leakage test on the front cylinder. Make a
variance between cylinders, compression is con- note of the percent leakage. Any cylinder with 20%
sidered normal. If compression does not meet leakage or more requires further attention.
specifications, see diagnostic chart following.
8. Usten for air leaks at carburetor intake, tailpipe,
8. Inject approximately 112 oz. of SAE 30 oil into each head gaskel and liming inspection hole. Air escap-
cylinder and repeat the compression tests on both ing through carburetor i ndicates leaking intake
cylinders. Readings that are considerably higher valve. Air escaping through exhaust pipe indicates
during the second test indicate worn piston rings. leaki ng exhaust valve. Air escaping t hrough timing
inspection hole indicates leaking, worn or broken
piston rings, worn piston andfor cylinder. listen
Diagnosis Test Results
around head gasket area to check for leaking
Ring Trouble Compression low on first gasket.
stroke, tends to build up on the
following strokes but does not NOTE
reach normal. Improves con-
Siderab ly when oil is added to If afr fs escaping through valves, check tappet adjustment.
cylinder.
Valve Trouble Compression low on first 9. Repeal procedure on rear cylinder.

stroke, does not build up much
on following strokes . Does not CAUTION
improve considerably with the
addition of oil. Check tappet Make sure throttle plate is in the closed position before
adjustment. starting engine.
Head Gasket Leak Same reaction as valve trouble
STRIPPING MOTORCYCLE
Cylinder Leakage Test
FOR ENGINE REPAIR
The cylinder leakage test will pinpoint engine problems
including leaking valves, worn, broken or stuck piston WARNING
rings and blown head gaskets. The cylinder leakage
tester applies compressed air to the cylinder at a con- To prevent accidental starter operation, disconnect bat·
trolled pressure and volume and measures the percent tery cables (negative first) before doing any work on the
engine, drive or electrical system.
of leakage from the cylinder.
Use a cylinder leakage tester such as the Sun MODEL 1. Remove air cleaner assembly and back plate.
Disconnect the cranKcase breather hose at the back
CLT-228 or equivalent. Follow the specific instructions
suppl ied with the tester. plate.
The fo llowing are some general instructions that apply 2. Remove seat.
to Harley·Davidson V-twin engines :
3. Disconnect fuel hose at carburetor and drain
1. Run engine until it reaches normal operating gasoline. Remove gas tank.
temperature.
4. Disconnect throttle cables and choke wire from car-
2. Stop engine, clean dirt from around spark plugs and buretor. On 1983 and later models, disconnect
remove the spark plugs. vacuum operated electric switch (V.D.E.S.) advance
hose from carburet or.
3. Remove the air cleaner and set the carburetor choke
and throttle In the wide open position. 5. Remove exhaust system.
4. Remove the liming inspection plug from the crank- 6. Drain crankcase oil. On 1980 and later models,
·case. disconnect oi l filter line at the filter.
5. The piston in the cylinder being tested must be at 7. Remove rear top engine support bracket. On 1983
top dead center during the test. and laler models, it is necessary to remove the
V.O.E.S. before the rear top engine support bracket
6. To keep the engine from turning over when air can be removed.
pressure is applied to the cylinder, engage transmis-
sion In fourth gear and lock the rear brake. 8. Remove front top engine support bracket.
7. Following the manufacturer's instructions, perform 9. Disconnect both spark plug wires.
3·11
"'218
vent
Transmission
line
r-,~//~e~t ~in:
"
" ''
I, Main :
oil
feed
Figure 3·6. Oil Hose Routing - 1983·Early 1984

10. Remove bracket which supports ignit ion switch, 18. On 1979 to early 1984 models, disconnect wires to
choke, and horn. Let hang loose. generator. On late 1984 and 1985 models, discon·
nect the regulator/rectifier from the alternator
11. To provide work space, remove ignition coil from stator at the plug beneath the crankcase.
frame.
19. Disconnect black grounding wires attached to
NOTE crankcase boll.
At this point upper end can be worked on see
20. Detach tachometer cable, if applicable.
CYLINDER HEAD section. Otherwise proceed to next
step below.
21. Detach clutch cable, along with hand lever.
12. Remove rear brake master cylinder mounting bolts.
Disconnect brake line at master cylinder. Remove 22. Remove the oil feed, return and vent lines. Remove
kick starter if applicable. the feed and return lines at the oil pump and vent
line on top of the oil tank.
13. Remove rear chain sprocket cover.
23. Remove hardware attaching front of engine to frame.
14. Remove the rear chain.
24. Remove hardware attaching rear of engine to frame.
15. Disconnect wire to oil pressure switch and remove Rear mount remains attached to and is removed
oil pressure switch from motorcycle. along with engine.
16. On 1979 models, disconnect ignition module wires 25. Engine is now free to be removed from chassis. Left
from frame downtubes by cutting the cable straps. engine up off the mounting pad. Then, slip engine
On 1980 and later models, unplug ignition timer from left side of chassis, top of engine tipped slight·
plate wires from module, and on 1983 and later Iy off center of chassis.
models disconnect vacuum operated electric switch
(V.O.E.S.) from module. NOTE
17. Disconnect wiring from solenoid· plus battery cable Late 1984 and all 1985 engines (models with alternator)
on large upper post and black wire from starter relay should be removed from the right side of the chassis to
on small post. avoid jiffy stand interference.
3·12
" 218
Oil tank return
Figure 3·7. Oil Hose Routing - Late 1984 • 1985
3·13
CYLINDER HEAD
REMOVAL remove spring keepers (2).
1. Strip motorcycle as described in STRIPPING 6. Push upper covers (8) Into lower covers (4).
MOTORCYCLE FOR ENGINE REPAIR, Steps 1-11.
7. Turn engine over unt il both valves, in head being
2. Remove carburetor and manifold assembly from removed, are cfosed.
engine.
8. Loosen tappet adjustment screw locknut and back
3. See Figure 3-9 and 3-10. Loosen two oil line nuts it all the way up to end of thread .
(2).
9. Thread adjusting screw all the way Into tappet
4. Remove spark plugs. body.
10. Carefully lift push rod assembly out of gearcase

NOTE assembly and move to side to remove. Be careful
not to bind push rod upper end in rocker arm hous·
With engine in chassis, the resr cylinder rocker arm ing as this may cause damage to rod.
cover and cylinder head must be removed from engine
as an assembly. There is not enough clearance between 11. See Figure 3·9. Remove four cylinder head bolts (1).
rocker arm cover and frame to remove rocker arm cover
only. 12. Free cylinder head assembly and carefully 11ft it
over all lines from left side of motorcycle. Discard
5 Push spring retainers (7, Figure 38) down and gasket.
Early 1979 Late 1979 & Later
/n
r-l r-l
@
[6----7 /~ 6----7
1/ !
I
~---6
0 ____
1/ 1---6
0 ____
V I
II~
.. ~
5
V O~
5
~
r-
~iff~: lJ~:
~
s/
\i!l
s/
~\ 02 _________ 3
'-;~ ___2JI ~ _________ 3
:....- ___ J 0
1. Push rod 5. Washer 1. Push rod 5. Washer
2. Spring keeper 6. Spring 2. Spring keeper 6. Spring
3. Cork washer (3) 7. Spring retainer 3. O-ring (3) 7. Spring retainer
4. Lower cover 8. Upper cover 4. Lower cover 8. Upper cover
Figure 3·8. Push Rod Assembly
3·15
9. Rocker arm shaft (2)
2 --0
10. Rocker arm spring (2)
11. Rocker arm (2)
12. Racker arm spacer (2)
13. Rocker arm bushing (4)
14. Valve key (4)
1. Cylinder head bolt and washer (4) 15. Valve spring upper collar (2)
2. 01llln8 nut and rubber sl.ev8 (2) 16. Inner valve spring (2)
3. Rocker arm cover to crankcase oil lin. 17. Outer valve spring (2)
4. Rocker arm cover screw and washer In 18. Valve spring lower collar (2)
5. Rocker arm cover gasket (2) 19. Intake and exhaust valve
6. Rocker arm cover 20: Intake and exhaust valve guide
7. Rocker arm shaft screw, shim and O·rlng (2) 21. Cylinder head
8. Rocker arm shaft acorn nut and washer (2 each) 22. Cylinder head gasket
Figure 3·9. Cylinder Head Assembly - 1979·Early 1983
NOTE Rocker Cover

If cylinder head does not come loose on removal of
head bolts, tap lightly with rawhide hammer. Never try 1. Remove cover screws (4) and lift off rocker arm
to pry head off. cover assembly.
Mark push rods to Identify cylinder head and valve from
which they were removed. Reassembly into same loca·
tion will reduce ad;ustment required.
NOTE
DISASSEMBLY
Before further disassembly, carefully inspect rocker
(Figures 3·9 and 3·10) arm pads and ball sockets for pitting or excessive wear.
NOTE
Check rocker arm ( 11) for appreciable play on rocker
arm shaft (9). If rocker arm assembly is noticeably worn,
Mark a1/ parts In some manner, as they are removed, so disassemble unit for further Inspection and / or replace·
they may be reassembled In same location. ment of parts.
3·16
12
\
10 \ ~
11~~@
13\:11'
9 (; _ ~©
"\~ l'¥"
~,©O
#~
V '"
A ~
(
1 /~ fij)@ 1~~
16 17 /~,
18 /
20 ~
19
9. Rocker arm shaft (2)
10. Rocker arm spring (2)
11. Rocker arm (2)
12. Rocker arm spacer (2)
13. Rocker arm bushing (4)
14. Valve key (4)
1. Cylinder head bolt and washer (4) 15. Valve spring upper collar (2)
2. Oil line nut and rubber sleeve (2) 16. Inner valve spring (2)
3. Rocker arm cover to crankcase all line 17. Outer valve spring (2)
4. Rocker arm cover screw and washer (7) 18. Valve spring lower collar (2)
5. Rocker arm cover gasket (2) 19. Intake and exhaust valve
8. Rocker arm cover 20. Intake and exhaust valve guide
7. Rocker arm shaft screw, shim and a-ring (2) 21. Cylinder head
8. Rocker arm shaft acorn nut and washer (2 each) 22. Cylinder head gasket
Figure 3·10. Cylinder Head Assembly - Late 1983 and Later
2. Remove rocker arm shaft screw, shim(s) (if used) arms have an extra oil hole to provide lubrication and
and a-ring (7). Retain screw and shim(s) but cooling to end of valve stem.
discard a-ring.
3. Remove acorn nut and washer (8).
4. Carefully tap rocker arm shaft (9) through cover (6).

Valve Disassembly
Remove the following parts: spring (1), rocker arm
1. See Figure 3·11. Compress valve springs using
(11) and spacer (12).
VALVE SPRING COMPRESSOR, Part No. HD-8062.
CAUTION
2. Remove valve keys (14, Figure 3-9 or 3-10) from
Rocker arms are not interchangeable. Exhaust rocker valve stem end.
3·17
3. Remove valve spring compressor and the lollowing 4. If valve seat is pitted, corroded or shows indication
parts: Upper valve spring collar (15), valve springs of improper valve seating, it must be relaced or
(16 and 17), lower valve spring collar (18) and valve replaced. See REFACING VALVE SEAT.
(19).
5. Check length and tension 01 each spring (16 and

4. Remove valve guide (20) only il necessary. Reier to
17) with a VALVE SPRING TESTER, Part No.
engine SPECIFICATIONS to determine il valve
HD·96796·47. Replace spring il compression or
guide removal is necessary. If valve guide removal
length wear limit is exceeded. See engine
is necessary, heat the cylinder head and drive or
SPECIFICATIONS lor applicable information.
press the old guide Irom the head using a suitable
drill.
6. Clean and inspect valve . Use a wire wheel to
remOve carbon from valve head and stem. Never
use a lile, or other hardened tool, as it will scratch
CLEANING AND INSPECTION or nick valve. Replace valve il it is badly scored,
warped or bent. Reface valve il lace is pitted, burnt
1. Inspect oil line nut rubber sleeve (2) and replace il or corroded . See REFACING VALVE .
damaged or worn.
7. Clean valve guide with a soft brush and solvent.
2. Carelully inspect rocker arm (11). Replace rocker Check valve lit in guide. Reier to REPLACING
arm bushings (13) il rocker arm shall (9) lit exceeds VALVE GUIDE lor correct procedure.
se rvice wear specification. Replace rocker arm (11)
il pad or ball socket are pitted, worn or elongated .
8. Inspect push rod lor damage or wear. II ball ends
are worn or flattened, replace push rod.
REPLACING ROCKER ARM

BUSHINGS
NOTE
Replacement rocker arms are supplied with bushings

installed and correctly rea.med.
1. Thread a 9/16-18 in. tap into bushing.
2. From opposite end 01 rocker arm, use a drift and

press or drive bushing from arm .
3. Carefully press replacement bushing into rocker

arm . Oil holes must be correctly aligned and split
portion of bushing must be towards top of arm.
Press bushing .003·.013 in. inside arm.
4. Line ream new bushing, using REAMER Part No.

Figure 3·11 . Compressing Va lve Springs HD·94804-57, and opposite end bushing as a pilot.
5. Replace remaining bushing, repealing Steps 1-4.
3. Soak cylinder head (21) in GUNK HYDRO-SEAL un ·

til deposits are sofl. Carefully clean inside and out-
side with a wire brush . Blow off loosened carbon VALVE GUIDES
and dirt particles and wash cylinder head in sol-
vent. Clean all oil passages with compressed air. New style shoulderless intake and exhaust valve
guides, Figure 3·12, have been incorporated on the XL
series 1000cc engines, beginning with crankcase
CAUTION number 783101037. New, f lal, lower sp ring COllars, new,
longer, inner springs and new longer outer springs are also
Avoid contacting gasket surfaces with wire brush. being incorporated at the same time, to provide increased
Scratches or nicks will result in leakage_ spring tension.
3·18
The new style valve guides will also be used for service
replacement of the old style, shouldered guides on all
XL series 1000cc engines.
When new style Valve guides are used to replace the old
style guides, it is not necessary to replace the old lower
spring collar, old inner spring, old outer spring, upper
spring collar, or the valve keys. Refer to the current XL
Parts Catalog for old part number information.
The new, flat, lower spring collars, the new, longer, in-
ner springs, and new, longer outer springs, can be used
only with the new style shoulderless valve guides. Refer Figure 3-13. Shoulderless Valve Guide Driver Set
to engine SPECIFICATIONS for new spring data.
If replacement valve springs or lower spring collars are

needed on models with old style, shouldered guides, the 1. After removing the valve keys, valves, collars and
old springs or spring collar part numbers should be springs, heat the cylinder head and drive the old
ordered from the XL Parts Catalog. valve guides from the head with a hammer and drift
pin.
NOTE
2. install the new valve guides using the VALVE
To prevent possible mismatch of new springs with the GUIDE DRIVER SET. Place the correct end of the
old shouldered guides, or possible mixing of old and tooll over the guide and drive the guide into the
new springs, the new springs are identified with red or head until the tool bottoms on the head. See Figure
orange paint on several coils. 3-14 for correct valve guide projection.
Because the new style valve guides do not have a

CAUTION
shoulder, a special two-piece VALVE GUIDE DRIVE SET,
Figure 3-13 must be used for guide installation to obtain
Excessive force may damage the cylinder head or
the proper installed height. See Figure 3-14. The set con-
guides.
sists of DRIVER, Part No. HD·34740, and VALVE GUIDE
TOOL, Part No. HD·33871.
3. After installing a new guide, it must be checked to
determine proper valve to guide fit as follows.
REPLACING VALVE GUIDES
To ensure new valve guide is press fit, standard, .001,
.002, and .004 oversize replacement guides are
available. VALVE STEM CLEARANCES
NORMAL MAXIMUM
Exhaust .0025 in. .0045 in. .007 in .
Intake .0015 in. - .0035 in. .006 in .
4. Clean up and size guides to .001 to .0005 under size

using INTAKE EXPANSION REAMER 5/16 In., Part
No. HD-94810-80 and EXHAUST EXPANSION
REAMER 11/32 in., Part No. HO-94809-80.
5. Hone guide to final size using VALVE GUIDE

HONE, Part No. HD-34723, Figure 3-15. Be sure to
use a liberal amount of honing oil to prevent
damage to the hone or the valve guide.
6. Any time a guide is removed and reinstalled or

replaced, the valve seat must be reI aced to ensure
concentricity. If valve lace and seat are not con-
centric or true, leakage and burning 01 valve may
result or valve may break due to cocked seating
and deflection 01 valve stem. See REFACING
Figure 3·12. Valve Guides and Collars VALVE and REFACING VALVE SEAT.
3·19
Figure 3-14. Valve Guide Projection - Late 1983 and Later
3. If, after grinding, valve edge is very thin or sharp,

replace valve.
4. If grinding indicates valve stem warpage, replace

valve.
5. If end of valve stem shows uneven wear, true the

end on a valve grinder equipped with suitable at-
tachment or replace valve.
REFACING VALVE SEAT

Valve seats, like valves are subject to wear, pitting and
burning and should be refaced each time valves are
refaced.
See Figure 3-16. Prior to refacing valve seat, determine

if seat is still usable or if replacement is necessary. A
special GAUGE TOOL, Part No. HD-96489·63, is
Figure 3-15. Final Honing Valve Guide available to accurately measure the "A" dimension.
We recommend using a NEWAY VALVE SEAT CUTTER,

to cut valve seats.
REFACING VALVE
A suitable valve grinding machine must be used to pro-
perly rei ace valves. Valve lace angle is 45 0 for both in- 1. Decarbonize combustion chamber.
take and exhaust valves . Adjust valve grinder according-
ly. Observe the following guide lines when grinding 2. Cut 46- seat angle first, Figure 3-17. Cut only
valves. enough to clean up seal.
1. Make very light cuts, remove no more material than 3. See Figure 3-18. Applying blueing to valve face and
is necessary to clean up and true valve face. install in head. Rotate valve against seat. Remove
valve and check contact pattern. Valve seat con-
2. Pits and burnt surfaces must all be removed from tact area should be 1/16 in. wide and 2/3 of the way
valve face. toward the outside edge of the valve face.
3·20
..A Gauge
/
~""'""""{
Valve seat
1116 in. centered
on valve face
'> Valve face
A
A'<'"'--=--~~~~-
Max. Min.
Figure 3·18. Valve Contact Pattern
1.420 1.375
Figure 3·16. Valve Seat Specifications
,! ....
Head
Valve
Figure 3·19. Lapping Valve Face and Seat
Figure 3·17. Cutting Valve Seat
4. If valve seat pattern Is too close to stem side of few oscillations. Do this just enough to give face
valve face, cut 60· angle to raise seat. If pattern Is and seat a lapped finish.
too close to edge of valve face, cut 31 0 angle to
lower seat. 7. Recheck valve seat width and location as de·
scribed in Step 3.
5. After cutting either or both 31° or SOo angle to posi·
tion seat, final cut 46° seat angle to obtain proper
1/16 in. width.
VALVE SEAT INSERTS
6. See Figure 3-19. Apply a louch of lapping com-
pound to valve face, Insert valve In guide, and us- As valve and seat are refaced from time to time, valve
ing I APPING TOOL, Pari No. HD·96550-36A, give a seat will widen and valve will seat lower when fully
3·21
closed, Passage around valve, when fully open, is CAUTION
restricted and valve will tend to float as spring tension
is reduced. When Installing gasket (22) make sure oil return hole, in
gasket, lines up with oil drain hole in cylinder head or oil
Valve seat inserts are available from the factory. Instal- flow will be restricted.
lation requires accurate boring equipment to machine
correct counterbore in head, for installation within 2. Turn engine over until tappets are at their lowest
.004-.006 in. interference fit. position. Install push rods and cover ,assemblies in
their original positions.
CYLINDER HEAD ASSEMBLY 3. Carefully , from left side of motorcycle, place

cylinder head assembly over oil lines and push
(Figures 3·9 and 3·10) rods.
4. Thread cylinder head bolts (1) and washers,

Valve Assembly through head assembly, into cylinder. Just snug
bolts, do not tighten.
1. Apply a light coating of oil to valve seat and stem.
5. Carefully square manifold faces with cyliT1der head
2. Install valve (19) into original location, or location
intake port faces. Install seals and clamps to
it was fitted to.
se'cure manifold to cylinder heads.
3. Install lower spring collar (18), springs (16 and 17)
6. Tighten each bolt (1) 118 or 114 turn at a time until
and upper spring collar (15).
all are tightened to 55-65 ft-Ibs torque.
4. See Figure 3·11. Compress valve springs using
7. Make sure oil line fitting rubber sleeve is in place.
VALVE SPRI NG COMPRESSOR, Part No. HO-8062.
Apply Loctite PIPE SEALANT WITH TEFLON, to
threads and tighten oil line nut (2) to 70·100 in ·lbs
5. Install valve keys (14, Figures 3-9 and 3·10) on
torque.
valve stem end. Position keys so spaces between
key halves are equal.
8. Reassemble remaining parts.
6. Remove spring compressor.
ADJUSTING TAPPETS
Rocker Cover Assembly
1. Engine must be cold during adjustment.
1. Place the following parts into cover: spring (10),
rocker arm (11) and spacer (12). 2. See Figure 3·8. Push spring retainer (7) down and
remove spring keepers (2).
2. Carefully tap rocker arm shaft (9) through cover.
3. Turn engine over until valves are closed.
3. Secure rocker arm shaft (9) with shaft acorn nut
and washer (8), tighten to 8·16 ft·lbs torque. Check 4. See Fig ure 3-20. Loosen tappet adjusting screw
rocker arm action to make sure it is not binding. locknut (3).
4. Coat new o·ring with rubber lubricant and in stal l 5. Turn adjusting screw (2) downward (into tappet
rocker arm shaft screw (7) with shim(s), if requir ed. body) until push rod (I) is just free and has
To rque screw to 8-16 ft-Ibs. noticeable up and down movement.
5. Carefully clean top of cylinder head and rocker 6. Slowly turn adjusting screw (2) upward, toward
arm cover faces. Install a new gasket (5). push rod (1), unt il nearly all play is removed.
6. Position rocker arm cover on cylinder head. Install 7. Tighten locknut (3), again!>! adjusting screw (2), to
rocker arm cover screws (4) with flat washer under 72-132 in-Ibs.
head of each screw. Screws must be tightened
evenly to attain a tight jOint. First turn them snug; 8. Recheck for correct adjustment. Push rod (1)
then, tighten each one 1/8 to 1/4 turn at a time until should have a sl ight amount of play or shake and
all are tightened to 14·19 ft·lbs torque. must freely turn completely around without trace
of binding, when rotated by fingertips.
CYLINDER HEAD INSTALLATION 9. Reassemble push rod covers. Make sure both ends
are properly seated against O-rings or cork
1. Place a new gasket (22) into position on cylinder. washers.
3-22
2. Push upper cover (8) into lower cover (4).
3. Turn engine over untillhe appropriate valve is closed.
4. Loosen tappet adjustment screw locknut (3) and

back il all the way up to end of thread.
5. Thread adjusting screw (2) all the way into tappet

:;t--- 3 body.
6. Carefully lift push rod assembly out of gearcase

assembly and move to side to remove. Be careful
not to bind push rod upper end in rocker arm hous-
ing as this may cause damage to rod.
1. Push rod
Inslallalion
2. Tappet adjusting screw
1. Inspect O-rings or cork washers and replace as
3. Tappet adjusting screw locknut
necessary .
4. Tappet bOdy
Figure 3·20. Adjusting Tappets 2. Carefully locate ball end of push rod assembly into
rocker arm socket and lower end of push rod into
alignment with tappet screw.
PUSH ROD REMOVAL 3. Turn adjusting screw out to meet push rod.
AND INSTALLATION
4. See ADJUSTING TAPPETS section preceding, to
(Figure 3·8) properly adjust push rod tappets and to complete
reassembly .
Removal
1. Push spring retainer (7) down and remove spring
keepers (2).
3·23
CYLINDER AND PISTON
6. Carefully pull cylinder (2) over piston (7). Do not
REMOVAL allow piston (7) to fall against crankcase. Discard
(Figure 3·21) cylinder base gasket (3).
1. Strip motorcycle as described in STRIPPING 7. Spread piston rings (4) outward until they clear
MOTORCYCLE FOR ENGINE REPAIR, Steps 1·11. grooves in piston (7) and lift off.
Remove cylinder head as described in CYLINDER
HEAD REMOVAl. 8. Remove and discard piston pin retaining rings (5).
use an INTERNAL RETAINING RING PLIERS. Part
No. HO·96215·49. Be extremely careful not to over
expand or twist rings, or to damage piston surface
9. Support piston (7) and tap out piston pin (6) using a
suitable drift
NOTE
It may be necessary to heat piston to remove pin.
10. Remove piston pin bushing (8) from connecting rod

if necessary, See CLEANING AND INSPECTION.
CLEANING AND INSPECTION

1. Soak cylinder and piston in GUNK HYDRO·SEAL
until deposits are soft, then clean with a brush.
Blow off loosened carbon and dirt particles and
wash in solvent.
2. Clean oil passage with compressed air.
3. Clean piston ring grooves with a piece of compres·

sion ring ground to a chisel shape.
1. Cylinder base nut (4) 6. Piston pin
2. Cylinder 7. Piston 4. Examine piston pin to see that it is not pitted or
3. Cylinder base gasket 8. Piston pin bushing scored.
4. Set piston rings 9. Connecting rod
5. Piston pin retaining ring (2) 5. Check piston pin bushing to see that it is not loose
in connecting rod, grooved, pitted or scored. A
Figure 3·21. Cylinder & Piston piston pin, properly fitted, is a light hand press fit
in piston and has .0008 in. clearance in connecting
rod upper bushing. If piston pin to bushing free fit
2. Clean crankcase around base of cylinder to pre- exceeds .002 in. replace worn parts. See CON·
vent dirt from entering crankcase while removing NECTING ROD BUSHINGS.
cylinder,
6. Examine piston and cylinder for cracks, burnt
3. Turn engine over until one piston (7) is at bottom of spots, grooves and gouges.
its stroke.
7. Check rods for up and down play in lower bearings.
4. Remove cylinder base nuts (1). When up and down play is detected, lower bearing
should be refitted. This requires removing and dis-
5. Carefully raise cylinder (2) just enough to permit assembling engine crankcase.
placing a rag over crankcase opening. This will
prevent dirt and other foreign matter from entering
crankcase.
NOTE REFINISHING CYLINDER

If cylinder does not come loose on removal of nuts (1), Measure pistons and cylinder to determine if they are
tap lightly with rawhide hammer. Never try to pry worn to the point where cylinders must be rebored and
cylinder up. oversize pistons installed.
3·25
NOTE
Inside and outside micrometers used for piston to
cylinder fitting should be calibrated to ensure accurate
readings.
Measuring Cylinder Bore

1. Mount Ihe cylinder in TORQUE PLATE, Pari No.
HD·34198, as shown in Figure 3·22.
2. Take cylinder bore measurement in ring palh, slarl·

ing aboul 112 in. from top of cylinder measuring
from front to rear and then side to side. Record
readings.
3. Repeal measurement at cenler and then bottom of

ring path. Record readings. This process will deler·
mine if cylinder is out·of·round or "egged" and will
also show any cylinder taper or bulge. See WEAR
LIMITS.
4. If cylinder is not scuffed or scored and pislon

clearance is within service limit, it is not necessary
to rebore for an oversized piston. If desired, a new
piston and rings may be installed to reduce clear· Pistons are measured front to rear at base of piston skirt
ance for quieter operation. as shown. Pistons are cam ground to an egg or oval
shape so only front and rear surfaces touch cylinder
5. If piston clearance is more than service limit, wall.
cylinders should be rebored and lo r honed to next
standard oversize and refitted with the correspond· LATE 1985 MODELS
ing piston and rings. XL model vehicles, starting with crankcae number 785
306029, manufactured after November 1, 1984 have a
new late style pistonlring package.
These pistons have a cam ground, barrel shape and
must be measured 90° from the piston pin and .890 in.
above the bottom of the piston.
Fitting Cylinder to Piston
See SPECIFICATIONS for piston to cylinder clearance.
For acceptable service wear of piston to cylinder
clearance see SERVICE WEAR LIMITS.
Pistons for 1979 to Early 1985 models are available in
the following oversizes: .010, .020, .030, .040, .050, .060
and .070. in. Oversize pistons have their size stamped on
the head. For example: 10, 20, etc.
Pistons for Late 1985 models are available in oversize
.005, .010, .020, .030 and .040.
Cylinders can be refinished oversize with a hone only, or
with a boring bar followed by a finishing hone. In general
practice, only cylinders not scored and not badly worn
are refinished entirely with a hone. Cylinders badly worn
or deeply scored are first rebored to nearly the required
oversize and then are finish·honed to exact size.
NOTE
It is essential that cylinder be mounted in TORQUE
PLATE, Part No. HD·34198 for measurements, boring,
honing, or other machining operations, to prevent
Figure 3·22. Measuring Cylinder Bore distortion of the cylinder.
Exact final size of cylinder bore is determined by size of
Measuring Piston piston to be used in that cylinder. Measure piston
(Figure 3·23) diameter accurately, as described previously and then
add desired piston clearance (.003 .. 004 in.). This will
1979· EARLY 1985 MODELS equal the exact final size to which cylinder bore should
3·26
be ref inished .
Example: a .010 in. overs ize piston measures 3.1963 in ., 1983 to Early 1985
adding .003 in . (desired clearance) equals 3.1993 in .
(finish-honed size). Instal l dots towards top
When cylinder requires reboring to beyond .070 in. over-
size to clean up , the oversize limit has been exceeded
and cyl i nder must be replaced .
Cylinder walls MUST be finish -honed with a No. 280 grit
hone prior to installing the late style piston .
The late style pistons are a retrofit for earlier XL model

vehicles. Part numbers for the late style pistons, rings
and piston, and cylinders are:
PISTON & PISTON &

SIZE RINGS RINGS CYLINDER
Standard 22251-83A 22260·83 Fronl-16464-73C
.0050.8. 22252-85 22265·83 Rear·16465-73C
.0tO 0.8. 22253-83A 22261·83
.0200.S. 22254-83A 22262·83 2747
.0300.S. 22255-83A 22263·83 late 1985 Second ring - install
.0400.S. 22256·83A 22264-83 dot toward top
NOTE
The same piston may be used if cylinder bore was not
changed, unless it is scuffed or grooved. However,
replace rings and hone the cylinder walls with a No. 280
grit hone to facilitate ring seating.
FITTING PISTON RINGS

1979-1982 piston rings are of two types : compression
(plain face) and oil control. The two compression rings
are positioned in the two upper piston ring grooves,
chamfered side up . The oil control ring is a full width , Oil control rings
slotted ring, having a spring expander.
Top ring - install
either sIde up
See Figure 3·24.1983 to early 1985 piston rings include a
beveled barrel-faced, moly-filled top ring, a taper·faced
second ring and a three·piece oil control ri ng with two Figure 3-24. Piston Rings
chrome plated rai ls and a corrugated expander.
Ri ngs for 1979 to early 1985 models are available in the

following overs izes to fit standard oversize pistons: in. from top. Set ri ng to be checked squarely
.010, .020, .030, .040, .050, .060 and .070 in . against piston as shown. Ch eck end gap with
thickness gauge . See SPECIFICATIONS for
See Figure 3-24. late 1985 piston rings include a moly- to lerance.
filled top ring, a taper-faced second ring, and a three-
piece oil control ring with two chrome plated rails and a
corrugated expander. The second ring must be installed NOTE
with dot toward top .
End gap may be increased by filing with a fine -cut-file.
late 1985 rings are available in oversizes .005, .010, .020,
.030 and .040.
See Figure 3-27 and 3·28. Use a piston ring expander
Piston rings must be properly fitted to piston and too l to slip compress ion rings over piston into their
cylinder: respective grooves. Be extremely careful not to over ex-
pand or twist rings, or damage piston surface when in-
1. See Figure 3·25. Check for proper side clea rance stalling rings.
with thickness gauge, as shown. See SPECIF ICA-
TIONS fo r tolerance. Install rings so end gaps of adjacent rings are 90° apart
minimum . Ring gaps are not to be within 10° of the
2. See Figure 3·26. Place piston in cylinder about 1/2 thrust face centerline.
3·27
.." CONNECTING ROD BUSHING
(Figure 3-29)
When connecting rod bushing is worn to excessive pin
clearance (.002 in. or more) It must be replaced or fitted
lor an oversized pin.
NOTE
FItting 8 rod bushing for en oversized pin (.004 in. over·

s/zed) a/so requires reaming the piston oversized. It Is
generally more economical to replace the bushing so a
standard pin can be used.
1. Secure connecting rod with ADD CLAMPING FIX-

TURE , Part No. HD·95952.J3.
Figure 3-25. Measuring Ring Clearance in Groove 2. Remove worn bushing and Install new bush ing
with a BUSHING INSTALLATION TOOL, Part No.
HO-95970-32A.
On early 1982 and earlier mOdels, when starti ng
All1
Stagger ring gaps at these locations
Front
Rear
Figure 3·28. Positioning Ring End Gap
Figure 3-26. Measuring Ring End Gap new bushing be sure to position oil slot so it will
align with 011 slot In connecting rod .
,.
On late 1982 and later models, drill 3/16 In. hole
through connecting rod oil hole Into bushing.
, ...
Figure 3·27. Installing Piston Rings Figure 3·29. Installing New Piston Pin Bushing
3·28
3. Clean up and size bushing to .001 10 .0005 under· 2. Press piston pin Into place. Piston pin should be a
size using REAMER Part No. HO·94800-26. light hand press at 70-F.
SizIng bushing with less than .0008 In. clearance 3. For 1979 to Early 1985 style pistons, use an
can resulilo a seized pin andlor bushing loosening INTERNAL LOCK RING PLIERS, Part No.
in rOd . HD·96215~9, to install new retaining rings. Install
retaining rings with sharp edge oul.
4. Hone bushing to final size using CONNECTING
ROO BUSHING HONE, Part No. HD·35102. Drive
For Late 1983 style pistons, use PISTON PIN RE·
hone with an electric drill and work for a cross·
TAINING RING INSTALLER, Part No. HD·34623.
hatch pattern of approximately 60-. Use a hone or
Retaining ring end gap must be Installed away
bushing. Clean bushing bore with cleaning solvent.
from piston slot at the bottom of the piston. Direct
gap at least 90- away from piston bottom.
ASSEMBLING CYLINDER AND
PISTON
(Figure 3·30) CAUTION
Always use new retaining rings. Make sure retaining

ring groove Is clean and ring seats tirmly In groove. If It
doesn't, discard the ring. Never use a retaining ring On·
eluding a new one) If it has been Installed and then
removed for any reason. A loosely Installed ring will
come out of piston groove, resulting in damage to
piston and cylinder.
4. Lubricate cylinder walls and piston with engine oii.
5. Turn engine over until crank pin is at top center.
6. Install new cylinder base gasket.
7. Position RING COMPRESSOR, Part No. HD·96333·

51B, over piston rings and slide cylinder over
assembly.
8. Remove ring compressor, rotate cylinder so push

rod slots tine up with tappet guides and slide over
mounting bolts.
Figure 3·30. Installing Cylinder Over Piston 9. Install cylinder base nuts and lighten to 25-35 fI·lbs
torque.
1. Install piston assembly over connectIng rod. In· 10. Assemble cylinder head and remaining parts of
slall wlth Intake valve pocket toward Intake valve, engine as Indicated in CYLINDER HEAD IN·
when head Is installed. STALLATION.
3·29
GEARCASE
OIL PUMP 2. During next 180· of rotation, the size of the cavity
decreases forcing oil Inio Ihe outlet.
General See Figure 3·32. Gravity fed oil from the oil tank enters
(Figure 3·31) the pump through fitting (4). II is forced by gerotor sel
(13) Into valve (11).
The all pump consists of two gerolar pumps, feed and
scavenge (return), housed In one pump body. The feed
pump forces all to the engine while the scavenge pump Note
collects and returns oil to the lank.
Valve (11) is a check valve that contains a spring loaded
A gerolar type pump has two parts, an inner and an cup which maintains 4 to 6 psi pressure. The check
outer gerolor. The inner gerolar always has one less valve must always be installed in pump with arrow on
tooth than the outer gerolor. Both gerolors are mounted side of valve pointing in direction of lIow.
on fixed centers but are offset to each other.
From valve (11), oil exits pump under pressure into
In a gerolar pump, oil is transferred from inlet to outlet crankcase. 0il pressure Is sensed by oil pressure switch
as it Is trapped between the rotating inner and outer (26).
gerolars. The illustration shows the principle of gerolar
operation :
0il passages within the engine are shown in Figure 3·5.
1. During first 180- of rotallon, the cavity between In· Return oil from the flywheel compartment is drawn back
ner and outer gerolars gradually increases in size inlo the pump and is forced by gerolor set (20, Figure
until it reaches its maximum size, equivalent to the 3-32) back to the oil tank.
full volume of the " missing tooth." The gradually
enlarging cavity creates a vacuum into which oil Spring (17) bears against plates (15 and 18) to maintain
flows from the inlet. zero side clearance on both gerolor sets (13 and 20).
Outer 011 drawn

Inlo cavity
between teeth
011
forced
Trapped
011
Inner
gerotor
outlet
Figure 3·31. Principle of Gerolor Operation
3·31
r
I
I
20
© 19
(?)-18
Gg-17
@J 16
8 ,~:#- 15
8 &>;;
,
0:
4 "
13
9.---0 ~C) , _________ 6

7
1. Screw (4) 10. O·rlng 19. Retaining ring

2. lockwasher (4) 11. Check valve 20. Gerotor set, return (thick)
3. Washer (4) 12.0·rlng 21. Gear shaft pin
4. Filling, tee 13. Gerolor set, feed (thin) 22. Gear shaft
5. Fitting, return 14. Gear shaft pin 23. Gasket
6. Cover 15. Outer plate 24. Body
7. O-ring 16. Outer plate seal 25. Bushing
8. Bushing 17. Spring washer 26. 011 pressure switch
9. Roll pin 18. Inner plate
Figure 3-32. Oil Pump
The oil pump seldom needs servicing. Before weather, the oil feed line may clog with Ice and
disassembling pump because of no oil pressure, be ab- sludge preventing circulation of oil.
solutely certain that all possible related malfunctions
have been eliminated. 3. Check for a grounded oil pressure switch wire or a
faulty switch if 011 indicator light fails to go out
1, Make sure all oillln8 clamps are tight. with engine running.
2. Check oil level and condition of oit in oil tank. If oil 4. See ENGiNE LUBRICATION foradditionallnforma·
is diluted, pressure will be affected. In freezing tion.
3·32
9. Press seal (16) from outer plate (15) and discard.
Removal And Disassembly
(Figure 3·32)
Oil pump can be removed while engine is in frame and
without removing gearcase cover.
Cleaning and Inspection
1. Clean ali parts In cleaning solvent. Blowout holes
1. Disconnect and tag all all lines and pressure
and oil passages with compressed air.
switch wire.
2. Inspect check valve (11). The spring loaded cup
2. Carefully remove four screws (1) thai secure pump
within valve must be free to move and must return
to crankcase, With screws removed, pump will
to its closed, seated position. If valve is damaged
drop. Discard gasket (23).
or if improper operation is observed replace valve.
3. Lift cover (6) off body (24). Remove and discard
3. Inspect spring (17), replace if fingers are broken
D-ring (7).
off.
4. Slide both pieces of feed gerolor set (13) off gear
4. See Figure 3-33. Inspect both gerolar sets for wear.
shaft (22). Use a long.nosed pliers to pull pin (14)
Mesh pieces of each set together as shown. Use a
out of gear shaft (22).
feeler gauge to determine clearance.
5. With pin (14) removed the following parts will be
free for removal: outer plale (15), spring washer
(17), inner plale (18) and outer gerolar of scavenge
gerolar set (20).
6. Use an EXTERNAL LOCK RING PLIERS, Part No.

HD·95017-61, to remove and discard relaining ring
(19). Inner gerolor, of the scavenge gerotor set (20),
will now be free for removal.
7. Use a long-nosed pliers to pull pin (21) out of gear

shaft (22). Gear shaft (22) can now be removed. .004 In.
max.
8. Push check valve (11) from hOusing (24) with a 5/16
i n. diameter rod. Remove and discard O-rings (10
Figure 3·33. Gerotor Wear limits
and 12).
Feed and scavenge

~ gerolor sets
~
No chamfer
~~~~~~~~I:===-:: .020 x 45° chamfer I

It;; or .020 radius
.010 radius max •

.015 radius max. undercut for clearance
(same radius on oil pump body) (same under-cut on oil pump body)
~ Oil pump cover / Oil pump cover
Early 1983 and earlier Late 1983
Figure 3-34. Gerotor Oil Pump
3·33
The maximum allowable c learance between Assembly
gerotors is .004 in. If clearance exceeds this
dimension replace gerotors as a set. 1. Install gear shaft (22) through housing (24) and
careful ly, with a long-nosed pliers, push pin (21) in-
Early 1983 and earlier outer gerotors have chamfered to p lace.
outer edges . Late 1983 and later outer gerotors do not
have chamfers. Refer to Figure 3-34. The late 1983 and NOTE
later pump bodies are undercut for ouler gerolor
clearance. Liberally coat all moving parts with engine oil, to ensure
easy assembly and smooth beginning operation.
Either early or late style outer gerotors may be used
with the late style undercut pump bodies and covers. 2. Insert inner gerotor, of the scavenge gerolor set
However, only the chamfered outer gerolors may be (20), over gear shaft . Lock in place with a new re-
used with the early style pump bodies and covers. tain ing ring (19) using an EXTERNAL LOCK RING
PLIERS, Part No. HD-95017-61 , to install.
WARNING
3. Install a new seal (16) into outer plate (15). Install
Use of late style ouler gerotors in early style oil pump so lip of seal will be toward feed gerotors (13).
bodies and covers could cause the oil pump to bind.
NOTE
Use Loctite LOCK N'SEAL ADHESIVE to secure seal

5. Measure thickness of feed gerotors with a (16) into outer plate (15).
micrometer. If they are not the same thickness,
replace as a set. 4. Place outer gerotor over inner to complete
scavenge set (20).
6. Place feed gerotors in cover. Both gerotors must
be the same height, if not, cover is warped and 5. Position inner plate (18) into case and line up slot
must be replaced. with pin (9). Place spring washer (17) on inner plate
(18), with fingers away from inner plate (18).
7. See F igure 3·35. Place feed gerotors in cover. Us·
ing a straightedge and feeler gauge measure the 6. Carefully push outer plate (15) over gear shaft (22).
distance gerotors extend above cover surface. The Line up slot in plate with pin (9). Install seal side in·
dimension should be .001·.011 in . If dimension is ward.
more than .011 in . or less than .001 in . replace
cover. 7. Use a long·nose pliers to push pin (14) into gear
shaft (22). Place feed gerotor set (13) over gear
8. Inspect gear shaft (22, F igure 3-32), fil in bushings shaft (22).
(8 and 25), clearance should be .0005 in. Rep lace
bushings if worn, scored or damaged . 8. Install a new D-ring (10) over check valve (11) and
push into place. Install with arrow pointing in
Bushing (25) should be pressed in .100 in. below direction of oil flow . Place a new D·ring (12) into
surface. groove between valve and pump bOdy.
Bushing (8) should be pressed in .120 in. below sur- 9. Install a new O-ring (7) into groove in cover (6) and
face. place onto pump bOdy.
9. Check gear shaft (22) teeth for wear or damage. 10. Coat a new gasket (23) with a non-hardening
Replace if necessary. gasket sealer and place into position.
Straightedge
(scale)
Feeler gauge
Cover
Figure 3·35. Measuring Gerotor Height

3·34
11. Secure pump to gearcase with screws (1) and hard· Excessive tappet-gu ide clearance is corrected by
ware as shown. Tighten to 90-110 in-Ibs torque. fitt ing a new tappet andlor guide.
12. Reinstall oil lines as removed. Use new clamps. NOTE
13. Loosely install oil pressure switch and prime pump Inside and outside micrometers used for measuring tap -
per instructions following. pets and tappet guides must be calibrated to ensure ac·
curate readings.
Priming Oil Pump 3. Check tappet roller free play. Roller clearance on
pin should be within the .0005·.0012 in. wear limit.
Oil pump must be primed whenever oil lines have been
Recommended service practice is tappet replace-
removed or pump has been d isassembled.
ment. See SPECIFICATIONS.
1. Remove pressure switch wire then loosen switch
NOTE
and oil tank filler plug.
A tappet rol/er kit (6) Is available to rebuild a tappet
2. Start engine and allow about 2 oz. of oil to be forc-
assembly; however, roller must turn freely on needles
ed through pressure switch threads.
and have correct side play after new roller pin is riveted
to tappet.
3. Stop engine, tighten pressure switch and install
wire. Tighten nut securing wire to 4-10 in-Ibs tor-
4. Check tappet roller end clearance. Wear limit Is
que.
.008-.012 in.
4. Check oil tank for correct oi l level.

5. If tappet ad just ing screw is damaged , worn, egg-
shaped or pitted , It must be replaced. This will en·
sure accurate tappet adjustment.
VALVE TAPPETS AND GUIDES
Disassembly Assembly
1. Clean all dirt from around crankcase and blow 1. Assemble adjusting screw and nut and install
loose particles from area with compressed air. screw on tappet (4).
2. Remove push rod assembly. See REMOVING AND 2. Liberally coat tappet assembly and especi all y
INSTALLING PUSH ROD. roller needles with engine oil, to ensure smooth
beginn ing operation.
3. See Figure 3·36. Remove tappet guide screw (1)
and guide (3). 3. Apply rubber lubricant to new a-ring (5) and install
on guide (3), carefully seating the erri ng in Its
4. Remove and discard tappet guide o·ring (5). groove.
4. Insert the tappet Into the bottom of the guide.

NOTE Holding tappet up to extreme limit of travel, posi-
tion guide and tappet assembly over gearcase.
If tappet guide does not come loose after removing Rotate tappel so It will properly align with cam and
screw, tap lightly with rawhide hammer. Never tl}' to pry gu ide will align with mount ing hole.
tappet guide out.
Mark all components to ensure reinstallation into same CAUTION

location. This will ensure an even wear pattern between
tappet guide and cam surface. If tappet is not correctly positioned within guide (roller
crosswise to guide and cam) serious damage may result
when assembly Is Inserted into crankcase.
Cleaning And Inspection 5. Carefully press guide assembly into gearcase.
1. Clean all parts thoroughly in solvent and blow dry

with compressed air. CAUTION
2. Inspect valve tappets for excessive clearance in Tappet guides are a soft die cast aluminum. Be ex·
guide (3). Clearance should be .001-.002 in. (WEAR tremely careful not to damage guide while pressing.
LIMIT).
6. Install screw (1) and tighten to 8-14 ft-Ibs torque.
A gauge should be used to accurately measure
tappet guide inner diameter. 7. Check free movement of tappet in guide.
3·35
11
- - ~----- - - - -~~" 1-8 <! / 5

~ ~--
~ ri-'
..
0- V
I
19 ~.
I 18
8
J'
20
9
22 \, O~
,,
6 ,
I
I
I
I
I
/ 11 "-~-
10
2
13
11,,~ "
19. Rear exhaust cam gear

1. Tappet guide screw 11. Cam gear plate (2) shaft bushing
2. Tappet screw with nut 12. Idler gear shaft bushing (2) 20. Cam gear and timer shaft
3. Tappet guide 13. Idler gear bushing
4. Tappet and roller 14. Gearcase cover gasket 21. Pinion gear shaft bushing
5. Tappet guide Q·rlng I S. Flywheel shaft pinion gear 22. Front intake cam gear
6. Tappet roller kit 16. Nut and lockwasher shaft bushing
7. Rear cylinder exhaust cam gear 17. Oil pump drive gear 23. Front exhaust cam gear
8. Rear cylinder Intake cam gear 18. Cam gear needle roller shaft bushing
9. Front cylinder Intake cam gear bearing (4)
10. Front cylinder exhaust cam gear
Figure 3-36. Gearcase and Tappet - 1979 to Early 1984
3·36
6
\
23. Screw (2) 26. O'ring
24. Spacer (2) 27. Plug
25. Oiler manifold
1. Tappet guide screw 10. Front cylinder exhaust cam gear 17.011 pump drive gear
2. Tappet screw with nul 11. Cam gear plate (2) 18. Cam gear needle roller
3. Tappet guide 12. Front Intake cam g8ar bearing (4)
4. Tappet and roller shaft bushing 19. Rear exhaust cam gear
5. Tappet guide a·rlng 13. Front exhaust cam gear 20. Cam gear and timer shaft
6. Crankcase half shaft bushing bushing
7. Rear cylinder exhaust cam gear 14. Gearcase cover gasket 21. Pinion gear shalt bushing
8. Rear cylinder Intake cam gear 15. Flywheel shaft pinion gear 22. Breather assembly
9. Front cylinder intake cam gear 16. Nut and lockwasher
Figure 3·37. Gearease and Tappet - Late 1984 and 1985
3·37
GEARCASE COVER AND CAM ON MODELS WITH CAM GEAR OILER:
GEARS 12. Straighten the cam gear oiler clamps and remove
the two screws (23) and spacers (24) .
General
13. Remove the socket head pipe plug (27) from the
Carefully read the complete gearcase section before gearcase.
any serv ice work is begun.
14. Inert a 1/4 in. pin punch in the plug hole and tap the
For the gearcase components to operate al their op- oiler out of the crankcase.
t imum, all components must be properly fitted and mal-
ched. Changing one component can affect many others .
It is important to know and understand all inspect ion Cleaning and Inspection
procedures and how components interact.
1. Thoroughly scrub gearcase compartment, cover
Disassem bly and gears in solvent to remove oi l and carbon
deposits.
1. Thoroughly clean area around gearcase c ove r and
lappets. Blow loose dirt from crankcase with com- 2. Blowout all cover oil passages and bushings with
pressed air.
compressed air.
2. Remove any parts thai will interfe re with gearcase
3. Clean old gasket material from case and cover
disassembly (i.e., exhaust pipe, footres t , air
faces, with cleaning solvent.
cleaner, brake pedal, etc.).
4. Clean the valve breather tube and baffle with SO l-
3. Remove push rods. See PUSH ROD REMOVAL
vent and dry with compressed aire. Also blowout
AND INSTALLATION .
the bleed back passage in the cover with com-
pressed air.
4. Remove tappets and guides, see VALVE TAPPETS
AND GUIDES .
5. Inspect the valve for cuts, tears, deterioration or
other damage. Replace valve , if damaged.
5. Check for minimum cam gear end play. See
ASSEMBLY procedure. Record readings.
6. Check the baffle and tube for cracks and other
6. Remove ignition system, SECTION 7. damage. Replace damaged parts.
7. Place a pan under gearcase to collect oil. Remove 7. If gearcase is equipped with cam gear oiler, check
cover screws and generator mounting screws. the a-ring (26) for damage. Replace if necessary.
Carefully remove cover. Discard old gasket. Check that oil flows without restriction through
the oiler (25).
NOTE
ff cover does not come loose on removal of screws, tap
lightly with a rawhide hammer. Never try to pry cover 2 3 4 7
off.
8. On 1979 to early 1984 models, see Figu res 3-36 and

3-37. Remove cam gears (7, 8, 9 and 10, Figure
3-37), cam gear plates (11) and shims . Discard
shims.
On late 1984 and 1985 models, see Figures 3-37
and 3-39. Remove cam gears (7, 8, 9 and 10, Figure
3-37) and cam gear plate (11). Carefully mark each
component to ensure correct replacement.
9. Free idler gear (13) by lifting generator up and 5

away from crankcase.
10. Remove nut and lockwasher (16), then slide pinion 2. Rear intake cam gear
gear (15) and oil pump drive gear (17) from pinion 3. Front intake cam gear
shaft. 4. Front exhaust cam gear
5. Pinion gear
11. On late 1984 and 1985 models, refer to Figure 3-37. 6. Generator drive gear
Remove the breather baffle, then pry the breather 7. Idler gear (has no timing mark)
tube from the gearcase cover. Separate the
diaphragm valve from the tube. Figure 3-38_ Timing Gears - 1979 - Early 1984
3-38
Cam Gear Selection
(Figure 3-38 and 3-39)
NOTE
"P" type cams were used in 1979 production and "Q"

type cams for 1980 and later production. These "P" and
"Q" type cams must not be Intermixed. When replacing
cams use the same type cam as removed.
Cam gears must be properly sized and fitted to each

other to ensure quiet and smooth operation.
5
1. See Figure 3-40. Measure cam gears with a
micrometer over .105 In. diameter GAUGE PINS,
2. Rear intake cam gear
Part No. HO-95632-79. Compare gear diameter, as
3. Front Intake cam gear
measured, with sizes on cam gear chart. A worn
4. Front exhaust cam gear
gear may be coded red, but may actually measure
5. Pinion gear
a blue code.
1979· EARLY 1984 Figure 3·39. Timing Gears - Late 1984 and 1985
GEAR
NO. 1
Rear
2
Rear
3
Front
4
Front
5
•
COlor Rear In ta ke Intake Front Ex haust Exhaust
Code Exhaust Inner Outer Intake Inner Outer Pinion Idler
Brown 1.8893 1.8953 2.3902 1.8893 1.8953 2.3902 1.2681 3.0223
1.8903 1.8943 2.3912 1.8903 1.8943 2.3912 1.2671 3.0213
Blue 1.8903 1.8943 2.3912 1.8903 1.8943 2.3912 1.2671 3.0213
1.8913 1.8933 2.3922 1.8913 1.8933 2.3922 1.2661 3.0203
Red 1.8913 1.8933 2.3922 1.8913 1.8933 2.3922 1.2661 3.0203
1.8923 1.8923 2.3932 1.8923 1.8923 2.3932 1.2651 3.0193
White 1.8923 1.8923 2.3932 1.8923 1.8923 2.3932 1.2651 3.0193
1.8933 1.8913 2.3942 1.8933 1.8913 2.3942 1.2&11 3.0183
Green 1.8933 1.8913 2.3942 1.8933 1.8913 2.3942 1.2641 3.0183
1.8943 1.8903 2.3952 1.8943 1.8903 2.3952 1.2631 3.0173
Yellow 1.8943 1.8903 2.3952 1.8943 1.8903 2.3952 1.2631 3.0173
1.8953 1.8893 2.3962 1.8953 1.8893 2.3962 1.2621 3.0163
Black 1.8953 1.8893 2.3962 1.8953 1.8893 2.3962 1.2621 3.0163
1.8963 1.8883 2.3972 1.8963 1.8883 2.3972 1.2611 3.0153
LATE 1984 AND 1985
GEAR
NO. 1 2 3 4 5
Rear Rear
Color Rear Intake Intake front Front
Code Exhaust Inner Outer Intake Exhaust Pinion
Brown 1.8893 1.8953 2.3902 1.8893 1.8953 1.2681
1.8903 1.8943 2.3912 1.8903 1.8943 1.2671
Blue 1.8903 1.8943 2.3912 1.8903 1.8943 1.2671
1.8913 1.8933 2.3922 1.8913 1.8933 1.2661
Red 1.8913 1.8933 2.3922 1.8913 1.8933 1.2661
1.8923 1.8923 2.3932 1.8923 1.8923 1.2651
White 1.8923 1.8923 2.3932 1.8923 1.8923 1.2651
1.8933 1.8913 2.3942 1.8933 1.8913 1.2641
Green 1.8933 1.8913 2.3942 1.8933 1.8913 1.2641
1.8943 1.8903 2.3952 1.8943 1.8903 1.2631
Yellow 1.8943 1.8903 2.3952 1.8943 1.8903 1.2631
1.8953 1.8893 2.3962 1.8953 1.8893 1.2621
Black 1.8953 1.8893 2.3962 1.8953 1.8893 1.2621
1.8963 1.8883 2.3972 1.8963 1.8883 1.2611
3·39
NOTE Needle bearings are press fit into crankcase.
Prior to changing any cam gears check gear shaft fit
within corresponding bushings. Worn bushings can 1. Inspect each needle bearing against its
cause excessive backlash. See REPLACING NEEDLE corresponding cam gear shaft. Correct fit should
BEARINGS AND BUSHINGS for measurement probe .0005·.003 in. loose.
cedures.
2. Measure the outer diameter of each shaft.
2. A size increase of cam gears 1 and 3 may be Measurement should fall between .6860 in. and
necessary to correct excessive gear backlash. In· .6865 in. Worn cam shafts should be replaced.
crease gears 1 and 3 by one color code, above
what gears measured. 3. Recheck clearance between new shaft and needle
bearing to determine if bearing will also need re-
Example: Gear 1 may have originally been coded placement.
red but now measures lor a blue code. An increase
01 one color code would mean replacing with a 4. See Figure 3·41 or 3-42. Use BEARING PULLER,
new red coded gear. Part No. HD-95760-69, to pull worn needle bearing
from crankcase.
3. Reassemble gearcase, recheck gear backlash and
record readings. 5. See Figure 3·43 or 3·44. Use BEARING INSTALLA-
TION TOOL, Part No. HD·97273·60, to install new
4. A second size increase of gears 1 and 3 may be nec- needle bearing.
essary, but no more than two size increases should
be made before also increasing size of gear 5. To avoid permanent damage to bearing, always
press on printed side. Press bearing flush to .020
5. Reassemble and run engine checking for noise. in. below surface.
Gear whine or howl indicates gears are too tight.
Affected gears must be reduced in size. Rattling in-
dicates there is still excessive gear backlash.
NOTE
If crankcase is equipped with a cam gear oiler, tighter
gear fitment is possible. With tighter gear fitment, a
slight gear whine is normal and does not indicate gears
are too tightly fitted.
Figure 3·41 . Pulling Gearcase Bearings -

1979 . Earl y 1984
Figure 3·40. Measuring Cam Gear Size
Replacing Needle Bearings and Bushings

Figure 3·42. Pulling Gearcase Bearings -
NEEDLE BEARINGS Late 1984 and 1985
3·40
2_ See Figure 3·45. Use a BUSHING AND BEARING
PULLER, Part No. HD-95760-69, to remove
bushings from gearcase cover.
3. Use a smooth surfaced disc or plate sligh tly larger

than bushing flange when pressing bushing into
position. Apply a few drops of Loctite STUD'N
BEARING MOUNT, to outside diameter of bushing
before installation on 1979 to early 1984 models.
Press bushing until flange is tight against surface.
On late 1984 and 1985 models, press the new

bushing in until it stops on the boss. Drill a dowel
pin hole 9132 in. deep using a No. 31 drill bit.
NOTE
If bushings were previously pinned in the cover, be sure

Figure 3·43. Installing Cam Gear (1979 - Early 1984) the new dowel pin hole is bored 118 in. to either side 01
the original dowel pin hole.
Press in the dowel pin making sure it Is no more than

.020 in. below the bushing surface. If the pin is install ed
too deep, it will not prevent the bushing from rotating in
the cover. Peen the bushing to stake the pin in place.
4. After a new bushing is installed. it must be reamed

to correct size_
All bushings except idler gear must be line reamed

usi ng the corresponding bearing In crankcase
bushing to guide reamer. If the crankcase is not
disassembled use another right side crankcase
half.
Special REAMERS are avai lable for the rear

cylinder intake cam shaft bushing, Part No.
HD-94803-67, and the pinion gear shaft bushing,
Part No. HD·94812-77. Use a standard 11116 in.
Figure 3·44. Installing Cam Gear (Late 1984 and 1985) diameter reamer for all other cam shaft bushings.
Crankcase and gearcase cover must be assembled

while bushings are being line reamed. Turn ream
clockwise in bushing until It bottoms. Continue to
BUSHINGS turn reamer clockwise as It is drawn out.
Bushings (12, 19, 20, 21, 22, 23, Figure 3-36) and On 1979 to early 1984 model s, ream the idler shalt
bushings (12,13,19,20,21, Figure 3-37) are a press fit in bushings with case separated. Use REAMER, Part
to crankcase and gearcase cover. No. HD-94806·57. Carefully align reamer and turn it
clockwise until it bottoms.
1. Inspect each bushing against its corresponding
cam gear shaft, idler gear shaft or pin ion gear
shaft. Correct fit should be: NOTE
Idler Gear Shaft After reaming check shaft fit In new bushing. It may be
(1979-early 1984 models) .....0005-.00 1 in. loose necessary to make a second pass with reamer to attain
Cam Gear Shafts. . .........0005-.002 in. loose proper fit.
Pinion Gear Shaft ... _..... 0005-.0015 in. loose
Service wear limits have an expanded range_ See 6. Clean all metal chips from case and blowout all 011
SPECIFICATION S. passages with compressed air.
3-41
3. On late 1984 and 1985 models, assemble the
Assembly diaphragm valve to the tube, then press the tube in-
(Figures 3-36 -and 3-37) to the cover and Inslalilhe baffle.
1. Models with cam gear oiler: 4. Install cover with a new dry gasket (14). Tighten all
a. Install the pipe plug (27) to the crankcase using screws evenly to 80-110 in·lbs torque, except for oil
teflon thread sealant. filter mounting bracket on late 1984 and 1985
b. Inslall the oiler manifold (25) to the crankcase as models. Tighten filter bracket bolls to 13-16 ft-Ibs.
shown.
5. Turn engine over until number one cam gear lobe is
NOTE facing up, as viewed through tappet guide hole.
With a screwdriver, pry cam gear toward cover.
The oiler must be installed so that the oiler mounting
tabs extend from behind the oiler tube. 6. Measure gap between gear plate and shalt
shoulder with a feeler gauge. This is the cam gear
C. Place two drops of LOCTITE REMOVABLE end play. Minimum cam gear end play should be
THREAD LOCKER 242 (blue) on the screw .005 in. except rear intake gear which should be
threads. Install the screw (23) through the oiler .004 in.
clamp and into the spacer (24). Thread the screw
in to the crankcase and lighten using 5 to 7 in- For specifications of componenls that are not new
Ibs torque. Repeat for the other screw. see SERVICE WEAR LIMITS.
d. Bend a corner of each clamp to form a lock tab 7. Install tappets and guides. See VALVE TAPPETS
over the aligning screw flat. AND GUIDES.
2. Assemble oil pump drive gear (17) to pinion gear 8. Inslall ignition system. See SECTION 7.
shaft. Inslall pinion gear (15) with beveled edge
towards crankcase. Timing marks on gear and 9. Install push rods and adjust tappets as described
shaft must be aligned. Assemble lockwasher and in PUSH ROD REMOVAL AND INSTALLATION and
nut (16) to shaft. Tighten nut to 35·45 ft-Ibs torque. ADJUSTING TAPPETS.
Bend tabs on lockwasher against flats on nut.
10. Reinstall any components removed to gain access
Assemble cam gears (7, 8, 9, 10) case with cam to gearcase (i.e. exhaust, fool rest, air cleaner).
plates (11). The beveled side of gear plates face
toward the gears. Align timing marks on cam 11. Time Ignition system as described in SECTION 7.
gears. On late 1984 and 1985 models, the front ex-
haust cam gear has a dimple rather than a straight
timing mark_ OIL FILTER
NOTE Removal
Liberally coat bushings, bearings, shafts and gears with 1. Drain oil from 011 tank.
engine oif, to ensure smooth beginning operation.
2. Place drain pan beneath front of engine. Remove
and discard oil filter.
3. If it Is necessary to remove oil filter bracket ,

disconnect and tag oit lines to bracket . Remove
capscrews securing bracket.
Cleaning
Wipe filter gasket contact surface of bracket with a
clean cloth.
Installation
1. If removed, position oil filter bracket against
crankcase and secure with capscrews. Tighten
capscrews to 13·161t·lbs and reconnect 011 lines to
the bracket using new clamps.
2. Coal filter gasket with engine oil. Instail filter.

Hand tighten Ihe filter 1/4 turn alter gasket con·
Figure 3·45. Removing Bushing from Gearcase Cover tacts bracket surface.
3·42
CRANKCASE
GENERAL 1. Remove cylinder heads as described in CYLINDER
HEAD.
When rod bearings, pinion shaft bearing, or sprocket
shaft bearing are In need of repair, the engine must be 2. Remove cylinders and pistons as described in
stripped as described in STRIPPING MOTORCYCLE CYLINDER.
FOR ENGINE REPAIR. If desired, the crankcase may
slay in the chassis for repair procedures. It is recom· 3. Remove clutch alternator rotor (late 1984 and
mended procedure to check and make repairs to 1985), and clutch release mechanism as described
cylinder heads, cylinders, gearcase and transmission at in CLUTCH, Section 6.
the same time.
4. Remove starter as described in STARTER, Section
5.
CHECKING FLYWHEEL END PLAY 5. Alter checking flywheel end playas previously
described, use TWO JAW PULLER, Part No.
(Figure 3·46) HD-97292-61, with two appropriately sized screws
and washers to pull engine sprocket.
Before completely disassembling cra nkcases it is
recommended that flywheel end play be checked to 6. Remove tappets, tappet guides, ignition system,
determine the amount of sprocket shaft bearing wear. gearcase cover, cam gears and generator
To check flywheel end play, the sprocket shaft nut must (1979·early 1984) as described in GEARCASE.
be tight. Do not remove or loosen sprocket.
7. Remove oil pump as described in OIL PUMP.
1. Secure a dial indicator to crankcase, with indicator
stem against sprocket shaft nut. 8. Remove front engine mounting hardware (2).
Remove Ihe hardware securing Ihe rear engine
2. Rotate flywheels and at the same time, push and mount to the frame, leaving the mount attached 10
pull on sprocket shaft. Read shaft travel on dial In· the crankcase. Remove the crankcase from the
dicator. Shaft end play should not exceed .007 in. If chassis.
end play exceeds maximum, sprocket shaft bear·
ing must be replaced. 9. Remove alternator stator (late 1984 and 1985) and
transmission as described in TRANSMISSION
DISASSEMBLY, Section 6.
10. Remove remaining bolts securing crankcase

halves together, including the rear engine mount
boll.
11. Position crankcase on work bench, gearcase side

up. Tap crankcase with rawhide mailet to loosen
top half and separate the halves.
12. See Figure 3·50. Mounl the left case half and
flywheel assembly on a press table, supporting
crankcase on parallel bars. Press on end of
sprocket shaft with arbor press until flywheel
assembly is free from case half. Do not drive
flywheel assembly from case half as flywheels
may be knocked out of alignment.
NOTE
See Figure 3-51. If it is necessary to remove either the

pinion shaft bearing (5) or sprocket shaft bearing (6 &
Figure 3·46. Checking Flywheel End Play 11), proceed as follows:
13. Press pinion bearing (5) from right crankcase half

DISASSEMBLY (1).
(Figures 3·47 and 3·48) 14. See Figure 3-52. Pull pinion shaft ra ce (1979 - ear-
To completely disassemble crankcase, follow steps ly 1981 only) with PINION RACE PULLER, Part No.
1·12. HD·96030·77.
3-43
1. Crankcase
2. Front engine mounting hardware
3. Engine rear mount
4. Rear engine mounting hardware
Figure 3·47. Crankcase - Mounting Hardware, 1979·1981
15. See Figure 3-53. Use CRANKSHAFT BEARING Except for torque values, all assembly and disassembly
TOOL, Part No. HD-94547-BO, to remove sprocket procedures remain unchanged for the late style com-
shaft outer races. monized flywheel assemblies. late style and early style
components must not be intermixed.
16. See Figure 3-54. Pull sprocket shaft bearing with
TWO JAW PULLER, Part No. HD·96015-77. CAUTION
17. See Figure 3-55. Use a pin punch or similar tool to Intermixing late and early style components can cause
remove lock ring-spacer. Rotate lock ring in groove permanent damage to flywheel assembly.
so one edge covers oil hole. Insert tool through oil
hole and force ring out of groove. The following figures and charts include information to
identify the components.
FLYWHEELS
General Disassembly
(Figure 3·56)
A commonized flywheel taper design was a running
change in 1981 production. All tapers have been com- 1. Place flywheels in holding fixture. Remove
monized al 6 degrees and all keys have been standard- crankpin nut (1) with FLYWHEEL NUT WRENCH,
ized. Part No. HD-94546-41. Strike left flywheel with soft
3·44
4
1. Crankcase
Figure 3·48. Crankcase - Mounting Hardware, 1982· Early 1984
metal mallet at about 9Q degrees from crankpin 4. Remove crankpin nut (9), then tap crankpin (10) out
hole on wheel periphery to loosen. Lift left flywheel of flywheel and remove key (11).
(2) off crankpin.
5. Place sprocket shaft and flywheel in fixture and
2. Hold down crankpin bearing assembly (4) with a remove sprocket shaft nut (12). Remove sprocket
short length of pipe or tubing so connecting rods shaft (13) by tapping it out of flywheel.
(3) may be slipped off bearings, then remove bear·
ing assembly. Secure bearings (4) together in set
until they are washed and refitted to crankpin. Cleaning and Inspection
3. Remove pinion shaft nut (5), then tap pinion shaft 1. Wash all parts in solvent and blow dry with com·
(7) out of flywheel (6) and remove key (8) from shaft. pressed air. Examine crankpin for wear, grooving
Turn flywheel over in fixture. and pitting. If the surface is at all worn, replace
3·45
1. Crankcase
Figure 3-49. Crankcase - Mounting Hardware, Late 1984·1985
LATE STYLE EARLY STYLE

TORQUE IF TORQUE IF
PART NOTABLE MARKING REQUIRED NOTABLE MARKING REQUIRED
Flywheel Rear cylinder liming - Keyway -
Sprocket Side mark ( =), no keyway
Flywheel Gear fide Single ho le oil path - Compound (2) hole -
(See Figure 3-50) oil path
(See Figure 3-50)
C rankpi n Oil hole 90· 10 key
(See Figure 3·51)
- Oil hole 110' to key
(See Figure 3-51)
-
Crank Pin Nuts '·20 in. thread, 150-185 ft-Ibs 1-20 in. thread 150-175 ft-Ibs
f it of thread changed
Sprocket Shaft No keyway - Large keyway -
Gear Shaft One piece construction - Two piece construction -
Sprocket Shaft Nut 3/4·20 in. thread 100·120 ft·lbs 11/16·18 in. thread 100·120 ft·lbs
Gear Shaft Nut 3/4·20 in. thread 100·120 ft·lbs 11/16·18 in. thread 100·120 ft·lbs
Gear Shaft Key Small woodruff key - Large woodruff key,
3/16 in. wide x 1/2 in. long
-
Crank Key Small Woodruff key, - Large woodruff key,
1/8 in. wide x 112 in. long
-
Sprocket Shaft Key Not used - Large woodruff key, -
3/16 in. wide x 1/2 long
3·46
with new pin. Examine flywheel washers. If either
w'asher is worn or grooved, it should be replaced.
See REPLACING FLYWHEEL WASHERS.
2. Examine connecting rod lower races. If they

appear slightly grooved or shouldered where edge
of bearing rollers ride, they may be lapped out and
oversize bearing rollers installed. II they appear
badly worn, grooved or pitted, new rods should be
installed, preferably as an assembly with new
bearings and crankpin.
3. Inspect bearing lor wear, pitting and heat

discoloration, replace as required.
4. Carefully inspect crankpin, crankpin railer and

connecting rods for correct free play. See FiniNG
ROD BEAR INGS to determine if oversized railers
are required.
Replacing Flywheel Washers

Replace worn flywheel washers as follows:
1. The washer is a close fit in flywheel recess and is

secured originally by punching flywheel metal
light against the washer at several points. It is
usually necessary to drill a small hole (118 in. or
smaller) at the outer edge of the washer to permit
gelling a painted tool underneath to pry it out. The Figure 3·50. PreSSing Flywheel from Crankcase
6 8
I I
1;0 II
7 9
1011
@ol\
@fJ
5'---(1 C/)-4
1. Right crankcase half 1. Sprocket right outer race

2. Left crankcase half 8. Spacer
3. Connecting rod and flywheel assembly 9. Lock ring
4. Pinion rIIC. (1919 - •• rly 1981) 10. Sprocket left outer race
5. Pinion bearing 11 . Sprocket left bearing
6. Sprocket right bearing
Figure 3·51. Crankcase and Flywheel Assembly - Exploded View
3·41
hole should . only be d ril led slight ly deeper than fully, forked rod will not have necessary clea rance
thickness of washer, to avoid removi ng more (side play).
material than necessary.
3. Carefully tap new washers into place and using a
2. Before Installing a new washer, sc rape outer edge punch, peen metal over edge to retain washer.
of recess, where metal was punched against
origi nal washer, so new washer will seat fu lly NOTE
against recess bottom. If washer does not seat
If the ou tside surface of the crankpin bearing re tainer(4,
Figure 3·56) appears grooved near its inside diameter;
flywheel area, to the inside of the thrus t washer (15,
Figure 3·56), must be pressed down flush or below the
'"' washer surface.
""
I
Figure 3·52. Pinion Shaft Inner Race Removal
Figure 3·54. Removing Sprocket Shalt Roller Race
Figure 3·53. Sprocket Shaft Outer Race Removal Figure 3·55. Lockring Removal
3·48
,.
4 10 I I
11
\
/ J-n©)
.~®
~
1
I \
~ 13 .............. '4
1. Crankpin nut 9. Crankpln nut

2. Flywheel (left) 10. Crankpin
3. Connecting rods 11. Crankpln key
4. Crankpin roller & retainer set 12. Sprocket shaft nut
5. Pinion shaft nut 13. Sprocket shaft
6. Flywheel (right) 14. Sprocket shaft key
7. Pinion shaft 15. Flywheel washer (2)
8. Pinion shaft key
Figure 3-56. Flywheel and Connecting Rod - Exploded View
Old, compound (2) hole aU path Early style, 110 degrees to

keyway
Late style, 90 degrees to keyway
Crank pin hole
_ _ _-\- New, single hole

all path
Gear shaft hole
Figure 3-57. Flywheel Gear Side Oiling Hole Figure 3·58. Crankpin Oil Hole
Lapping Connecting Rod Races 1. Clean lap before using.

(Figure 3·59)
2. Clamp lap into lathe chuck, carefully load lap with
Connecting rod lower races that are likely to clean up 1#220 grit grinding compound, mixed with oil. Ad·
within range of oversize beari ng rollers and are other- just lathe tei turn at approximately 150·200 rpm.
wise In serviceable condition, should be trued and sized
with CONNECTING ROD LAPPING ARBOR, Part No. 3. Carefully slide connecting rod over lap. Adjust lap
HO·96740·36. 10 a dragging but free fit in rod race.
3".
NOTE
1. Use a micrometer to measure the outside diameter
A loose lap will BELL MOUTH bearing races, so lap of the crank pin at its center. Use an inside
must be kept adjusted at all limes. micrometer or telescoping hole gauge to measure
the inside diameter of the rod races. Subtract the
4. Start lathe and work rod back and forth, over full diameter of the crank pin from the inside diameter
lenglh of lap. Hold rod as near race end as possi· of the bearing race. Subtract from this figure the
ble. standard allowance for bearing running fit size.
This answer, divided by two will give proper roller
5. Check rod frequenlly. When rod is lapped Irue and size. To lind oversize amount 01 bearing, subtract
all traces of pit marks or grooves are cleaned up, Irom this figure the diameter of a standard roller.
wash and blow rod dry.
EXAM PLE:
6. Repeat lapping procedure for other rod race.
The rod bearing race measures 1.6262 in. alter lapping
7. Bearing races should have a soft velvety appear· and truing. The crank pin is slighlly worn and measures
ance and be free of shiny spots. 1.2485 in. Subtract 1.2485 in. from 1.6263 In. The answer,
0.3778 in., represents the diameters of both rollers (one
on each side) plus clearance for running fit (0.001 in.).
The answer, 0.3768 In., is then divided by two to get the
diameter 01 each oversize roller. In this case it would be
0.1884 in. To find how much oversize each roller roust
be, subtract from this figure the diameter of a standard
roller, or 0. 1875 in. Railers must be 0.0008 in. oversize.
2. Install any new set of oversize rollers 10 bearing

races and position on crank pin. Slip rods over
bearings, If Ihey will nol fit, it is obvious rollers are
100 large and a smaller size musl be tried. If they fit
and spin freely, install a larger set of rollers. Try
various roller sizes until the rods will turn with a
very slight drag. This is a plug fit. Determining run-
ning fil is merely a matter 0' subtracting one half
the desired running fit clearance (0.0005 in.) from
the roller size to find the running 'il roller size.
It may be easier to gauge a plug iii as follows:
Fit any size rollers into races. Position bearings in rods.

Support rods and bearings with left hand. Drop crank
pin (not attached to flywheel) through crank pin hole.
Plug 'it has been achieved when crank pin will slide
slowly through hole from its own weight. Running fil is
Figure 3·59. Lapping Connecting Rod then determined by subtracting one half running
clearance from oversize of rollers used to make plug lit.
Fitting Rod Bearings

CAUTION
Oversized rollers are used in the rod bearing to adjust
connecting rod free play on crankpln. Fitting bearings tighter than described may result in
seizing and bearing damage when heat expands parts.
Oversize rollers are available .0002, .0004, .0006, .0008,
.0010, .0015 and .0020 in. oversize.
Check overall width of roller retainer assembly. II must
be less than width of female rod end.
Prior to selecting oversized rollers, rod races must be
lapped to remove wear spots, grooves or other flaws.
See LAPPING CONNECTING ROD RACES. NOTE
There are two ways to determine which oversized rollers Roller bearIngs are not available in odd numbered sizes;
10 use. Bol h will result In properly lilled bearings, if ap- therefore, when determIning a plug fit, if the bearIngs
plied correctly. are too loose with an even numbered roller bearIng (Ex-
ample .0008 In. oversize) and too tight with the next size
NOTE even numbered rol/er bearing (.001 in. oversize), it must
be assumed that a theoretical odd size bearing (.0009 In.
All fittfng and checking must be made with bearings, oversize) would achieve a plug fit. Use this theoretical
rods and crank pin clean and free of oil. size to compute running fit.
3·50
Assembly 4. See Figure 3·61 . Ho ld steel straightedge along
outer face of wheel rims at 90 degrees from
On ear ly 1981 and earlier models apply 640 retaining crankpin as shown. Tap outer rim of top wheel until
compound to shaft tapers as shown in Figure 3-60. On wheels are concentric . Tighten nut, recheck with
late 1981 and later models, apply two drops of 620 re - straightedge at frequent intervals. Use soft metal
taining compound to the shaft threads and no more hammer to rea lign wheels.
than two drops to the nul bearing faces.
After correct connecting rod bearing fit has been al-

tained , clean and assemble parts as fo llows:
1. Assemble the sprocket shaft (13, Figure 3-55) to

the left flywheel (2).
m]]]]]]]]]
~~~s~p~rO~C~k~e~I~S~ha~I~I~~
rFo
One drop on 640-retaining
compound these locations Figure 3-61. Squaring Flywheel Faces
5. See Figure 3-62. When nut is fairly tight, install

flywheel assembly in Harley-Davidson FLYWHEEL
Pinion shaft
TRUING DEVICE , ParI No. HD-96650-80, as shown.
Adjust so centers are sn ug. Wheels must turn free-
ly but shafts may not be loose in centers. If
fly wheel assembly is either loose or squeezed, in-
dicators will not ' ind icate accurate ly. Adjust in-
dicators to take reading as near to flywheels as
possible, so pointers read at about the mid dle of
the scales.
6. Tu rn flywheels slow ly and observe the movement

Crank pin of indicator pointers. Movement toward flywheels
i ndicate high poi nts of shafts . Find highest point
of each shaft and chalk-mark flywheel rims at
Figure 3-60. loctite Application those points. Remove fl ywhee l from stand and
- Early 1981 and Earlier make corrections as follows:
7. See Figure 3-63. Flywhee l may be out of true three

2. See ENGINE SPECIFICATIONS for proper torque. ways, A, Band C or a combination of two of the
Assemble pinion shaft (7) and crankpin (10) to right three ways.
flywheel (6) making sure that keys (8, 11) are in
proper position. See ENGINE SPECIFICATIONS 8. When wheels are both out of tru e as i nd icated in A,
for proper torque. tighten C-clamp on rims or wheels opposite crank-
pin and lightly tap the rim at the crankpin with lead
Check to make sure oil passages through pinion shaft, or copper mallet.
right flywheel and crankpin are clear by blowi ng com-
9. When wheels are both out of true as indicated in 8 ,
pressed ai r into hole near end of pinion shaft.
drive a hardwood wedge between the wheels oppo-
site the crankpin and lightly tap the rims near the
3. Position right flywheel assembly in a flywheel fix· crankpin with a lead or copper mallet.
ture, crankpin up. Wipe crankpin taper clean. Sl ip
bearings, and connecting rods over crankpin with 10. When wheels are out of true as indicated in C,
forked rod 10 rear cylinder. Inslailieft flywheel and strike the rim of Ihe wheel a firm blow at about 90
tighten nut lightly. degrees from crankpin on high side.
3·51
11. When wheels are out of true in a combination of A. Flywheels and crank pin assembled with oil on
any of thE! conditions shown, correct A or B first, tapers and nut over·tightened. Disassemble,
tapping rim of offending wheel only, and then cor- clean and reassemble.
rect condition C.
B. New flywheel washers installed and not fully
NOTE seated. Disassemble, inspect, replace deepest
seating flywheel or crankpin. As last resort,
The number of blows required and how hard they should grind down width of forked rod.
be struck depends on how far shafts are out of true and
how tight nuts are drawn. C. Taper holes enlarged as a result of having
been taken apart several times. Replace
Remember that centers must be loosened slightly deepest seating wheel.
before striking flywheels. Making them too loose may
result in damaged centers. D. Cracked flywheel at tapered hole. Replace
flywheel.
Never strike wheels a hard blow near crank pin. This
could result in a broken crank pin. NOTE
12. See Figure 3·62. Readjust centers, revolve wheels If sides of forked rod are ground to get desired
and take reading from indicator. Repeat truing clearance, backs of bearing retainers must be ground
operation until indicated shaft runout does not ex· down to remain narrower than width of female rod.
ceed 0.001 in. (each graduation on indicator is
0.002 in.). After rod side play is checked and adjusted and
crankpin nut tightened to specified torque, again
13. If it is impossible to true wheels, check for a recheck wheel trueness on truing device. Correct any
cracked flywheel, damaged or enlarged tapered runout as above.
hole, or a sprocket or pinion shaft worn out-of·
round at surface where indicator reading is being
taken. When wheels are true, position in vise and
draw crankpin nuts very tight using CRANKPIN
and FLYWHEEL NUT WRENCH, Part No. ASSEMBLY
HD·94546·41. Use torque wrench to finish tighten·
ing as specified in SPECIFICATIONS. Lubricate all parts with (POWER BLEND SUPER
PREMIUM) engine oil and proceed as follows:
14. See Figure 3-64. Check connecting rod side play
with thickness gauge as shown. If it is greater than 1. Referring to Figure 3-51, place lock ring (9) into
tolerance shown in engine SPECIFICATIONS, groove In left crankcase half (2). Position lock ring
draw up crankpin nuts until within tolerance. Insuf- gap over oiling hole to allow oil flow to bearing.
ficient play between rods and flywheel face is Press both outer races (7 and 10) back in place
caused by one of the following conditions: against ring (9).
1811
F igure 3-62. Truing Flywheel
3·52
10. Install alternator rotor (late 1984 and 1985), clutch 13. Install cyl inder heads as described in CY LI NDER
and cl utch release mechanism as described in HEAD.
CLUTCH, Section 6.
14. Install cam gears, gearcase cover, tappet guides, tap-
NOTE pets, and generator as described in GEARCASE.
Be sure to refill transmission with oil as described in 15. Install ignition system and time engine as de·
LUBRICA TlON, Section 6. scribed in IGNITION SYSTEM, Section 7.
11. Install oi l pump as described in OIL PUMP.
12. Install cylinders and pistons as described in ""

CYLINDERS.
""
Figure 3-67. Assembling Left Crankcase

Figure 3-66. Installing Crankshatt Roller Race to Flywheel Assembly
3·54
SPECIFICATIONS
(XR·1000)
GENERAL Maxi mum (at 60 mph) 15PSI
Shaft / bushing clearance ........... . .0005 In .
Number of cylinders ..................... 2 Feed gear height i n pump c over . .011 In.
Type .. . .... 4·Cycle, 45 Degree V-Type
Bore ... . .... . . ....... 3.188 In. (81 mm)
Stroke ... 3.8125 In. (96.8 mm) TAPPETS
Piston displacement ........ 60.9 cu. In. (997.5 e el
Compression ratio . . .. . 9.0 to 1 Fit In guide (loose) .001 in . - .002 In.
Roller lit .. .0005 in.· .001 In.
Roller end clearance ... .008 in. - .010 In.
VALVES Tappet clearance
Engi ne cold .. .002 in.· .003 in. lash
Fit In guide
Exhaust . . .0015 in.· .0030 In.
Intake . . . . . . . . . . . . . . . .0010 In. · .0025 in. VALVE TIMING
Outer spring load ( @O.005 in. tappet lift)
Valve closed . 138·'46Ibs. at 1.46 In .
Valve open . . . . ..... . 215-245 Ibs. at 1.05 In.
Intaj(e
Inner spring load
Opens . . 66 * :t:4 - BTDC
Valve closed ....... . . 58-66lbs. at 1.32 in.
Closes . . .. 13O - :t:4 - ABDC
Valve open . . . 12()'136lbs. at .91 in.
Exhaust
Spring free length
Opens .. . .... 110-:t:4 - BBDC
Outer . . . .2.10 In .
Closes .. . .. 81 - :t:4 * ATDC
Inner •.. .... 1.72 ln.
ROCKER ARM GEARCASE

Idler gear shaft
Shaft fit In bearings (loose) . . .0005 in.· .0025 In.
in bushing. .0005 In. - .001 In.
End play. . . . . . . . . . . . . . . . . . .005 in. · .010 In.
Cam gear shaft In bushing . .0005 In. - .002 in.
Cam gear shaft
in needle bearing ............... .0005 in. -.003 in.
CYLINDER HEAD Minimum cam gear end play ..... . ...... 005 in.
except rear exhaust wh ich is ................004 In .
Valve guide to cylinder head Cam gear backlash . . ....0000 in. - .0005 In.
(Interference). . . . . . . . . . . . . .0014 In ... 0028 In.
Valve seat Insert to cylinder head
(Interference). .006 in.·.OO9 In. FLYWHEEL ASSEMBLY
Runout at rim (flywheels) .. .003 In.
PISTON Shaft runout at flywheel . . ........ . . . .001 In .
End play .... . ............. . .001 In.
Fit In cylinder (loose) . . . . ........0025 to .0035 In.
Ri ng gap
Top compression. . . . . ............008 In. SPROCKET SHAFT BEARING
2nd compression . . . . . . . . . . . . . . . . . . . . . . .. .008 In.
all control ........................... . .015 in. Cup lit In crankcase (tight) .......... 0004 In. - .0024 in.
all control ring side clearance . . .003 In. Cone fit on shaft (Ught) .............0002 In .•. 0015 in .
Compression ring side clearance .... .004 in. End play . . . . . . ...001 In.· .007 In.
Piston pin. .. . Light hand press fit at 70-F
PINION GEAR SHAFT

CONNECTING ROD
Fltln roller bearing (tight) ........... 0005 In . . .0015 In .
Piston pin / bushing clearance ....... . .001 in.· .002 In. Fit In cover bushing (loose) .. .0005 In. - .0015 in.
Side play between flywheels .. . .005 in. - .025 In.
Crank pin / rod bearing clearance . ....001 In.· .0015 In.
IGNITION
Ignition timer air gap .. . not adjustable
OIL PUMP Retarded ... . ........... . 2- ATDC
Idle advance (600·1600 rpm) . 16 - BTDC
Pressure (Oil hot) Full advance (above 1600 rpm) .. 30 * BTDC
Minimum (at Idle) 4 PSI Spark plug gap setting (RN7YC, 6R7) .... .038·.043 In.
3·55
TORQUES Piston
Gear shaft nut ........ _............. 100to120fl·lbs Fitln cylinder (loose) .002Sln. to .000Sln.
Sprocket shaft nut .................. 100 to 120 ft·lbs Ring gap
Crank pin nuts ...................... 150 to 175 ft·lbs Top compression. .OOB in. to .022
011 pump mounllng screws. . ... 90 to 110 in·Jbs 2nd compression. .008 in. to .030
Cylinder head nuts .................... 25 to 30 ft·lbs 011 control .01S in. to .OSS
Rocker arm locknuts .......... 18 to 22 ft-Ibs Oil control ring side clearance. .003 In. to.OO6
Rear molor mounting boll·nut . .... 16to24ft·lbs Compression ring side clearance . .004 In. to .006
Rocker cover bolts. . ..... 141019 ft·tbs
Connecting Rod
SERVICE WEAR LIMITS Piston pin fit (loose) . .0008 in. · .003 in.
Side play between flywheels. .OOS in.· .030 In.
NOTE
Fit on crank pin (loose) ........... . .001 In.· .0017 In.
Wear limits 8r8 given 8S 8 guideline for measuring
engine components that 8re not new. For new com-
ponents or for measurements not given here, use
Oil Pump
measurements given under SPEC/FICA TlONS.
Feed and scavenge innerfouter
gerotor clearance .004 in.
Shaftfbushlng clearance .000s in.
Feed gear height In pump cover. .001 in.
Valves
Fit In guide
Exhaust .001S in.· .007 in.
Intake .. .0010 in.· .006 In.
Tappets
Outer spring toad
Fit in guide (loose) .001 in.· .003 in.
Valve closed. . ...... 123·146 Ibs. at 1.46 in.
Ronerflt .000s in.· .0012 in.
Valve open. . . . . . . . . • . . .. 200·24S Ibs. atl.0S in .
Roller end clearance ... .00Bln. ·.012In.
Inner spring load
Valve closed .. . SO-66tbs. at 1.32 in.
Valve open ... . . .115-136Ibs. at.91 in.
Spring free length Gearcase
Outer ............... . . . ... 2.04 in .
Inner .. .... . 1.66 in. Idler gear shaft
In bushing. .000Sln ... 003 In.
Cam gear shaft In bushing. .000s in.· .003 In.
Rocker Arm Cam gear shaft
In needle bearing .. .......... .000s in ... 0031 In.
Shall fit In bearings .000S ln.· .003S in. Minimum cam gear end play .................OOS in.
End play. . ............ . .OOS In ...020 in. except rear exhaust which is ................004 in.
Cylinder Head
Flywheel Assembly
Valve guide to cylinder head
(interference) .. .0014 in.· .0028 in. Runout at rim (flywheels) .006 In.
Warpage. .00Sln. Shall runout at flywheel. .002 In.
End play. . .............•.. .007 in.
Cylinder
Pinion Gear Shall
Taper .. .002 n.
Out of round .. .001 n. Fltln rolier bearing (tight). .000s In.· .002 in .
Warpage head and base gasket surfaces .. .003 n. Fit in cover bushing (loose) .000Sln.· .003S in.
3·56
ENGINE
(XR·1000)
GENERAL INFORMATION 4. When adequate pressure is produced, the oil pres-
sure Indicator light sending unit is activated and
Although similar to the Xl models engine, the XA·1000 the check valve opens.
does incorporate definite engine design features that
make it unique. It is an effective hybrid or cross of the 5. With check valve open, oil f lows into the right
XA-750 racing engine and the XL models 1000cc engine. crankcase through a hole located i n the oil pump
The information presented in this section represents gasket surface. Oil enters gearcase passage
the unique differences found in the XA·1000 engine. through hole in gearcase cover gasket.
6. Oil flow Is then routed to both the crankshaft and

the cylinder head areas. Oil enters a hole in the
The XA-l000 engine Is a two-cylinder, four cycle, air- end of the pinion shaft and travels to the right
cooled, overhead valve, V·type engine with 1000cc (61 flywheel where it is routed through the flywheel to
cu. in.) displacement. It has three major component as- the crank pin. 011 is forced through the crank pin to
semblies: cylinder, crankcase, and gearcase. The trans- properly lubricate the rod bearing assembly.
mission is a constant mesh 4-speed identical to the XL
models transmission. 7. 011 which does nol enter the pinion shaft travels
upward through the gearcase cover to the right
crankcase. Oil flow continues through a passage
in the crankcase to the overhead oil feed lines.
(One line to the front cylinder intake rocker arm
components and one line to the rear cylinder ex-
LUBRICATION haust rocker arm components.) The oil provides
lubrication to the rocker arm shafts, bearings,
valves, and pushrods.
General
8. 011 flow continues around a groove machined in
The engine has a force-Ieed (pressure) type oiling the outside diameter of the large end of the rocker
system incorporating oil feed and return in one pump arm shaft and through the rocker arm cover. The
body, with one check valve on the oil feed side. The feed front cylinder oil flow in the rocker arm cover Is
pump forces oil to the engine, lubricating lower con- from Intake to exhaust side. The rear cylinder oil
necting rod bearings, timing gears and bushings, gen- flow in the rocker arm cover is from exhaust to in·
erator drive gear, rocker arm bearings, valve sIems, take side. The valves are lubricated and cooled by
valve spring, push rods and tappets. Cylinder walls, a hole drilled In the rocker arm which sprays oil
pistons, piston pins and main bearings are lubricated directly onto the tip of the valve stem and valve
by all spray thrown off from connecting rods and crank- spring.
shaft. 011 drains from rocker arm boxes to the crank-
case through two external hoses from each cylinder 9. Oil collected In the pushrod area of the cylinder
head. heads flows down the pushrod covers to lubricate
the tappets.
10. Oil flows from the rocker cover to the upper

Oiling System (Figure 3·68) chambers of the cylinder head. Oil continues to
flow from the upper or inside valve chambers to
1. Oil is supplied to the gerotor type oil pump by grav- the lower or outside valve chambers of the cylinder
ity feed from the oil tank. Oil enters the feed sec- head where It exits out an external oit return line.
tion and fill s a cavity located under the feed pump. 011 returning from the heads, rod assembly, and
gearcase collects in the sump area below the
NOTE flywheels.
A complele explanation of lhe gerolor pump is given In

11. 011 collected in the sump area rei urns to the
GEARCASE section. See OIL PUMP.
scavenge section of the oil pump through a pas-
sage located in the rear section of the sump. Oil
2. The feed gears transfer oil from the inlet cavity to flow to the pump is accomplished by the scaveng-
the check valve located in the outlet l ine. ing effect of the pump and by the pressure created
by the downward stroke of the pistons.
3. The one way check valve is preset to open at 4 to 6
PSI all pressure. This valve prevents gravity oil 12. Return oil fills a cavity just above the scavenge
drainage from tank to engine and acts as a restric- pump. The pump transfers return oil to the outlet
tion to activate all pressure switch . side of the pump and back to oil tank.
3·57
Figure 3·68. Oiling System - Part I (XR·1000)
3·58
FIgure 3·68. Oiling System - Part II (XR·1000)
3·59
13. All engine breathing is accomplished through the 7. Remove rear top engine bracket which supports ig·
gearcase breather system. Oil carried by the crank· nition switch and allow to hang free.
case exhaust air is centrifugally separated from
the air by an oil slinger on the end of the generator 8. Remove front top engine bracket.
drive gear shaft.
9. Disconnect both spark plug wires.
14. On the piston downstroke, exhaust air escapes
through a one way check valve and Is routed to the
rear air filter. NOTE
15. Any oil that condenses in the breather hose, drains At this poInt, only the front cylinder, front cylinder head,
into the gearcase from drain hole below breather and rocker cover can be worked on or removed. See
valve. CYLINDER HEAD and CYLINDER AND PISTON sec·
tions. Otherwise proceed to next step.
16. Scavenge pump.
10. Remove rear brake master cylinder mounting bolts
17. Return oil to tank. and rear brake line clip screw.
18. Vent line to rear cylinder air filter. 11. Remove rear chain sprocket cover with footpeg
and brake pedal atta~hed.
STRIPPING MOTORCYCLE 12. Disconnect master link and remove rear chain.
FOR ENGINE REPAIR
13. Disconnect wire to oil pressure switch. Remove oil
WARNING pressure switch.
To prevent accidental starter operation and possible 14. Unplug ignition timer plate wires from ignition
personal Injury, disconnect battery cables (negative module.
first) before doing any work on the engine, drive or elec-
trical system. 15. Disconnect battery cable on large upper post and
black wire from starter on small post.
1. Remove seat.
16. Disconnect wires to generator.
2. Remove exhaust system.
17. Disconnect black ground wire attached to
3. Disconnect fuel hoses at fuel valve and drain crankcase rear motor mount bolt.
gasoline. Remove gas tank. Disconnect wires to ig·
nition coil. Allow throttle cable junction box and Ig· 18. Introduce free play to clutch cable. Detach clutch
nition coil to hang free. Disconnect wire from horn. cable, along with hand lever, and allow to hang
free.
4. Disconnect crankcase vent hose from rear air filter
assembly. Disconnect intake manifold clamps. 19. Remove the oil feed and return lines at the oil
Carefully, swing carburetor/air filter assemblies, pump and the vent line on top of the Oil. tank.
with throttle cables attached, out of the way of
engine. 20. Remove hardware attaching front of engine to
frame.
5. Remove only rear cylinder intake manifold.
21. Remove hardware attaching rear of engine to
NOTE frame. Rear mount remains attached to engine.
/n order to remove engine from chassis it is necessary 22. Engine Is now free to be removed from chassis. Lift
to remove only rear cylinder intake manifold. engine up off the mounting pad. Slip engine from
left side of chassis with top of engine tipped
6. Drain oil tank slightly off center of chassis.
3·60
011 pump To 011 filter
Figure 3·69. Oil Hose Routing (XR·1000)
3·61
CYLINDER HEAD
(XR-1000)
REMOVING have been color coded to ensure installation In the cor·
rect location. Coding is as follows:
(Figure 3-70)
Front intake - red
1. The front cy li nder can be serviced with the engine Front Exhaust - white
inthe chassis. For rear cylinder head removal strip Rear Intake - blue
motorcycle as described earlier in STRIPPING Rear Exhaust - yellow
MOTORCYCLE FOR ENGINE REPAIR, Steps 1·9.
2. Remove carbu retor and manifold assembly from 4. Discard a·rings (6 and 7).
cylinder head.
3. Disconnect cylinder head 011 feed (1 5) and ret urn

REPLACING
(27) lines at fittings. ROCKER ARM BEARINGS
4. Remove spark plugs. Turn enQine over until piston NOTE
is at top dead center of compression stroke and
both valves (25) are closed. Replacement rocker arms are supplied with bearings In·
stalled.
5. Loosen rocker arm shat! locknuts (5), Remove
rocker cover bolts (1), stud (2), and rocker cover 1. From opposite end of rocker arm, use a BUSHING
assembly. Remove one piece push rod tubes (32) AND BEARING PULLER, Part No. HD·95760·69,
and push rods (33). Mark push rods so they wil l be press or drive bearing from arm .
reassembled in the same position . Push rods (33)
2. Caref ully press replacement bearing into rocker
are two different lengths. The inside (longer) push
arm using an arbor press until bearing seats on
rods (rear cylinder exhaust and front cylinder in·
shoulder.
take) are ident ified by a red stripe. The outer
(shorter) push rods (rear cylinder intake and front CAUTION
cylinder exhaust) are ident if ied by a white stripe.
Rolled side of the bearing enters arm first. Apply
6. Remove the four head nuts (17). Free cylinder head pressure to numbered or hardened flat side of bearing.
(19) and remove .
NOTE REPLACING VALVE GUIDES

/I cylinder head does not come loose on removal of The aluminum heads use bronze al loy valve guides.
head nuts, tap lightly with a rawhide hammer. Never pry
head off. Replacing valve guides, if necessary, must be done
before valve seat and face are ground since the valve
stem hole in valve guide is the basis from which all face
DISASSEMBLING and seat grinding is done. Valve stem-valve guide
(Figure 3·70) clearances are listed in c hart below. If valve stems
and lor guides are worn beyond service wear limits, new
parts must be installed.
Rocker Cover
1. Before further disassembly, carefully check rocker Valve Stem to Guide Clearance
arm pads and ball sockets for pitting or excessive
wear. Check rocker arm (9) for excessive end play Valve Clearance Wear Limit
on rocker arm shaft (8). Intake .001· .0025 .006
Exhaust .0015 - .003 .007
2. Remove rocker arm shaft locknut (15) and washer (6).
3. Carefully tap rocker arm shaft (8) through cover 1. Decarbonize combustion chamber.
(14). Remove rocker arm (9), spacer (12), shims (11),
2. Tap valve guides out with a shouldered drift pin
and a·rlngs (6 and 7). Mark components so all
(from chamber side) and insert replacement guide.
parts may be returned to their respective locations
Be particularly careful to tap replacement guide
during assembly.
squarely i':lto hole.
CAUTION 3. When guides are pressed Into cylinder heads, they

may close up slightly; also the ends may be burred .
Rocker arms are not interchangeable. Therefore, they Therefore, after new guides are in place, they must
""
~~I I
1
10 '@( ~
10,
9-e~~~
'13 13
14
12 11 '"
...
f,) 1
_18
1. Rocker cover boll (8) 18. Cylinder and cylinder head stud (4)
2. Rocker cover stud 19. Cylinder head
3. Rocker cover washer 20. Valve key (4) and upper valve spring collar (2)
4. Rocker cover stud nut 21. Inner and outer valve springs (2 each)
5. Rocker shaft locknut (2) 22. Lower valve spring collar (2)
6. Rocker shaft washer (2) 23. Valve guide seal (2)
7. Rocker shaft O·rlng (4) 24. Valve guide (2)
8. Rocker arm shaft (2) 25. Intake and exhaust valve
9. Rocker 8rm (2) 26. Valve seat insert (2)
10. Rocker arm needle bearings (4) 27. Cylinder head 011 return fitting (2 piece)
11. Rocker shaft shims (4 each) 28. Exhaust valve port Insert
12. Rocker shaH spacer (2) 29. Intake manifold bolt and washer (2)
13. Rocker cover access hole plug & washer (2) 30. Intake manifold
14. Rocker arm cover 31. Intake manifold gasket
15. Rocker cover oil feed fitting 32. Push rod cover tube (2)
16. Rocker shaft screw Insert (2) 33. Push rod (2)
17. Cylinder head nut & washer (4) 34. Push rod cover tube seal (4)
Figure 3·70. Cylinder Head Assembly (XR·1000)
3·64
be sized with a 5/16 in. EXPANSION REAMER, Part
No. HO-94810-80.
4. It is of prime importance that valve guides fit tight-

ly in cylinder heads or valves may not seat proper·
Iy. There is a minimum interference fit of .0014 in. If
original guide or new standard guide is not a light
press fit, an oversize guide must be installed.
5. To ensure new valve guide is press fit, new over·

sized valve guides are available in five sizes:
.002" 0.0. 1slover White

.004" 0.0. 2nd over Yellow
.006" 0.0. 3rd over Green
.008" 0.0. 4th over Blue
.010" 0.0. 51h over Black
Both intake and exhaust oversized guides are identified

by a series of colored paint dots on the guide's outside A
diameter. Max. Min.
1.700 1.654
REFACING VALVE SEAT
Figure 3-72. Valve Seat Specifications
(Figure 3·71)
Valve seats, like valves, are subject to wear, pitting, and
burning and should be refaced each time valves are 2. Cut 46" seat angle first. Cut only enough to clean
refaced or replaced. up seat.
See Figure 3-72. Prior to ref acing valve seat, determine 3. See Figure 3-73. Apply blueing to valve face and in·
if seat is still usable or if replacement is necessary. A stall in head. Rotate valve against seal. Remove
special GAUGE TOOL, Part No. HO-96489·63, is valve and check contact pattern. Valve seat should
available to accurately measure the "A" dimension. be .060 in. wide and centered on valve.
We recommend using a NEWAY VALVE SEAT CUrrER, 4. If valve pattern is too close to stem side of valve
to cut valve seats. face, cut 52° angle to raise seat. If pattern is too
close to edge of valve face, cut 40" angle to lower
seat.
1. Decarbonize combustion chamber.
,
Head "'
s.. t.060.~ ~
A. 45° _ _
Valve seat
//~"'"' Valve
.060 In. centered
on valve face
/-":;"'---~~~~~"" ....
Figure 3-71. Cutting Valve Seat Figure 3·73. Valve Contact Pattern
3·65
5. After cutti ng ei ther or both 40- or 52- angle to posi·
tion seat, final cut 46- seat angle to obtai n proper
.060 In. width.
6. If seats were ground, apply a small amount of lap- Valve guide seal
ping compound evenly all the way around valve
face.
7. Insert valve in guide and attach LAPPING TOOL,

Part No. HD·96550·36. Allowing the spring to pro·
vide pressure against seat, oscillate valve and
listen to abrasive sound of the compound. When Protective sleeve
the sound becomes smooth, indicating lapping
compound has worked out of seat, lift valve off
seat and rotate It 1/3 turn. Repeat procedure until
valve has been rotated one full tu rn.
8. If the seat and valve face have an unbroken lapped Figure 3·74. Valve Guide Seal and Protective Sleeve
finish and a uniform width, no furt her lapping Is reo
qulred.
IMPORTANT
g. Wash the head and valves in warm soapy water.
Rinse off and dry thoroughly with a clean cloth.
Valve guide seal must be Installed squarely and firmly
onto gu ide or it will not stay on during engine operation.
CAUTION
Do not remove the valve after seal has been Installed.
Doing so will destroy the seal.
Discard cloth Immediately to prevent transferring lap·
ping compound to internal engine parts .
VALVE SEAT INSERTS
10. Apply a fitm of oit to components to prevent corro-
sion. As valve and seat are refaced from time to time, valve
seat will widen and valve will seat lower when fully
CAUTION closed. Passage around valve, when fully open, Is
restricted and valve will tend to float as spring tension
When removing valve seats, valve height ('A,), Figure is reduced.
3·72, must be mainlined. This can be achieved by care-
fully grinding material off the valve stem head. Do not Valve seat Inserts are available from the factory. In-
remove more than .020 In. If more Is required to meet stallation requires accurate boring equipment to
height ('A') replace valve andlor seat. machine correct counterbore in head, for installation
within .006 In. - .009 In. In terference fit.
REPLACING VALVE GUIDE SEALS PUSH RODS

(Figure 3-74)
Replacing
NOTE
Replacement of the push rods for either cylinder reo
Whenever 8 v8/ve /s removed from a head, the valve quires removing the rocker arm covers. This can be
guide seal mus t be replaced. Also, whenever a valve accomplished on the Iront cylinder with the engine
guide Is replsced, the vs/ve seat must be re-ground. remaining In the chassis. The rear cylinder push rods
cannot be removed without pulling the engine from the
1. Install and position a protective sleeve over the chassis. Refer to STRIPPING MOTORCYCLE FOR
valve stem so that it completely covers the keeper ENGINE REPAIR and REMOVING CYLINDER HEAD as
area 01 the stem. Coal the sleeve with oil. described earlier.
2. Slide a new valve guide seal down the valve stem ASSEMBLING ROCKER COVER
and position it squarely against valve guide.
Remove the protective sleeve. AND INSTALLING (Figure 3-70)
3. Carefully tap seal down on guide unt il it Is fi rmly 1. Remove any old sealant or debris from cylinder
seated on guide. head and rocker cover.
3·66
2. ~ssemble the following parts into cover (14): shims 4. Inslall the Ihick washers. Start nuts onlo studs.
(1 1), rocker arm (9), and spacer (12). Turn nuts snug and check to make sure sealing
surfaces are still flush. Then using a torque
Be sure the color 90ded rocker arms are installed
wrench, tighten each nul 1/4 turn at a lime, observ-
in their proper locations as follows: front intake -
ing a proper cross pattern, until all are drawn to
white; front exhaust - red; rear intake - blue,
25·30 ft·lbs lorque. (See Figure 3·75.)
and rear exhaust - yellow.
3. Replace O-ring (7) on rocker shaft end. Carefully

tap rocker arm shaft (8) through cover (14) with the
index mark on the shaft end between the adjusting
marks on the cover (14).
4. Check rocker arm end play. (See SPECIFICATIONS

and SERVICE WEAR LIMITS In this section.) If not
within specifications, reshlm as required.
5. Install new O·ring (7), washer (6), and finger tighten

locknut (5).
6. Use a non·hardening sealant such as "Gasolla" or

"Gasgaclnch" between cylinder head (19) and
rocker cover (14) faces. No gasket required.
7. In spect push rod tube seals (34) and replace, if Figure 3·75. Cylinder Head Nut Torque Pattern
necessary.
8. Turn engine until piston Is at the top of its com- NOTE

pression stroke.
If oil fitting on cylinder head or rocker cover Is removed,
9. Install push rods (33) and cover tubes (32) through apply a coal of PIPE SEALANT WITH TEFLON, Pari No.
cylinder head holes into tappet guides. HO·99630-77 on threads before reinstalling.
10. Position rocker arm cover (14) on cylinder head

(19). Insert push rods (33) and cover tubes (32 into
ball sockets of rocker arm cover (14). Install VALVE CLEARANCE ADJUSTMENT
washers (3), motor mounts, and rocker arm cover
bolts (1). Bolts must be tightened evenly to altaln 1. Engine must be cold during adjustment.
an oil tight fit. First turn them snug; then, lighten
each one 1/8 to 1/4 turn at a time until all are 2. (See Figure 3-76). Remove rocker arm access hole
tightened to 18-22 ft-Ibs torque. 00 not overtighten. plugs on one cylinder.
NOTE 3. Turn engine over until piston of the cylinder to be

adjusted Is at top dead center (TOC) of the com-
The fronl cylinder rocker arm cover utilizes a stud (2) on pression stroke and both Intake and exhaust
the front right side. This enables service to be per- valves are closed.
formed on the 'rant cylinder without pulling the entire
engine 'rom the chassis.
INSTALLING CYLINDER HEAD

No gasket is used between the cylinder and cylinder
head. The sealing surface consists of a metal 10 metal
seat. For Ihis reason, it is very important that these two
sealing faces are cleaned throroughly. Avoid scratching
or damaging the sealing surfaces when disassembled.
1. Remove dirt and debris from cylinder head sealing

surface with a non-metallic type scraper.
2. Wash sealing surface with soap and water. Dry

thoroughly.
3. Position cylinder head over cylinder with push rod

holes aligned and slide cylinder head onto cylinder
studs. Make sure sealing surfaces between cylin- Figure 3·76. Valve Adjustment
der and cylinder head are flush.
4. Lo.osen rocker arm shaft locknut (2) on either in·
take or exhaust side.
5. Measu re the clearance between the rocker arm and

the tip of the valve stem with a feeler gauge through
the access hole (1) in the rocker box. Clearance Is
.002 .. 003 in.
6. Slowly turn the rocker arm shaft until the correct

clearance is obtained.
7. Hold the rocker arm shaft stationary and tighten the

locknut (2) to 18-22 ft·lbs torque at the same time. Do
not overtighten the locknut.
NOTE
1. Index marX 2. Adjuster marks
When tightening the rocker arm shalt locknut, the shaft
itself may move slightly dis turbing the correct clearance Figure 3·77. Push Rod Check
setting.
12. (See Figure 3·77). After correct valve clearance is
achieved, the index mark (1) on the rocker arm shaft
end must fall between the adjuster marks (2) on the
8. Always recheck the clearance. It should be within the rocker box. If the index mark falls outside of the
range limit of .002 ..003 in. If not, loosen the locknut limits on the rocker box , longer or shorter push rods
(2) and reset the clearance again repeating the must be substituted as required. This is necessary to
preceding sleps 4 . 7. maintain correct centering of the rocker arm pad on
the valve stem. Above the top mark requires a shorter
9. Once the clearance is set correctly. reinstall the push rod. Beneath the lower mark, a longer push rod
rocker arm access hole plug and tighten to 20·30 ft· is reQuired.
Ibs torque.
CAUTION
10. Adjust the cleara nce for the other valve on the same
cylinder following the preceding steps 4 . 9. Do not attempt to start or run engine If Index mark on the
rocker arm shaft end falls outside of the limit marks on the
11. Adjust the valve clearance on the opposite cylinder rocker box. Refer to the service manual supplement for
fallowing the preceding steps 2 . 10. push rod replacement.
3·68
CYLINDER AND PISTON
(XR·1000)
REMOVING NOTE
(Figure 3·78) If cylinder (2) does not come loose, tap lightly with
rawhide hammer. Never pry cylinder up.
1. For rear cylinder removal strip molorcyle as
descr ibed in STRIPPING MOTORCYCLE FOR 6. Carefully pull cylinder (2) over piston (8). Do not
ENGINE REPAIR. Front cylinder can be removed allow piston to fal l against crankcase. Discard
with engine in chassis . cyl i nder base gasket (3).
2. Remove rocker arm cover and cylinder head as 7. Spread piston rings (4 and 5) outward until they
described in CYLINDER HEAD REMOVAl. clear ring grooves in piston and lift off.
3. Clean crankcase around base of cylinder to pre· 8. Remove piston pin lock rings (6) using a sharp
vent dirt from entering crankcase when cylinder is pOinted tool. Lock rings should easily pop out. Be
removed. careful not to scratch aluminum piston.
4. Turn engine until piston (8) is at the bottom of 9. Support piston (8) and tap out piston pin (7) using a
stroke. suitab le drift.
5. Carefully raise cylinder (2) enough to permit plac- NOTE

ing a rag over crankcase opening. This will prevent
dirt and other foreign matter from entering It may be necessary to heat piston to remove pin.
crankcase.
10. Remove piston pin bushing (9) if necessary. See
CLEANING AND INSPECTION.
""
FITTING CYLINDER TO PISTON
Desired piston to cylinder clearance is .0025 in. - .0035 in .
For acceptable service wear of piston to cylinder clear-
ance see SERVICE WEAR LIMITS.
Pistons are available in the following oversizes: .005

std., .010, .020, .030, and .040. Oversize pistons have
their size stamped on the head .
Cylinders can be refinished oversize with a hone only, or

with a boring bar followed by a finishing hone. In gen·
era l practice, only cylinders not scored and not badly
worn are refinished entirely with a hone. Cy linders badly
worn or deeply scored are first rebored to nearly the re-
quired oversize and then are finish-honed to exact size.
Exact final size of cylinder bore is determined by size of

piston to be used in that cylinder. Measure piston dia-
meter accurately, as described previously and then add
desired piston clearance (.0025 - .0035 in.). This will
equal the exact final size to which cylinder bore should
be refinished.
1. Cylinder stud (4) 6. Piston pin lock ring (2)

2. Cylinder 7. Piston pin NOTE
3. Cylinder base gasket 8. Piston
4. Compression rings (2) 9. Piston pin bushing The same piston may be used if cylinder bore was not
5. Oil control ring (3-piece) 10. Connecting rod changed, unless it is scuffed or grooved. However,
replace rings and rough the cylinder walls with a No.
Figure 3-78. Cylinder and Piston Assembly 280 grit hone to facilitate ring seating.
3·69
1. Install piston assembly over connecting rod (10).
FITTING PISTON RINGS
Piston rings include a beveled barrel-faced , moly-filled 2. Press piston pin (7) into place. Piston pin should be
lop ring , a taper-faced second ring, and a three-piece oil a light hand press at 70° F.
control ring with two chrome plated rails and a co r-
3. Install new wire piston pin lock r ings (6) with a light
rugated expander.
finger press . It is important thai lock ring end gap
Rings are available in the following oversizes to fit slan- be positioned at 3 o'clock or 9 o'clock.
dard oversize pistons: .005, .010, 020, 030, and .040.
CAUTION
Piston rings must be properly fitted to piston and
cylinder. Make sure wire lock ring groove is clean and that the
new wire lock ring seats firmly in groove. A wire lock
ring loosely installed will rapidly loosen further in ser·
vice and will eventually come out of piston pin groove,
1. Check for proper side clearance with a thickness resulting in both piston and cylinder being damaged be-
gauge, Figure 3-25. See SPECIFICATIONS yond repair. Only new wire lock rings should be used.
(XR -l000) for tolerance. Once it has been installed in a piston and then removed
for any reason, discard it. Wire lock ring end gap must
2. Place piston in cyl inder about 112 in . from top. Set be positioned at 3 or 9 o'clock.
ring to be checked squarely against piston as
shown in Figure 3·26. Check end gap with 4. Check each cyl inder stud (1) height by measuring
thickness gauge. See SPECIFICATIONS (XR-l000) from the cylinder base surface of the crankcase to
for toleranc e. the top of the stud (1). The height is 8.05 in . to 8.09
in . Thread studs in or out 10 achieve correct mount-
3. Gap may be increased by filing with a fine-cut file. ing height for cylinder and cylinder head.
NOTE
Use a piston ring expander tool to slip compression Cylinder studs should be removed and installed with an
rings over piston into their respective grooves . Be ex- appropriate tool. Do not use a vise grips or double·nut.
tremely carefu l not to over-expand or twist rings, or Snap·On, A50 STUD REMOVER TOOL with a 7116 in . to
damage piston surface when installing rings . Ring end 112 in. capacity can be used. Grasp the stud as close to
gap should be staggered . the base as possible with the tool. Always check stud
height after installed.
5. Lubricate cylinder walls and piston (8) with engine

oil.
CAUTION
6. Turn engine unti l crank pin is at top center.
Piston ring end gap positioning should be no closer
than 90°. Piston ring end gaps should be no closer than 7. Install new paper cylinder base gasket (3).
10° from thrust face centerline.
8. Position PISTON INSERTER RING TOOL, Part No.
HD-96331-57, over piston rings and slide cylinder
ASSEMBLING (2) over assembly. Make sure cylinder (2) is aligned
so push rod slots line up with tappet guides.
(Figure 3-78)
9. Remove insertion ring and slide cylinder complete-
The XR-1000 aluminum pistons do not have a specif ic ly flush with base surface of crankcase.
intake or exhaust pocket. However, if the piston is being
reused , it is recommended that the piston be positioned 10 . Assemble cylinder head and rocker cover as
the same way it was removed to ensure a correct fit. described in INSTALLING CYLINDER HEAD.
3·70
GEARCASE
(XR·1000)
VALVE TAPPETS AND GUIDES 4. Inspect roller for correct side play clearance. Wear
limit is .008 ..012 in. clearance.
Disassembly 5. Discard tappet guide O-ring (5) and replace.
1. Clean aU dirt from around crankcase and blow

loose particles from area with compressed air. Assembly
(Figure 3·79)
2. Remove rocker box and push rod assemblies. See
the procedures for removing the rocker box and 1. If seal (2) was removed for replacement, coat seal
push rod assemblies given earlier In this section. with clean engine all and carefully press seal into
top of tappet guide (3).
NOTE
2. Liberally coat tappet assembly and especially
To remove the rocker box at the rear cylinder it w/fl first
roller needles with engine oil, to ensure smooth
be necessary to remove the engine from the vehIcle.
beginning operation.
3. See Figure 3·79. Remove tappet guide screw (1) 3. Grease and install O-ring (5) over guide (3), careful·
and guide (3). Iy push tappet through from bottom.
NOTE
4. Holding tappet up to extreme limit of travel, posi·
tion guide and tappet assembly over gearcase.
If tappet guide does not come loose after removing
screw, tap lightly with rawhide hammer. Never pry tap-
Rotate tappet so it will properly align with cam and
pet guide out.
guide will align with mounting hole.
Mark all components to ensure reinstallation into same
location. This will ensure an even wear pattern between CAUTION
tappet guide and cam surface.
If tappet roller is positioned Incorrectly within guide
(crosswise to guide and cam) serious damage may reo
Cleaning and Inspecting suit when Inserted Into crankcase.
1. Clean all parts thorougly in solvent, blow dry with 5. Carefully press guide assembly into gearcase.
compressed air. Tappet guides are a soft die cast aluminum; be ex·
tremely careful not to damage guide while press·
2. Inspect valve tappets for excessive clearance in Ing.
guide (3). Clearance should be .001 .. 003 in. (WEAR
LIMIT). 6. Install screw (1) and tighten to 8-14 ft·lbs torque.
A plug gauge should be used to accurately 7. Recheck tappet free movement in guide.
measure tappet guide Inner diameter.
Excessive tappet-guide clearance is serviced by

fitting a new tappet and lor guide.
GEARCASE COVER AND
CAM GEARS
NOTE
Inside and outside micrometers used for measuring tap· General

pets and tappet guides must be checked together to be
sure they are adjusted to read exactly the same. Carefully read the complete gearcase section before
any service work is begun.
3. Check tappet roller free play. Roller clearance on
pin should be within the .0005· .0012 in. wear limit. For a gearcase to operate at its optimum, all com-
Recommended service practice is lappet replace- ponents must be properly fitted and matched, changing
ment. See SPECIFICATIONS. one component can affect many others. It is Important
3·71
22 I
13
22 11~ ~J
""'6,) ~
1. Tappet guide screw 11. Idler gear 18. Cam gear and timer shaft
2. Tappet guide seal 12. Gaarease cover gasket bushing
3. Tappet guide 13. Flywheel shaft pinion gear 19. Pinion gear shaft bushing
4. Tappet and roller 14. Nut and loekwasher 20. Front intake cam gear
5. Tappet guide O·rlng 15. 011 pump drive gear shaft bushing
6. Rear cylinder Intake cam gear 16. Cam gear needle rolier 21. Front exhaust cam gear
7. Rear cylinder exhaust cam gear bearing (4) shaft bushing
8. Front cylinder Inlake cam gear 17. Rear Intake cam gear 22. Idler gear shaft bushing (2)
9. Front cylinder exhaust ge.r shaft bushing
10. Cam gear plate (2)
Figure 3-79. Gearcase and Tappet (XR·1000)
3·72
to know and understand all inspection procedures and 3. Inspect all parts for wear or damage. Replace as
how components interact. necessary.
Cam Gear Selection

Disassembly Cam gears must be properly sized and fitted to each
(Figure 3·79) other to ensure Quiet and smooth operation.
1. Thoroughly clean area around gearcase cover and ,. Proper cam gear backlash is .0000 - .0005 in. If
tappets. Blow loose dirt from crankcase with com· backlash Is within tolerance between all gears no
pressed air. replacements should be required.
2. Remove any parts that will interfere with gearcase If more than .0005 in. backlash is noted between
disassembly (I.e., exhaust pipe, footrest, air any two adjacent gears, disassemble gearcase
cleaner, brake pedal, etc.). and measure gears.
3. Remove spark plugs. 2. See Figure 3·40. Measure cam gears with a
micrometer over .105 in. diameter GAUGE PINS,
4. Posit ion engine rotation so that piston at rear Part No. HD-95632-79.
cylinder is T.D.C. of the compression stroke.
Remove access plugs and check that both valves Compare gear diameter, as measured, with sizes on
are closed. cam gear chart. A worn gear may be coded red, but may
actually measure a blue code.
5. loosen rocker arm locknuts and rotate the rocker
arms to obtain free play at the push rods. NOTE
6. loosen and remove front cylinder rocker box bolts. Prior to changing any cam gears, check gear shaft fit
within corresponding bushings; worn bushings can
7. Remove ignition system, see SECTION 7. cause excessive backlash. See REPLACING NEEDLE
BEARING AND BUSHINGS for measurement pro-
8. Place a pan under gearcase to collect oil. Remove cedures.
cover screws and generator mounting screws. Care-
fully remove cover, discard old gasket.
3. A size Increase of cam gears 1 and 3 may be nec-
essary to correct excessive gear backlash.
NOTE
Increase gears 1 and 3 by one color code, above
If cover does not come loose on removal of screws, tap
what gears measured.
lightly with a rawhide hammer. Never pry cover off.
Example: Gear 1 may have originally been coded
9. Remove cam gears (6, 7, 8 and 9), and cam gear
Red but now measure for a blue code. An increase
plates (10).
of one color code would mean replacing with a
new red coded gear.
10. Free idler gear (11) by lifting generator up and
away from crankcase.
4. Reassemble gearcase and recheck gear backlash,
record readings.
11. Remove nut and lockwasher (14), slide pinion gear
(13) and 011 pump drive gear (15) from pinion shaft.
5. A second size increase of gears 1 and 3 may be
necessary, but not more than two size jncreases
should be made before also Increasing size of gear
Cleaning and Inspecting 5.
(Figure 3·79)
6. Reassemble, run engine and check for noise:
1. Thoroughly scrub gearcase compartment, cover
and gears in solvent to remove oil and carbon Gear whine or howl indicates gears are too tight,
depOSits. affected gears must be reduced in size.
2. Blowout all cover oil passages and bushings with Rattling indicates there is still excessive gear
compressed air. backlash.
3·73
GEAR
NO. 1 2 3 4 5 6
Rear Rear Front Front
Color Rear Exhaust Intake Front Exhaust Exhaust
Code Intake Inner Outer Intake Inner Outer Pinion Idler
Brown 1.8893 1.8953 2.3902 1.8893 1.8953 2.3902 1.2681 3.0223
1.8903 1.8943 2.3912 1.8903 1.8943 2.3912 1.2671 3.0213
Blue 1.8903 1.8943 2.3912 1.8903 1.8943 2.3912 1.2671 3.0213
1.8913 1.8933 2.3922 1.8913 1.8933 2.3922 1.2661 3.0203
Red 1.9813 1.8933 2.3922 1.8913 1.8933 2.3922 1.2661 3.0203
1.8923 1.8923 2.3932 1.8923 1.8923 2.3932 1.2651 3.0193
White 1.8923 1.8923 2.3932 1.8923 1.8923 2.8932 1.2651 3.0193
1.8933 1.8913 2.3942 1.8933 1.8913 2.3942 1.2641 3.0183
Green 1.8933 1.8913 2.3942 1.8933 1.8913 2.3942 1.2641 3.0183
1.8943 1.8903 2.3952 1.8943 1.8903 2.3952 1.2631 3.0173
Yellow 1.8943 1.8903 2.3952 1.8943 1.8903 2.3952 1.2631 3.0173
1.8953 1.8893 2.3962 1.8953 1.8893 2.3962 1.2621 3.0163
Black 1.8953 1.8893 2.3962 1.8953 1.8893 2.3962 1.2621 3.0163
1.8963 1.8883 2.3972 1.8963 1.8883 2.3972 1.2611 3.0153
Replacing Needle Bearings and Bushings BUSHINGS

(Figure 3·79) Bushings (17,18, 19, 20, 22, Figure 3·79) are a press fit
into crankcase and gearcase cover. See Figure 3·12.
NEEDLE BEARINGS
1. Inspect each bushing against its corresponding
Needle bearings (16) are press fit i nto crankcase.
cam gear shaft, idler gear shaft or pinion gear
shaft. Correct fit should be:
1. Inspect each needle bearing against its
corresponding cam gear shaft, correct fit should Idler Gear Shaft .............0005· .001 in. loose
be .0005 ·.003 In. loose. Cam Gear Shaft ....0005 - .002 in. loose
Pin ion Gear Shaft ...........0005 - .0015 in. loose
2. Measure the outer diameter of each shaft. Mea·
surement should fall between .6860 in. and .6865
in. If shaft(s) is worn , it should be replaced. Service wear limits have an expanded range. See
SPECIFICATIONS.
3. Recheck clearance between new shaft and needle
bearing to determine if bearing will also need NOTE
replacement.
Use a plug gauge to accurately measure Inner diameter
NOTE of bushings. InsIde and outside micrometers used for
Use a plug gauge to accurately measure inner diameter measuring bushIngs and gear shafts must be checked
of needle bearings. InsIde and outside micrometers together to be sure they are adjusted to read exactly the
used for measuring needle bearings and cam gear same.
shafts must be checked together to be sure they are ad-
justed to read exactly the same.
2. See Figure 3·45. Use a BUSHING AND BEARING
4. See Figure 3·41. Use SEARING PULLER, Part No. PULLER, Part No. HD·95760·69, to remove bushings.
HD·95760-69, to pull worn needle bearing(s) (16)
from crankcase. 3. Use a smooth surfaced disc or plate slightly larger
than bushing flange when pressing bushing i nto
5. See Figure 3-43. Use BEARING INSTALLATION position. Apply a few drops of Loctite STUD'N
TOOL, Part No. HD-97273·60, to install new needle BEARING MOUNT, to outside diameter of bushing
bearing(s) (16). before installation. Press bushing until flange is
tight against surface.
To avoid permanent damage to bearing, always
press on printed side. Press bearing flush to .020 4. After a new bushing is installed, it must be reamed
in. below surface. to correct size. All bushings except idler gear (22)
3·74
must be line reamed; using the corresponding al igned . Assemble lockwasher and nut (14) to shaft.
bearing to guide reamer. If crankcase is not Tighten nut to 50 ft-Ibs torque. Bend tabs on lockwasher
disassembled, use another right crankcase half. against flats on nut.
Special REAMERS are available for the rear

cylinder intake cam shaft bushing, Part No. Installing Cam Gears
HD-94803-67 , and the pinion gear shaft bushing, and Gearcase Cover
Part No. HD-94812·77. Use a standard 11/16 in.
diameter reamer for all other cam shaft bushings. 1. Install plates (10, Figure 3-78) in case recess with
beveled side of hOles for cam shaft facing outward
Crankcase and gearcase cover must be assembled toward cam.
while bushings are being line reamed. Turn ream
clockwise in bushing until it bottoms, continue to 2. Lubricate cam gear shafts and position in
turn reamer clockwise as it is drawn out. crankcase with marks on gears (1), (2), (3), and (4) in
alignment as shown in Figure 3·38. Install idler
Ream the idler shaft bushings with case separ- gear (7) with la rge hole in idler shaft facing
ated. Use REAMER, Part No. HD-94806-57, care· crankcase bushing.
fully align and turn clockwise until it bottoms.
3. Position gearcase cover gasket on crankcase. Be
sure to install a new "factory-made" gasket. Never
use a "homemade" gasket as cover gasket has
NOTE
holes especially located for oil passages. If a hole
is left out or put in wrong place, Oiling system will
After reaming, check shaft fit in new bushing. It may be
not function normally.
necessary to make a second pass with reamer to attain
proper fit. 4. Install cover and tighten all screws evenly to
80-110 in·lbs torque.
5. Clean all metal chips from case. Blowout all oil
passages with compressed air. 5. Apply sealant to front cylinder rocker box surface.
Install rocker box and torque to specifications.
6. Adjust tappets as described in Installing and Ad-

Gearcase Assembly justing Tappets.
(Figure 3·78) 7. Install Ignition system. See Section 7.
Installing Pinion Gear 8. Reinstall any components removed to gain access

to gearcase (I.e. exhaust, footrest, air cleaner).
Assemble 011 pump drive gear (15) to pinion gear shaft.
Install pinion gear (13) with beveled edge towards 9. Readjust and re-time ignition system as described
crankcase. Timing marks on gear and shaft must be In Section 7.
3·15
CRANKCASE
(XR·1000)
FITTING ROD BEARINGS
Assembly
boss, at the female rod, and the side with the large
There is one important step that needs to be added to radius, at the male rod, are adjacent (lace each other) as
the flywheel reassembly procedure. The connecting shown in Figure 3-80. The side of the male rod with the
rOds can only be installed one way. When assembling larger radius is also narrower in the area where it 'ils
the connecting rods, be sure the side with the angular between the forks 01 the female rod.
Note position of boss
Forked or
female rod
Male rod
Note position I>"

of radius
Assemble rods as shown
Figure 3-SO. Connecting Rod Installation (XR-1000)
3·77
FUEL SYSTEM I
SUBJECT PAGE NO.
1. Specifications............ . ... . ..... .. ... . ..... . . . . .... 4·1

2. Carburetor .,.......... . ...... . .............. . .4-3
3. Air Cleaner ........................... . 4-17
4. Fuel Supply Valve ......... . . .•.. . . ...• . ...•...• • . ... . .•...• • ...... 4·19
5. Fuel Tank ........... .............. . .... 4·21
6. Carburetor (XA·1000) . . ......• _...............• _... • _........... 4·25
7. Air Cleaners (XA·1000) . . . . • • • . . •• . . .• • . . . • . . . ... . . • . . 4-37
8. Fuel Supply Valve (XR·1000) .. ... .. • ... . • •. • .••. .4-39
9. Fuel Tank (XR·1000) . . . . . . . . . . . . •. . . . . . . . . . . . ... 4-41
SPECIFICATIONS
JET SIZES CAPACITY
1979 Model Fuel Tank (U.S. Gallons)
Mainjet. . ..........•.. • .. • . ..... NO.16S 1979 1980 1982 1983 1984
Slow jet ........ . . .... NO.65 1981
XLH
Total 2.25 2.25 3.00 3.3 2.25
Reserve 0.25 0.25 0.25 0.8 .25
1980·1982 Models
XLS
Main jet . . ............. . .. No. 160 Total 2.25 3.6 3.6 3.8 3.8
Slow jet ...... • •.. . .• ' " • . . •.......... No. 68 Reserve .25 0.3 0.6 D.' 0.4
XLX
Total 2.25 2.25
Reserve 0.25 0.25
1983·1985 Models
TORQUES
Main jet. . . . . . . . . . . . . . . •. . . . . . ..... No. 160
Slow jet ........ . .. . . .. •. • .. • • ... . .. .... ... No. 52 Carburetor mounting nuts .... 19 ft-Ibs
4·1
CARBURETOR
GENERAL ""
The carburetor is a horizontal, gravity fed type with a
float operated inlet valve, an accelerating pump, a throt-
tle stop screw for idle speed adjustment, and choke
system with a fast idle speed adjustment.
The fast Idle speed cam operates in conjunction with

the choke to progressively raise the idle speed as the
choke disc closes.
The carburetor has been specifically designed to con-

trol exhaust emissions. All jets are fjxed. The idle mix-
ture has been preset at the factory. On 1979 models, the
idle mixture screw has a limiter cap. Tune-up ad-
Justments should be within the adjustment range that is
available without removing the limiter cap.
On 1980 and later models, the idle mixture screw has

been recessed in the carburetor casting. The opening is
sealed with a plug because it Is intended that the idle
mixture be non·adjustable. 1. Throttle lever
2. Throttle stop screw
3. Fast Idle cam
1010 4. Fast Idle adjusting screw
Figure 4-2. Carburetor - 1980
A high altitude carburetor conversion kit may be reo

Qulred to Improve carburetion at altitudes over 4000 feet
abOve sea level and should be installed where there is
evidence of over·rlchness causing loss of smooth com·
bustion, stumbling upon acceleration or other drive·
ability problems at high altitudes.
""
1. Throttle lever
2. Throttle stop screw
3. Fast Idle cam
4. Fast Idle adjusting screw
5. Low speed mixture screw limiter cap
1. Throttle lever
CAUTION 2. Throttle stop screw
3. Fast Idle cam
Adjusting mixture setting by procedures other than 4. Fast Idle adjusting screw
specified In this section may be In violation of Federal
or State regulations. Figure 4-3. Carburetor - 1981 ·1982
4-3
fast idle cam. The fast idle cam increases engine speed
as the choke knob is pulled out. By moving the choke
knob, the choke valve and fast idle can be adjusted for a
cold or a warm engine.
1. The choke knob has 4 basic positions. In the first

position, choke knob all the way in, the choke plate
is fully open and the engine operates at low idle
speed.
2. When the choke knob Is pulled out to the second

position, the choke plate is still fully open but the
fast idle cam moves the throttle valve to the fast idle
position.
3. In the third position, the choke plate Is half open and

the throttle valve opens further.
4. With the choke knob all the way out, the choke plate
1. Throttle lever 3. Fast idle cam is fully closed and the throttle valve is in its highest
2. Throttle stop screw 4. Fast idle adjusting screw idle position for cold engine starting.
Figure 4-4. Carburetor - 1983 Fuel Supply System (Figure 4-7)

Fuel from the gas tank passes through the inlet valve in·
to float chamber. The fuel entering the chamber causes
the lIoat to rise until it shuts oflthe fuel valve, stopping
flow at a level pre-determined by float level selling.
t~t~
I~""(~';t;on Iohok. ", ...
_ I,.. \ I fully open)
(- ....~v"y...... )- 2nd position
- >
{-~":;:y" __ ./I' ltd position
\\ 'I
II 4th position (choke plate
,-
fully closed)
Figure 4-6. Setting the Choke
2. Throttle stop screw screw

3. Fast Idle cam 5. V.O.E.S. port
Figure 4-5. Carburetor - 1964· 1985
CAUTION
If motorcycles modified for high altitudes are to be

operated at altitudes below 4000 feet, they must be con·
verted back to standard to prevent possible engine
damage due to over-lean fuel mixture.
Overflow line
OPERATION
Choke (Figure 4-6)
The choke system is composed of a choke valve and a Figure 4·7. Fuel Supply System
4·4
IDLE
Air - Blue
Fuel- Red
Air Fuel Mi)(ture - Purple
. - " __ Idle mixture screw
~~~~t--
Venturi
Idle port
Slow air jet
Throttle "al"e
Main air jet
Slow Jet bleed tube

Main
Main bleed tube

Slow jet
Main jet
Figure 4-8. Idle Circuli
MID RANGE
Air - Blue
Fuel - Red
Air Fuel Mixture - Purple Idle transfer ports
Idle mixture screw
Venturi
Idle port
Slow air Jet Mid range port
(.~"---H---- "rhr••III. Val".
Main air Jet
Main nozzle
~~~~f-~:::'~-- Slow Jet bleed tube
Main bleed tube

jot
Main jet
Figure 4·9. Mid Range Circuit

4-S
HIGH SPEED
Air - Blue
Fuel - Red
Air Fuel Mixture - Purple
1'-_- "... mixture screw
Venturi
,-<";\mr~ E~~L-- Idle port
Slow air jet
l~:=~~~Mr--Th"",tI. valve
Main air jet
Main nozzle Slow jet bleed tube
Main bleed tube

Slow let
Main jet
Figure 4-10. High Speed Circuit
ACCELERATING PUMP
Spring
Pump lever
Venturi --f-- Throttle
shaft
Pump
nozzle
Pump rod
valve
Fuel Diaphragm
Figure 4·11. Accelerating Pump

4-6
Idle Circuit (Figure 4-8) 2. Back screw out 1 V. turns.
The idle circuit functions at Idle, low and intermediate 3. Wilh screw in Ihis posilion, install limiter cap in cen·
speeds when the throttle valve Is closed or only partially Iral posilion on adjusting screw.
open. Fuel is first metered at the main jet and then is
metered again as il passes through the slow jet. Air is
drawn through the slow air jet and is mixed with fuel in ''''
the bleed tube portion of the slow jet. When the throttle
valve Is closed, this air fuel mixture flows into the ven-
turi almost entirely through the idle port where it is
metered by the idle mixture screw.
As the throttle valve opens slight ly the mixture also

flows through the idle transfer ports as they become un-
covered by the throttle valve.
Mid-Range Circuit (Figure 4-9)

As the throttle valve opens, the airlfuel mixture from the
slow jet Is drawn into the venturi through the id le
transfer ports. When the throttle valve uncovers the mid
range port, raw fuel from the float chamber is also
drawn into the engine.
High Speed Circuit (Figure 4-10)

During full throttle operation, fuel is metered through
the main jet, mixed with air from the main air jet in the
main bleed tube and this mixture is drawn into the ven·
turi through the main nozzle.
Accelerating Pump (Figure 4-11) Figure 4·12. Engine Side of Carburetor
The accelerating pump system uses sudden throttle

openings (rapid accelerations) to quickly inject raw fuel A,23
into carburetor venturi to provide extra fuel for smooth Main nozzle
acceleration.
Rapid throttle action, during the first half of throttle

travel, pushes the pump rod down, flexing diaphragm.
This flexing action forces raw fuel past a check valve in·
to the venturI. The check valve prevents back flow during
this stroke. A spring then returns diaphragm to its
original position and a new supply of fuel flows in under
the diaphragm from the float chamber for the next
acceleration.
ADJUSTMENTS
Low Speed .Mlxture Adjustment (1979)
NOTE
On 1980 and later models, the low speed mixture is set

at the factory and sealed.
In normal service, the low speed mixture limiter cap

should not be removed. Low speed mixture may be ad·
justed within the limited range of the cap if necessary. Accelerating pump nozzle
If the limiter cap has been removed and low speed mix· Figure 4·13• .Air Cleaner Side of Carburetor
ture altered, proceed as follows:
1. Carefully turn low speed mixture screw all the way 4. With the engine warm and the choke off, adjust the
in, clockwise, until just seated. Do not over tighten. throttle stop screw so that engine idles at 900 rpm.
""
Valve
fully closed
lip
f-_--I-_O.63 to 0.61 Inch

(16 to 11 mm)
Figure 4·14. Float Adjustment
5. Turn the limiler cap clockwise for a leaner mixture, 4. Assemble the float bowl and install the carburetor
counterclockwise for a richer mixture. The mixture as described in each respecllve section.
should be adjusted to the leanest setting that re-
sults In a smooth Idle. REMOVAL
6. Recheck slow Idle speed seltlng and readjust to 900 1. Remove the air cleaner and backing plate. See AlA
rpm II necessary. CLEANER REMOVAL section.
2. See Figure 4-15, 4-16 or 4-17. Turn the fuel supply

Slow Idle Adjustment valve off. Disconnect the fuel hose (I), throttle
cables (2) and choke cable (3) from the carburetor.
With the engine at normal operating temperature and On 1983 and 1984 models disconnect the vacuum
the choke knob all the way in (choke fully open), adjust hose.
the throttle stop screw (Figure 4-1 through 4-5) so the
engine Idles at 900-950 rpm. 3. On 1982 and earHer models, remove the two
locknuts and lockwashers that fasten the carburetor
Fast Idle Adjustment to the manifold. Remove the carburetor and gasket.
On 1983 and later models, remove the nut and
Pull the choke to the second position. Turn the fast idle washer securing the V.O.E.S. bracket to the car-
adjusting screw (Figure 4-1 through 4-5) In or out to set buretor mounting stud. Remove the stud and
the fast Idle at 1500 rpm. washer, then remove the lower bOlt and lockwasher.
Remove the carburetor and gasket.
Float Level
1. Remove the carburetor as listed in the REMOVAL
DISASSEMBLY
section. (Figure 4-18, 4-19, 4-20 or 4-21)
2. Remove the float bowl as described under car- Accelerating Pump
buretor DISASSEMBLY.
1. Remove two screws (31), one long screw (32), the ac-
3. See Figure 4-14. Use FLOAT LEVEL GAUGE, Part No. celerating pump housing (30), spring (29) and
HD-947S2-77, and adjust the float as shown In the diaphragm (28). Remove the O-ring (27) from the
figure. housing (30).
4·8
TROUBLESHOOTING
NOTE
Gal/outs refer to Figures 4-18, 4-19, 4-20 and 4-21
Overflow
Check for: Remedy:
,. Worn inlet valve (18) or dirty inlet valve seat. 1. Replace valve (18) or clean valve seat.
2. Improper fuel level in float bowl (26). 2. Adjust float (20) mounting labs for correct fuel level.
3. Worn float (20) mounting tabs. 3. Replace float (20).
4. Worn float pin (5) or loose float retaining screw (6), 4. Replace pin (5) or tighten screw (6).
5. Damaged float bowl gasket (25). 5. Replace gasket (25).
6. Loose float bowl screws (31). 6. Tighten screws (31).
7. Deformed float assembly (20). 7. Replace float assembly (20).
Poor Idling
Check for: Remedy:
1. Idle speed improperly adjusted. 1. a. Adjust last and slow Idle speeds.
b. Adjust low speed Idle mixture screw limiter cap
to full rich or full lean limit (1979).
2. Damaged low speed mixture screw. 2. Replace screw (1979).
3. Clogged bypass or idle port. 3. Clean.
4. Clogged low speed jet (22). 4. Clean jet (22).
5. Loose low speed jet (22). 5. Tighten jet (22).
6. Air leaking into system. 6. Replace gasket (17) and tighten screws.
7. Excessive fuel from accelerating pump. 7. Check accelerating pump rod (7) length.
Poor Fuel Economy
Check for; Remedy:
,. Fuel level too high. 1. Adjust level of float assembly (20).

2. Clogged bleed tubes. 2. Clean.
3. Loose Jets. 3. Tighten.
4. Idle speed improperly adjusted. 4. A. Adjust fast and slow idle speeds.
B. Adjust low speed mixture cap within Its limits
(1979).
5. Choke not opening fully. 5. Inspect choke and choke wire and adjust or replace.
6. Dirty air cleaner. 6. Clean.
Poor Acceleration
Check for: Remedy:
1. Clogged accelerating system. 1. Clean.

2. Damaged accelerating pump diaphragm (28). 2. Replace diaphragm (28).
3. low speed system improperly adjusted. 3. Adjust low speed system (1979).
4. Clogged low speed jet (22) or bleed tube. 4. Clean.
5. Fuel level too low. 5. Adjust level of float assembly (20).
Hard Starting
Check for: Remedy;
1. Choke plate (36) not opera ling properly. 1. Adjust choke system.
2. Generally dirty carburetor. 2. Disassemble and clean.
3. Loose carburetor mounting nuts. 3. Tighten mounting nuts.
4. Fuel overflow. 4. Inspect float assembly (20) and Inlet valve (18) and
adjust or replace.
4·9
NOTE
Cal/outs refer to Ffgures 4-18, 4-19, 4-20 and 4-21
Poor Performance On Road

Check for: Remedy:
1. Idle speed improperly adjusted . 1. Adjust idle.

2. Fuel overflow. 2. Inspect fioat assembly (20) and Inlet valve (18) and
adjust or replace.
3. Main Jet (23) loosened. 3. Inspect main jet (23) and tighten.
<. Air leak In intake system . 4. Check air cleaner backing plate and manifold
mounting.
5. Faulty operation of accelerating pump. 5. Correct accelerating pump rod (7) length.
B. Dirty or clogged carburetor or air cleaner. 6. Clean.
Poor High Speed Performance
Check for: Remedy:
1. loose main jet (23). 1. Inspect main jet and tighten.

2. Improper fuel level In float chamber. 2. Adjust float assembly (20) mounting tabs for cor-
rect fuel level.
3. Dirt lodged in strainer In fuel tank. 3. Clean strainer.
<. Clogged main jet (23) or main Jet air passage. 4. Clean.
Abnormal Combustion (Fuel Mixture)
Check for: Remedy:
1. Generally d irty carburetor. ,. Disassemble and clean.

2. Dirty or clogged fuel line. 2. Clean luel line or replace.
3. Air leaking Into system. 3. Check mounting nuts lor tightness or replace
gasket (17).
Loss of Power (Fuel Insufficient)
Check for: Remedy:
1. Clogged luel line. 1. Clean.

2. Dirty luel tank. 2. Clean.
3. Air leaking into system. 3. Check mounting nuts for lightness or replace
gasket (17).
<. Accelerating pump not working. <. Repair and adjust.
5. Clogged fuel strainer In luel tank. 5. Clean strainer.
B. Generally dirty carburetor. B. Disassemble and clean.
loss of Power (AIr Insufficient)
Check for: Remedy:
1. Dirty air cleaner. 1. Clean or replace air cleaner element.

2. Throttle cable not working. 2. Check throttle cable and adjust or replace.
3. Correct Jetting for high altitude operation. 3. Install high altitude kit .
4. loose Jets. 4. Tighten jets.
4-10
Carburetor Body
1. Remove the plug (24) to unscrew the low speed jet
(22). Main jet (23) can be threaded out.
2 . Remove the nut (16), washer (15), throttle lever or

high idle cam assembly (14) and spring (13) from the
throttle shaft.
3. If required , remove the brackets (2) and (12) by

removing the screws (1) and (11).
CAUTION
The throttl. valv. as••mbly should not be dlsas·

s.mbled. Th.s. part. ar. m.tched speclfic.lly to the
carburetor .nd .r. non .... pl.c.m.nt parts. If probl.m.
arls. Involving th•••••••mbll •• the carbur.tor mu.t b.
r.placed.
1. Fuel!!ne 3. Chok. wlr.

2. Throttl. cable(')
~ ?fI~
Figure 4·15. Carbur.tor Mounting - 1982 and Earll.r
,
\ ;:".(:-1'" •
K-·:
"" .•. ~-'
, ....4 ,
I,
~".~
,_ ,
\ ',:J'
. ----..
1. Fu.llln. 3. Chok. wire
I
I
2. Throttl. c.bl •• 4. Vacuum ho••

1. Fu.1 lin. 3. Choke wire
2. Throttl. cables 4. Vacuum hose Figur. 4·17. C.rbur.tor Mounting - 1984·1985
Figure 4-18. Carburetor Mounting - 1983
Float Chamber
CLEANING, INSPECTION AND
1. Remove the three screws (31), one screw (32), and REPAIR
float bowl (26).
2. Loosen float retaining screw (6) and remove the pin Accelerating Pump
(5) and float assembly (20). (Figure 4-18, 4-19, 4-20 or 4-21)
3. Remove the inlet valve (18) and clip (19) from the 1. lnspecl the accelerating pump diaphragm (28) lor
float assembly (20). hales, cracks or deformation and replace as
necessary.
4. Remove the rubber boot (8) from the float bowl (26)
and remove the accelerator pump rOd (7) from the 2. Replace the pump rOd (7) if It Is bent and replace the
rocker arm (40). boot (8) if It is cracked .
49
'~ '" 1979 only.
~, ~~~1{r~; (4 1.
2' 50 3.
, ' ~ ~::;~.1 " ..
43 44 '0' fi (N.6;i
39,40,4~ ~ ~/~
I
'- \ \\J
~/ ~~~~ 4.
23. J (
\.!)
~ 27
t-= 22~
.~ 2~.V
,U u.-- I. '\ 26
18 17
19 6
1. Screw and washer 29. Accelerating pump spring
30. Accelerating pump housing
2. Choke cable bracket
24 1 :;. ., ~/ 3. Fast Idle adjusting screw 31. Screw and washer (5)
1.-31 "'._.
~
L· ., ~ 20 4. Choke cable screw 32. Screw and washer
~ _ 5. Float pin 33. Overflow line clip
7 ( '1 . \.'6. Float retaining scraw 34. Overflow line
I 7. AcceleraUng pump rod 35. Fuel inlet lilting
V I
1 ) '"
28 I •. 8001 36. Choke plate (not shown)
8 n:'''~- 6 9. Throttle stop screw 37. Choke lever shaft
/"t 29 r ~ 10. Spring and wlSh.r. 38. Mounting flange
39. Accelerating pump lever
27 ....... Screw and washer
30 33 12. Throttle cable bracket 40. Rocker arm
13. Spring 41. Rocker arm spring
14. Throttle lever 42. Intermediate lever
31 34) 15. Lockwasher 43. Fast idle cam
32 16. Nut 44. Mounting stud
17. Gasket ~. Mounting nut and washer
18. Inlet valve 46. Intake manifold
19. Clip 47. Intake seal
20. Float assembly 48. Intake clamp
21. Screw and nut 49. Limiter cap x
22. Low speed jet 50. Idle mixture screw x
23. Main jet 51. Spring x
24. Plug 52. Washer
25. Rubber gasket 53. O.,ing x
26. Float bowl
27. O·rlng (2) x 1979 only.
28. Accelerating pump
diaphragm
Figure 4·18. Carburetor - 1979·1980
Float Bowl Carburetor Body

1. Blow any dirt out of the accelerating pump passage. Clean the carburetor body In a cleaning solvent such as
Blow from the side opposite the nozzle to prevent GUNK to remove varnish and carbon from the fuel and
the check valve Inside the bowl from closing. ai r passages. Blow dry with c ompressed air. Reverse
the air flow through ali passages to remove all dirt
2. Clean all dirt from Inlet valve and valve seat. particles.
3. Replace the float if it is c racked or damaged.
4·12
p-' \---:9
~2 F'O~"
\ tiL _ 12
l" \ ~~___ 35
'I \ I
y' I \ 1/
~
' /-1
I 37
\I ' . 1.2?;,/ /f') 2'
U,
m: ."
43 I ./ 38
,:~~~( i
> -~~
"\\ '5 ,n'\ f&!2 ~ : ~~
'6
I '9
23 2' r~ ~'5 48 21
rt r ~
. 20
7 . 25. Rubber "uke'
[ ,8 I 26. Float bowl

./ If!~\\'--~ 28 I 6 27. O....ln" (mid range port)
V 27A. O-ring (Icceleretlng pump)
27A----- 28. Acceler.tlng pump diaphragm
33 29. Acctleretlng pump spring
30. Acceler.tlng pump hou.lng
""'''''' --30 31. Screw and wI,her (5)
32. Screw and wuher
32 33. Overflow lin. clip
~\ 34. Overflow lin.
3'
35. Fuel Inlet fitting
38. Choke pl,'e (not shown)
1. Screw and w.. her '3. Spring 37. Choke IIYlr ,haft
2. Choke cable brlcket 14. F••t Idl. c.m ....mbly 38. Mounting IIlngl
3. F..t Idle adju.tlng screw 15. Lockw'lhar 39. Acetleretlng pump rod hoi,
4. Choke CIIble Icrew 18. Nut 40. Rocker arm
5. Flolt pin 17.0.. k.t 41 . W.. her
8. Flo.t ~t.lnlng IC~W 18. Inl.t v.lv. 42. Choke detent ball and aprlng
7. Acc.l.r.tlng pump rod 19. Clip 43. F..I Idle elm
8. Rubber boot 20. Float ....mbly ... Mounting .Iud
9. Throttl •• top .c,..w 21. Scre• • nd nut 45. Mounting nut and lockwuher
10. Spring .nd w••hera 22. low .pHd j.t 48. Intlke mlnltold
11 . Sc~w .nd w•• her 23. Main j.t 47. Intlke ••• 1
12. Throttl. cabl. br.ck.t 24. Plug 48. Intake cllmp
FJgure 4·19. C.rburlltor - 1t81·1982
CAUTION p....ge• • Anyone of the.. thlngl c.n ch.ng. the liz.

N.ver ,c~P' c.rbon d.poslt.from the carbUrlltor u.lng 01 the p.... g. hoi.. or .Iter the c.rbu~tor. Do not u..
It..1 In.trum.nt• . Do not u.. wl~ or drill. to clean c.rbu,..tor cleaner on rubber or pl•• llc part• .
"'3
2,
\
48
25. Rubber gasket

26. Float bowl
27. O·rlng (accelerating pump)
28. Accelerating pump diaphragm
33 29. Accelerating pump spring
31. Screw and washer (5)
32. Screw and washer
32 33. Overflow line clip
34. Overflow line
35. Fuellnl.1 fitting
36. Choke plata (not shown)
1. Screw and wISher 13. Spring 37. Choke lever shaft
2. Choke cabl. bracket 14. Fa.t Idle cam assembly 38. Mounting flange
3. Fast idle adjusting screw 15. LockwlSher 39. Accelerating pump rod hole
4. Choke cabl. screw 16. Nut 40. Rocker arm
5. Float pin 17. Gasket 41. Washer •
6. Float fatalnlng screw 18. Inlet valva 42. Choke detent ball and spring
7. Accelerating pump rod 19. Clip 43. Fast Idle cam
8. Rubber boot 20. Float assembly 44. Mounting stud
9. Throttle stop screw 21. Screw and nut 45. Mounting nut and lockwasher
10. Spring and washafa 22. Low speed Jet 46. Intake manifold
11. Screw and washer 23. Main Jet 47. Intake seal
12. Throttle cabl. bracket 24. Plug 48. Intake clamp
4·14
r.'"
t·.:1
'f
'"""
"
"
\
48
25. Rubber gasket

26. Float bowl
27. O-ring (accelerating pump)
28. Accelerating pump diaphragm
29. Accelerating pump spring
31 .Screw and washer (5)
32. Screw and washer
33. Overflow line clip
34. Overflow line
35. Fuel Inlet fitting
36. Fuel Inlet hose
1. Screw and washer 13 Spring 37. Choke levar shalt
2. Choke cable bracket 14. Fast Idle cam assembly 38. Accalaratlng pump lavar kit
3. Fast Idle adjusting screw 15. Lockwasher 39. Spring
4. Choke cable screw 16. Nut 40. Rockar arm
5. Float pin 17. Gasket 41. Washer
6. Float retaining screw 18. Inlet valve with clip 42. Choke datent ball and spring
7. Accelerating pump rod 19. Clip 43. Fast Idle cam
8. Rubber boot 20. Float assembly « . Mounting stud, washers and nut
9. Throttle stop screw 21. Screw and nut 45. Mounting boH and lockwashar
10. Washers 22. Low speed jet 46. Intaka manifold
11. Screw and washer 23. Main Jet 47. Intaka saal
12. Throttle cable bracket 24. Plug 48. Intake clamp
Figure 4·21. Carburetor - 1984 · 1985
4·15
ASSEMBLY Accelerating Pump
(Figure 4-18, 4-19, 4-20 or 4-21) Inslall the diaphragm (28), spring (29), D-ring (27) and
housing (30). Secure with the two screws (31) and one
long screw (32).
Carburetor Body
1. Install the brackets (2) and (12) using the two screws
(1) and (11).
2. Inslall the spring (13), throttle lever or fast idle cam

assembly (14), washer (15) and nul (16) on the throt-
tle shaft.
3. Install the low speed jet (22), plug (24) and main lei
INSTALLATION
1231. (Figure 4-18, 4-19, 4-20 or 4-21)
1. Fasten the carburetor and gasket to Intake manifold
Float Chamber using the lockwashers and nuts (45). Tighten the
nuts alternately to 6-10 It-Ibs torque.
to Install the rubber bool (8) on the 1I0ai bowl (26) and
Install the accelerator pump rod m on the rocker 2. See Figure 4-15, 4·16 or 4-17. Connect the fuel hose
arm (40). (1), throttle cable (2), choke cable (3), vacuum hose
(4), If applicable, to the carburetor.
2. Install the Inlet valve (18) and clip (19) on the float
(20). Secure the float (20) and pin (5) to the carburetor 3. For 1979 - 1983, run float bowl overflow tine (34)
using the screw (6), Figure 4·18, 4·19, 4·20 or 4·21 down between engine
and generator.
NOTE
4. For 1984 and 1985 models, run float bowl overflow
At this time, check the float level as described under line (34, Figure 4-21) down bet wen engine and oil
ADJUSTMENTS. filter.
3. Install the floal bowl to the carburetor body and 5. Install the air cleaner and backing plate on the car-
secure it with the three screws (31), buretor.
....
AIR CLEANER
GENERAL appear on the surface. ThIs indicates that dust Is drying
Qut the all, Use the following steps to clean the fi/ter.
The air cleaner contains a plasUc foam element that
traps air borne dust and dirt to keep It from entering the 4. Remove the foam element from the wire mesh core
carburetor and engine. and clean It with soap and hot water.
5. Allow the element to dry, then apply about 101/4

Remove the air cleaner cover and service the filter every
tablespoons of engine oil to the element, either
2500 miles, or more otten it the motorcycle is run In a
dusty environment. with an atomizer or by direct application. Thoroug·
Iy work the oil into the element.
SERVICING AIR CLEANER 6. Install the element, baffle plate, cover and grill , or
1982 and Earlier (Figure 4-22) seal band, cover and trim and secure with mount·
1983 and Later (Figure 4-23) ing hardware.
1. Remove the hardware securing air cleaner cover to

the backing plate.
REMOVAL
2. On 1982 and earlier models remove the grill , cover, 1982 and Earlier (Figure 4-22)
baffle plate and element. 1983 and Later (Figure 4-23)
3. On 1983 and later models remove the trim plate, 1. Remove the hardware securing the air cleaner
cover, seal band and element. cover to the backing plate, then remove the grill,
cover, baffle plate and element or the trim, cover,
NOTE seal band and element.
The fifter should be cleaned and re-oiled if a film of dirt 2. Remove the hardware securing the backing plate
has built up covering the surface pores or if light spots to the support bracket and carburetor. Carefully
1. Socket head screw (3)

2. Washer (3)
3. Grill
4. Air cleaner cover
5. Baffle plate
6. Filter element
7. Seal strip
8. Locknut (2)
9. Screw (3)
10. Backing plate
11. Crankcase vent hose
12. Gasket
6
13. Locknut and washer (2)
14. Backing plate bracket (2)
15. Bolt and washer (2)
5 16. Mounting bracket (2)
17. Hose clamp
18. Gearcase cover titting
4
/
7
Figure 4·22. Air Cleaner - 1982 and Earlier
4·17
move the backing plate forward to prevent damage INSTALLATION
to the gasket.
1982 and Earlier (Figure 4·22)
3. Disconnect the crankcase hose from the backing 1983 and Later (Figure 4·23)
plate discarding the hose clamp. If necessary,
remove the seal strip from the backing plate. 1. Connect the crankcase vent hose to the backing
plate, using a new hose clamp.
2. Assemble the mounting hardware to the backing

plate. Position the carburetor to backing plate
INSPECTION AND REPAIR gasket on the screws or bolts then install the back·
ing plate. Tighten the backing plate to carburetor
1. Inspect the backing plate to carburetor gasket for screws or bolts to 74-80 in·lbs torque. Tighten the
cracks, deterioration and damage. Replace gasket backing plate to support nuts to 10·15 ft·lbs torque.
if damaged.
3. Service the air cleaner element as previously
2. Check the vent hose, seal band or seal strip for described, then install the element, seal strip or
deterioration and other damage. Replace as need· seal band, baffle, cover, trim or grill and secure
ed. with hardware.
1. Phillips head screw (2) 10. Lockwasher

2. Trim 11. Nut
3. Cover 12. Bolt
4. Seal band 13. Lockwasher
5. Filter element 14. Nut
6. Backing plate 15. Bolt (3)
7. Gasket 16. External tooth washer (3)
8. Support bracket 17. Vent hose
9. Stud
Figure 4·23. Air Cleaner - 1983 and Later
4·18
FUEL SUPPLY VALVE
GENERAL (Figure 4-24) REMOVAL
The fuel supply valve is located on the underside of the WARNING
fuel tank. The gasoline supply to the carburetor Is shut
off when the handle Is In the horizontal poSition. Turn· Gasoline Is extremely flammable and highly exploslye
ing the handle down to the vertical position turns on the under certain conditions. Do not smoke or allow open
main supply. Turning the handle up to the vertical posi- lIame or apar1l:s anywhere In the area when r.fuellng or
tion turns on the reserve supply. Valve should always be servicing the fuel system.
in the OFF position when the engine is not running.
1. Remove the luel hose at the carburetor and drain the
gasoline Into a proper, clean container.
1979·1981 2. Turn the fitting and remove the valve assembly.

Gasoline
strainer
Handle position for
reserve supply on
CLEANING, INSPECTION AND
REPAIR
1. Clean or replace the filter strainer located on top of
~,lt--- Fitting the gas valve.
2. Flush the tank to remove all dirt.
Handle In
off position INSTALLATION
1. Coat the valve threads with Locute PIPE SEALANT
WITH TEFLON and tighten IllIIng .
Figure 4-24. Fuel Supply Valve 2. Connect the hose to the carburetor.
4-'9
FUEL TANK
GENERAL CLEANING, INSPECTION AND
REPAIR
The fuel tank is a one piece welded lank, manufactured
in several different configurations. 1. Clean the tank interior with commercial cleaning
solvent or a soap and water solution. Plug the tank
The tank interior is treated to resist rusting. However, if openings and shake the tank to agitate the clean·
the motorcycle Is to be stored for a long period of time, ing agent. If necessary, soft metallic balls or
the tank should be drained and the interior treated with pellets may be added to the tank to assist in
a one-Io-one oil/fuel mixture. This will protect the lank loosening depOSits.
during storage.
2. Flush the tank thorougly after cleaning and allow it
NOTE to air dry.
To be sure the filler cap is securely fastened to the tank WARNING

on 1983 and later models, turn the cap until at feast
three clicks 8re heard. If all traces of fuel are not purged, an open flame may
result In 8 tank explosion.
3. Where applicable, inspect the interconnect line

REMOVAL and fu el line tor cuts, cracks or holes. Replace
lines as needed.
The fuel tank is secured to the frame with screws,
washers, spacers, and locknuts at the front, and with a 4. Inspect the rubber mounts and bumpers for wear
screw, washers and nut, spring and clip or a strap at the and deterioration. Replace as needed.
rear. See Figure 4-25 for typical mounting hardware.
WARNING
INSTALLATION
Gasoline Is extremely flammable and highly explosive
under certain conditions. Do not smoke or allow open 1. If removed, install the fuel valve, then position the
flame or sparks anywhere In the area when refueling or fuel tank on the motorcycle. Make sure the wiring
servicing the fuel system. harness does not get pinched between the tank
and frame.
1. Remove the fuel line from the carburetor and drain
the fuel from the tank into a clean container. 2. Install the front and rear mounting hardware.
Remove the fuel supply valve if necessary to Tighten the mounting screws (with locknuts) to 19
facilitate cleaning and repair. See FUEL SUPPLY ft·lbs torque.
VALVE.
3. Where applicable, install the interconnect line us·
2. See Figure 4-26. On 1983 and later XLS models on- ing new clamps.
ly, remove three screws from the center panel,
disconnect the tachometer, remove the filler cap 4. On 1983 and later XLS models, connect the
and lift the center panel from the tank. Also tachometer electrical leads to the tach after posi-
remove the interconnect line, discarding the tioning the tachometer in the center panel. Posi-
clamps. tion the center panel on the fuel tank and secure it
with the three screws.
3. On all models, remove the front and rear mounting
hardware and remove the tank trom the motorcy- 5. Connect the fuel line to the carburetor using a new
cle. Discard the locknuts. clamp, then refuel the tank and check for leaks.
4·21
~10
3
I 4 ~11 ~
i "'~
I l1A~
13~
I
I
~
1. Fuel tank 10. Strap end

2. Nut 11 . Strap
3. Washer 12. Nut
4. Bolt
5. Bolt
13. Bumper strip
14. Clip ~14
~ 15
6. Washer 15. Spring
7. Spacer 16. Bolt
8. Nut 17. Washer
9. Fuel tank 18. Well nut
Figure 4·25. Typical Fuel Tank Mounting Hardware
4·22
""
Interconnect
Q}bQ} ~
Mounting tab / ~
~
\!i
Figure 4-26. Fuel rank Mounting - 1983

and leter XLS Models
4-23
CARBURETOR
(XR·1000)
specified in this section may be in violation of Federal
GENERAL or State regulations.
Fuel Supply
(Figure 4-27)
The carburetor is a horizontal , slide valve type with a
float operated inlet valve, an accelerating pump, a throt- OPERATION
tle stop screw for idle speed adjustment and an inde-
pendent starting circuit for cold starts. The carburetor
is gravity fed. Fuel Supply
(Figure 4-27)
The carburetor has been specifically designed to con-
trol exhaust emissions ..AII jets are fixed. The idle mix-
ture has been preset at the factory. Fuel from the gas tank flows through the inlet banjo fit-
ting and filter, past the inlet valve and into the float
CAUTION chamber. The fuel entering the chamber causes the
float to rise until it closes the inlet valve, stopping fuel
Adjusting mixture setting by procedures other than flow at a pre-determined float level setting.
Air - Blue
Fuel - Red
Fuel inlet
Vent passage ----+J!I .""r- Fuel filter
'-'~--Inlet valve seat

Fuel level ----Inlet valve needle
- - - - Float fork
Float
Float chamber
Figure 4·27. Fuel Supply
4·25
Starting Device (Choke) knob is rolated further and returns to the closed posi-
(Figure 4·28) tion. With the engine cranking, vacuum in the main bar-
rel (venturi) downstream from the throttle slide draws
The starting device is an Independent circuit, consisting the starting air/fuel mixture from the starter fuel
of a starter knob, starter valve, emulsion tube, starter passage. The mixture combines with additional air in
jet, and passages in the carburetor. The air/fuel mixture the starter air passage, then is delivered to the main
Is delivered directly to the main barrel (venturi), bypass- barrel.
ing the carburetor main supply system.
The starter valve is opened by lifUng the starter knob The slarting mixture is formed by fuel metered through
and rotating it slightly clockwise or counterclockwise. the slarler jel mixed with air from the float chamber and
The valve will remain in the raised position until the atomized through the emulsion tube holes.
Air - Blue
Fuel - Red
Slide closed
Starter valve ~~t:::::.::::::,::;!.. Main barrel
Starting mixture
delivery port
Starter air passage
rr~~;;~~;;;;;:;==F:::S:~ Starter jet air passage

Starter fuel pas",a.'/
Emulsion tube
Starter jet ----lIL~
Figure 4·28. Starting Device
4·26
Idle Circuit Fuel metered through the Idle jet and air metered
through a calibrated passage mix and are drawn into
(Figure 4-29) the main barrel. The idle mixture is pre-set at the factory
and is non-adjustable.
The idle circuit functions at idle and low speeds and
also during the transition from idle mixture del ivery , to
the beginning of delivery from the high speed circuil.
Idle speed Is controlled by the idle speed adjusting
At idle speed , weak vacuum on the upstream side of the screw. Turning the screw clockwise raises the thrott le
throttle slide is insufficient to activate the high speed slide sligh tly, allowing more air to enter the main barrel
circuit. Greater vacuum on the downstream side of the increasing speed . Turning the screw counterclockwise
slide will draw the mixture from the idle mixture delivery lowers the slide, decreasing speed .
port.
Air - Blue Throttle slide

Fuel- Red
Air Fuel Milc:ture - Purple
Idle speed screw
Throttle slide
Idle speed screw
Idle mixture
delivery port
Idle air passage
L-...,."-------- Low speed jet
Figure 4-29. Idle Circuit
4-27
Mid·Range
(Figure 4·30)
As the throttle slide opens, the increased ai r flow into
the main barrel req ui res that more fuel be made
available. Some of the ai r /f uel mixtu re is drawn into the
main barrel th rough the progression delivery port. This
port is Immed iately upstream from the throttle slide
closing edge and will supply the additional airffuet mix-
ture needed until the main circuit is activated .
Air - Blue
Fuel - Red
Air Fuel Mix ture - Purple
Throttle slide
Progression
delivery port
Idle mixture
delivery port
Mixture passage
idle & progression
Figure 4·30. Mid·Range Circuit
4-28
High Speed Circuit the engine. The vacuum is sufficient to draw luel from
the atomizer jet.
(Figure 4-31)
The fuel metered by the mai n jet and further regulated
Following the progression or mid-range phase, on fur· by the atomizer jet is mixed with air from the air channel
ther opening of the throttle, the full throttle (high speed) and the main barrel. The atomizer outlet area depends
circuit is activated. A partial vacuum is created in the on the position of the tapered needle moving through
main intake due to the speed of the air being drawn into the outlet.
Air - Blue
Fuel - Red
Atomizer needle
Main barrel
Atom~:-~~~~~~~~
Air channel
Mainjet
Figure 4·31 . High Speed Circuit
4-29
Accelerator Pump Slow Idle Adjustment
(Figure 4-32)
With the engine operating at normal operating
The accelerating pump system uses sudden throttle temperature and the starting devices (choke) in the
openings (rapid acceleration) to inject fuel into the car- closed position, turn the idle speed adjusting screws on
buretor for rapid acceleration. each carburetor clockwise to increase speed or
counterclockwise to decrease speed until the engine
When the throttle slide is opened, the cam follower lever idles at 900 - 950 rpm_
rides up the cam and acts directly on the pump dia-
phragm. The diaphragm, through the delivery valve and
pump jet , pumps fuel into the main barrel upstream of Float Level Adjustment
the throttle slide. When the throttle is closed, the dia- (Figure 4-33)
phragm returns to its original position and draws fuel
from the float chamber through the inlet valve.
1. Remove the carburetor as described in t~
REMOVAL section.
ADJUSTMENTS 2. Remove the float bowl nut ana Tloat bowl.
3. Place the carburetor on a flat, level surface, air in-

Low Speed Mixture Adjustment take side down.
The low speed mixture adjustment is set at the factory 4. With the needle valve seated, measure the dis-.
and is non-adjustable. tance from the float bowl gasket surface to the
Air - Blue
Fuel - Red
Air Fuel Mixture - Pu rple
Pump diaphragm - -__

Spring ------.l
Volume adj. screw
Delivery valve Actuation cam
Cam follower
Throttle slide
~:::::::j
Pump jet -''-_...J
Inlet valve
Figure 4·32. Accelerator Pump
4-30
edge 01 the float. If the dimension is not within
specified range, bend the float arms until the cor-
rect reading is obtained.
5. Assemble the float bowl to the carburetor body

and secure with nut.
6. Install the carburetor on the motorcycle as "de-

scribed in the INSTALLATION section.
0.69 . 0.73 inch

(17.5 - 18.5mm)
\
o Figure 4-34. Carburetor Synchronization
CAUTION
Throttle cable adjusting screws and locknuts are del-

icate parts. Handle carefully. Loosen adjusting screw
Table surface only 2 or 3 turns.
Figure 4-33. Float Adjustment 4. If necessary turn the idle setting adjusting screws
on both carburetors in or out to provide an idle
speed of 900 - 950 rpm.
Accelerator Pump
5. If using Carb·Stix, remove the rubber cap plugs
The amount of fuel injected by the accelerator pump
from the vacuum ports on the engine side of the
may be changed by loosening the locknut and turning
carburetors. Connect the Carb·Stix tubes to the
the adjusting screw counterclockwise to increase the
vacuum ports. Adjust the idle speed adjusting
fuel amount or clockwise to decrease the fuel amount.
screws to obtain equal readings within 2 em. of
mercury (one scale graduation) at 900 - 950 rpm.
Carburetor Synchronization Clockwise rotation of the screws lowers vacuum
reading and increases speed.
Synchronization is achieved by measuring the vacuum
in each carburetor velocity stack using MULTIPLE CAR- 6. If using the Synchronizer, place the flat circular
BURETOR SYNCHRONIZER, Part No. HD-23433, Figure end of the tool against the front carburetor velocity
4-34, or a manometer (such as Carb-Stix), then adjusting stack. Observe the rise of the float in the tube and
the throttle slides until the vacuum measurement is the note the level.
same for each carburetor. A float in a tube on the tool or
the mercury height in the manometer, provides a visual 7. Place the Synchronizer against the rear carburetor
indication of the amount of vacuum. velocity stack. Observe the rise of the float in the
tube and note the level. If the float rises in the tube
1. Run the engine at idle until it reaches normal to the same level for both carburetors, the car-
operating temperature. Be sure the cold starting buretors are synchronized at idle. If the float does
device (choke) is in the closed position when the not rise to the same level at idle, turn the idle set-
engine is warm. ting adjusting screw (1) on the rear carburetor in or
out until the float is at the same level as for the
2. If using the Synchronizer, disconnect the front carburetor. This indicates the throttle slide
crankcase vent hose from the rear air filter, then height is the same for both carburetors.
loosen each air filter clamp and carefully remove
the air filters. If using Carb·Stix, air cleaners can 8. After synchronization is achieved, turn each idle
remain on the carburetors. setting adjusting screw an equal amount until the
3. Loosen the locknuts where the throttle cables engine is idling at 900-950 rpm. Recheck the syn-
enter the top of the carburetors. Turn the adjusters chronization with the Synchronizer tool.
clockwise to give free play to the cables. Maintain
a 0.06 in. gap between the adjusting screw hex· 9. Increase the engine speed to 2500 rpm and lock the
agon and the locknut. throttle by tightening the throttle tension screw.
4-31
CAUTION
Increase or decrease engine speed slowly. Rapid throt·

tie movement may provide sufficient vacuum to pull
mercury from the Carb·Stix tubes into the engine.
10. Check synchronization of carburetors as described
in Steps 5 through 8. If Carb-Stix mercury column
heights or synchronizer float levels are not equal, ad·
justment is made at the cable adjusters (2).
11. Adjust the carburetor with the higher vacuum

reading' by rotating the cable adjuster screw coun·
terclockwise until the synchronizer float levels are
the same, or the Carb·Stix mercury columns are
within 2 cm .
12. Loosen the throttle tension screw and slowly reo

turn the throttle to idle.
13. Slowly increase engine speed to 2500 rpm and reo

check synchronization. Readjust if necessary.
CAUTION
Throttle cable adjusting screws and locknuts are del ·

Icate parts. Handle carefully and do not overtighten.
14 Recheck synchronization at idle speed following Figure 4·35. Carburetor Removal

steps 5 . 8. Repeat if necessary.
1. Remove the air cleaners (6) from the carburetor.
15. Slowly increase engine speed to 2500 rpm, reo
checking synchronization and readjusting cables 2. Make sure t he fuel supply valve (1) is in the OFF
as needed . position, then disconnect the fuel tine at the car·
buretor banjo fitting (2).
16. Continue recheck procedures unti l synchroniza·
tion is achieved both at idle and at 2500 rpm. 3. Loosen the cable adjuster locknut (3) then turn the
adjuster all the way into the slide cover (5).
WARNING
4. Loosen the slide cover screws until the sl ide cover
After synchronization is obtained, be sure the throttle (6, Figure 4-36) is free. Remove the slide assembly
friction screw Is loosened enough to permit free throttle (items 2, 3, 5, 7, 8, 9, 10, and 12) as a unit from the
grip rotation. carburetor. Refer to DISASSEMBLY section for
removal of the slide assembly from the motorcy·
17. Adjust the throttle cable free playas described in cle.
Section 2. Sufficient free play should be available
to prevent putting pressure on the carburetor 5. Loosen the intake manifold hose clamp (4, Figure
slides by the cable when the hand lebars are turned 4·35) and slide the carburetor from the manifold .
to the right and left stops.
18. Stop the engine and carefully instatl the air filters,
DISASSEMBLY
if needed. Make sure the worm drive clamp is (Figure 4·36)
secured but not cutting i nto the rubber sleeve on
the filters.
Accelerator Pump
19. Connect the crankcase vent hose to the rear air
fi lter. 1. Remove the three screws (49) and washers (50)
secu ring the accelerator pump cover (54) to the
20. If removed, install vacuum port rubber cap plugs . carburetor body (58).
2. Remove the diaphragm (55) and remove and dis·

card gasket (56).
REMOVAL
3. If necessary, remove the delivery valve (53) from
(Figure 4·35) the cover (54). Remove and discard gasket (52).
4·32
\,~=--
0 -34
~-35
38. Adapter
39. Idle speed jet
19. Sp'
20 Idle s peed screw 40. Accelerator p
41. Main jet at/u,m inlet valve
1. Vent tube • r ng
2. Spring 21. Washer 42. Startl ng m zer
43. o.rlng device Jet
3. Cam follower 22. 0·rlng
:: ~:~r1lng device 23. Filter disc 44. Rubber sle8ve
24. Banjo fitting 45. Air Intake
~: ;~'::gassembly 25. Gasket 46. Clamp
26. Screw 47. locknut
8. Plate 27. Gasket 48.
49. Accelerat
50 Screw or pump adjusting screw
9.0·rlng ~. ,'",let valve seat
10. Slide
30· F'
n at need'e valve . WasheT
11.0·rlng · oat 51. Gasket
12.
13 Tape
H rad needle 31 . Gasket 52. Gasket
14' I OS8 clamp 32. Float bowl 53. Delivery valve
33. Shaft
15: ~:~.c'::.,:lfOld hose 54. Cover
34. Gasket 55. Diaphragm
16. Clamp P 35. Nut 56. Gasket
17. Fuel lin. 36. Air filteT 57.
58. Aceelerat
Body or pump jet
18. Clamp 37. High speed jet
Figure 4·36 . Carburetor
4-33
4. Remove the pump jet (57) from the carburetor body (58). Throllle Slide
1. Thoroughly clean the slide (10) and tapered needle
Float Chamber (12) with solvent.
1. Remove nut (35), gasket (34), float bowl (32) and gas- 2. Inspect the cam follower (3) for wear. Replace if
ket (31). Discard gaskets (31) and (34). needed .
2. Remove shaft (33), float (30) and needle valve (29).

Separate the needle valve from the float. Carburetor Body
1. Clean the carburetor body in a cleaning solvent
Throttle Slide such as GUNK to remove varnish and carbon from
the fuel and air passages. Slow dry w ith com-
1. Compress the spring (7) between the cover (6) and pressed air. Reverse the air flow through all
the slide (10) until the throttle cable can be discon- passages to remove all dirt particles.
nected from the slide. The cable remains on the
motorcycle. CAUTION
2. Hold ing the slide (10) and cover (6) allow the spring Never scrape carbon deposits from the carburetor using
(7) to extend to its free length . steel intruments. Do not use wire or drills to clean
passages. Anyone of these things can change the size
3. Remove the spring (7), plate (8) and tapered·needle (12). of the passage holes or alter the carburetor. Do not use
carburetor cleaner on rubber or plastic parts.
4. Remove the cover (6) from the adjuster. Remove
and discard cover O-ring (11). 2. Clean the inlet filter disc (23) with solvent and blow
dry with compressed air. Replace filter if damaged .
Carburetor Body 3. Replace any damaged parts showing an excessive

wear pattern.
1. Remove the banjo fitting (24) and filter screen (23).
2. Remove fuel inlet valve seat (28) and gasket (27) on- ASSEMBLY
ly if replacement is necessary.
3. Remove the id le jet (39), main jet (37), atomizer (41), Carburetor Body
starting device jet (42), accelerator pump inlet
valve (40), idle speed adjusting screw (19), spring 1. Install the idle jet (39), atomizer (41), main jet (37)
(20), washer (21), and O-ring (22) only if necessary
and starting device jet (42) if removed.
for cleaning or replacement.
2. Install the accelerator pump inlet valve (40).
4. Remove the starting device (4).
3. Install the accelerator pump jet (57). The flat sur-
face on the jet must mate with a flat surface in the
bore before assembly is possible.
CLEANING, INSPECTION
AND REPAIR 4. Install the starting device (4) if removed.
5. Place the filter disc (23) in its bore. Install the banjo
Accelerator Pump fitting (24) so the hose stem is approximately 45 0
from vertical towards the intake manifold hose

1. Inspect the diaphragm (55) tor holes, deterioration connection.
or other damage and replace as needed .
6. If removed , install the idle speed adjusting screw
2. Clean the passage in the delivery valve (53) if needed. (19), spring (20), washer (21) and O-ring (22). Turn
the screw in several turns.
Float Chamber
Throtlle Slide
1. Clean all dirt from the inlet needle valve (29) and
valve seat (28). 1. Install a new cover O-ring (11) in the slide cover (6).
2. Check the float for damage. Replace if necessary. 2. Install the slide cover (6) on the cable adjuster
4·34
which is on the motorcycle. Turn the cable adjuster 2. Position the diaphragm (55) on the locallng pins.
all the way into the cover.
3. install the cover (54) and secure with screws (49)
3. Assemble the tapered needle (12) in the slide (10). and washers (SO).
4. Position the spring (7) on the cover (6). Compress 4. II removed, Install the delivery valve (53).
the spring making sure the throttle cable goes
through the center of the spring.
INSTALLATION
5. Slide the plate (8) onto the cable and against the
spring. 1. If removed, Install the intake manifold hose (14) on
the carburetor main barrel , and secure with hose
6. Install the cable end in the key slot in the bottom of clamp (13).
the slide (10). Push the tapered needle (12) upward
to engage the mating hole in plate (8). 2. Slide the Intake manifold hose onto the Intake
manifold. The hose must be installed to the 'X'
7. Slowly release the spring (7) making sure the plate stamped on the manifold. Secure the hose with
is positioned properly in the slide (10). clamp (15).
3. Position the slide assembly In the slide bore and

Float Chamber compress the spring so the cover is on the car-
buretor body. Check for free movement of slide. If
1. Assemble the needle valve (29) to the float (30). slide does not move freely, the cam follower may
be binding. Allow the cover to rise Slightly then
2. Position the 110at in the carburetor body and push it down again. When free slide movement is
secure with shaft (33). attained tighten the cover mounting screws.
3. Install a new gasket (31) in the float bowl (32) 4. install air filter (36) and secure with clamp (46).
recess. Position the bowl on the body and secure
with nut (35) and new gasket (34). 5. Adjust carburetors as described In AOJUST-
MENTS section.
Accelerator Pump WARNING
1. Position new gasket (56) on the locating pins on After adjustment, be sure the throttle friction screw is
the carburetor body. loosened enough to permit free throttle grip rotation.
4-35
AIR CLEANERS
(XR-1000)
GENERAL
The one piece wet type air fil ter elements trap airborne
dust and dirt, to prevent their ent ry In to the carburetor
and engine. Remove the air filters and service them every
2500 miles, more often under dusty road conditions.
SERVICING AIR CLEANERS

(Figure 4-37)
1. Disconnect the crankcase breather hose at the
rear air filter.
2. Loosen the clamp and carefully remove bot h t he

rear and Iront air fitter elements. 2. Air filter
Figure 4·37. Ai r Cleaners
3. To clean fllter, roll it in a shallow amount of filter
cleaner/degreaser (3/4 the depth of one pleat). Do
not lei dirty solution run to inside of filter. Let fi lter INSTALLATION
sit for 5 minutes to dissolve dirt. From the inside
out, rinse the filter with cold water. Shake and 1. Install the air filters on Ihe carburetors and secure
allow to air dry. Do not use air hose! with clamps. Be sure the worm drive clamps are
secure, but not culling Into the rubber sleeves on
4. Ae-oil filter using Air Fi lter Oil. Apply along the full the Illters.
length of each pleat and allow to set untilihe ele-
ment Is a uniform color_ Allow excess 011 to drain 2. Connect the crankcase breather hose to the rear
oft. air fi lter.
4·37
FUEL SUPPLY VALVE
(XR-1000)
GENERAL
(Figure 4-38)
Gasoline
The fuel supply valve Is located under the right side of strainer
the fuel lank. The gasoline supply to the carburetors Is Handle position for
shut off when the handle is in the horizontal position. reserve supply on
Turning the handle down to the vertical position turns
on the main supply. Turning the handle up to the vertical
position turns on the reserve supply. Valve should
always be in the OFF position when the engine is not
running.
REMOVAL
WARNING
Handle position lor
Gasoline is extremely flammable and highly explosive main supply on
under certain conditions. Do not smoke ao allow open
flame or sparks anywhere In the area when refueling or
servicing the fuel system. Figure 4-38. Fuel Supply Valve
1. Remove the fuel hoses at the carburetors and drain
the gasoline into a proper, clean container.
2: Flush the tank to remove all dirt.
2. Turn the fitting and remove the valve assembly.
CLEANING, INSPECTION INSTALLATION

AND REPAIR 1. Coat the valve threads with Loctlte PIPE SEALANT
WITH TEFLON and tighten fitting.
1. Clean or replace the filter strainer located on top of
the fuel supply. 2. Connect the hoses to the carburetors.
4-..
FUEL TANK
(XR·1000)
GENERAL
The fuel tank is a one piece welded tank. The fuel tank is
treated to resist rusting. However, when the motorcycle
is not operated for a lone period 01 time, tanks should
be drained and treated with an oil/fuel mixture of equal
proportion. This will protect the inside of the tank while
the motorcycle is stored.
NOTE
Be certain the filler cap is securely fastened to the tank.

Turn the cap until at least three clicks are heard.
REMOVAL
WARNING
Figure 4-39. Fuel Tank Mounting
Gasoline Is extremely flammable and highly explosive
under certain conditions. Do not smoke or allow open
flame or spar1ts anywhere in the area when refueling or WARNING
servicing the fuel system.
It all traces of fuel are not purged, an open flame repair
1. Place a suitable, clean container beneath the car- may result In a tank explosion. Extreme caution should
buretors. be taken when repairing tanks.
2. Disconnect the fuel lines at the carburetors, then

turn the gasoline supply valve to the "ON" position
and allow the tank to drain. INSTALLATION
3. (See Figure 4-39). Remove the locknut, screw, and Position the fuel tank on the motorcycle, then
washers at the rear of the tank. loosely Install the rear mounting screw, washer
and locknut.
4. Remove the nut, washers, spacer and bolt from the
front of the tank. The Ignition coil and cable drum 2. Start the front mounting screw through the horn
bracket and horn bracket also mount on this bolt. bracket, spacer, fuel tank and the ignition coil and
cable drum bracket. Be sure the external tooth
lockwasher Is between the screw head and horn
bracket. Install and tighten the locknut.
REPAIR
3. Tighten the rear locknut.
Many tanks can be repaired by arc welding, gas welding
or soldering . Only people trained in this type of work 4. Connect the fuel lines to the carburetors, then
should be allowed to make any repairs. refuel the tank and check for leaks.
...,
EVAPORATIVE EMISSIONS CONTROL
1985 CALIFORNIA MODELS ONLY
General
(Figure 4·40) 10
~~~
All 1985 model year Harley-Davidson motorcycles sold
in the state of California are equipped with an evap-
orative emission control system. This system is de-
signed to meet the CARB regulations in effect al the
time of manufacture.
if XLS
The system is virtually maintenance free. All that should
only . /4
be required is periodic inspection to be sure hoses are
properly routed and not kinked or blocked and that all
fittings are secure. Mounting hardware should also be
checked for tightness.
The purpose of the evaporative emissions system is to

prevent fuel hydrocarbon vapors from escaping into the
atmosphere. When the engine is not running, any pres-
surized build-up of hydrocarbon vapors are directed
through the vapor valve and stored in the charcoal can-
ister. At engine start-up, a vacuum line from the carbur-
etor will purge or draw off the vapors in the canister and
direct them to the engine combustion chambers, The
vapor valve prevents gasoline from escaping through
the vapor vent when the vehicle is tipped at an abnormal
angle. A large diameter hose purges the canister with
fresh air from the air cleaner through the air cleaner
backing plate.
1. Canister 8. Hose, _235 10
2_ Down tube 9. Hose, .500 10
3. Ty·wrap 10. Gas tank
Canister Mounting 4. Vapor valve 11. Hose clip
(Figure 4·41) 5. Air cleaner 12_ Backbone tube
6. Carburetor 13_ Coil bracket
The canister is mounted to the left frame down tube. 7. Hose, .190 10 14. Hose clip
CAUTION Figure 4·40. Evap_ System

Hose Routing
Be certain to mount the canister in the location speci-
fied. The canister must be mounted below the carbur-
(Figure 4·40)
etor for the system to be operational.
1. See Figure 4-40. Push hose clip (11) around right
hand downtube. Push hose clip (14) around left
hand downtube.
Vapor Valve Mounting 2. Take large diameter pre-formed hose and push end
(Figure 4·42) with large radius bend over fitting at bottom of
canister. Bring hose across to right and left down
The vapor valve is mounted to the right frame down tube attaching hose to hose clips (11) and (14).
tube. Connect free end of hose to the fitting installed at
air cleaner. Do not cut hose. Reconnect air cleaner
CAUTION vent hose and secure with new hose clamp.
The vapor valve must be maintained in an upright at· CAUTION

titude and the proper end must be towards the top or ex·
cessive fuel tank pressures may occur. Do not tighten Ty-wraps to the point of collapsing hoses.
4-43
8
4 5
1
@
IT ~
~o
1f1
~I
. 6
\
I
~---)
,,,
'
5 I '
~/
1 :
4 1
lr !1'Q~i~
/ f~~_4:
i
5
131~
"o .. iTI 1. Bolt
2. Washer
3. Vapor valve bracket
4. Clamp
5.
6.
7.
8.
Vapor valve
Bolt
Nut
Washer
1. Down tube clamp 5. Washer
2. Canister bracket 6. Canister Figure 4·42. Vapor Valve Mounting
3. Rubber mount 7. Fitting (carb.) over fitting at top of canister labeled "tank". Lead
4. Nut 8. Fitting (tank) hose (7) under hose (9) and across to right hand
down tube. Secure hose (7) to hose (9) with ty-wrap
Figure 4·41. Canister Mountmg (3). Bring hose up to bottom of vapor valve (4) and
cut to length. Push free end of hose over lower fit·
3. Take hose (8) and push one end over fitting at top ting on vapor valve (4).
of canister labeled "carb", Lead hose up through
coil bracket (12) and under backbone tube (12). Se· 6. Take remaining hose and attach to top of vapor
cure hose to backbone with two ty-wraps (3) can· valve. Bring hose up to gas tank vent tube and cut
nected end to end. Bring hose up to carburetor to length. Push free end of hose on tank filling.
purge fitting. Be sure not to kink hose. Push free
end of hose over carburetor purge fitting.
NOTE
4. Connect fuel line to carburetor and secure with
hose clamp from kit. On XLX and XLH tanks, vent tube is on the bottom of the
gas tank. On the XLS, tank vent tube is at gas tank filler
5. Take small diameter hose (7) and push one end neck and hose is routed up front of tank under console.
4·44
SUBJECT PAGE NO.
1. Elect ri c Starter System 1979 - 1980 . . . . . . . . . . . . . . . . . . . .......... 5-1

2. Electric Starter System 1981 . 1985 . . . . . . . . . . . . . ............ 5·9
3. Electric Starter System XA·1000 ........•.. . . . .. . ........... 5·17
ELECTRIC STARTER I
ELECTRIC STARTER SYSTEM
1979·1980
NOTE switch. Check each switch using a Jumper to by·
pass the switches, one at a time.
Kick starter information can be found in TRANSMIS-
SION Section 6. 4. Excessive friction in the engine caused by tight
bearings, tight pistons or too heavy oil makes the
engine harder to turn over. If the engine is in good
SPECI FICATIONS condition and all else checks okay, the trouble Is in
the starter motor.
Starter
STARTER RELAY
Free speed. .. 10,000 rpm (min.) @ 10.DV
Free current. .. ..... .. 45 amp (max.)@ 10.DV The starter relay is a non·repalrable part and must be
Stall current .300amp@4.0V replaced if it is not functioning.
Stall torque. ............. 3.2 fI·lbs@4.0V
Figure 5-1 shows a test circuit using a 12-volt battery
and stop lamp bulb. Contacts should close and bulb
DESCRIPTION should light when connection is made at positive post
of ballery and should go out when connection is broken.
The starter motor is a l2·vall, 4-pole drive motor. The
starter engages the clutch ring gear through a Bendix
drive and a reduction gear unit. A solenoid relay pro- 1979
vides battery current directly to the starter. The solenoid
is controlled by the starter button on the handlebar.
Small
terminal -;:O-lo~JI
NOTE
Never operate the starter motor continuously for more

than 30 seconds without pausing to let it cool for at
least two minutes. The starter can be seriously damag· '2V
ed if run for long periods of time. bulb
TROUBLESHOOTING
If the starter motor fails to operate properly, the follow· 1980
ing checks should be made before removing the starter
86
for inspection.
1. Make sure the mounting and wiring connections are

tight and in good condition. The solenoid switch
should be firmly mounted and all wiring connections
shOuld be clean and tight.
2. Check the battery state of charge. See the BATTERY

Section. If the battery is charged and full voltage is
reaching the starter, the trouble is In the engine or
the starter motor.
3. If the battery is charged but there is no current flow

to the starter, check the handlebar starter switch, Figure 5·1. Starter Relay Internal Wiring
RUN·OFF switch, starter relay or the solenoid Diagram and Test Circuit
5·'
STARTER MOTOR (8) and brush holder (4),
Removal Cleaning, Inspection And Repair
WARNING FRAME AND FIELD ASSEMBLY
Disconnect battery cables (negative cable first) to avoid Test the frame and field assembly using a continuity
accidental start-up of vehIcle and possible personal in· tester.
jury.
1. Place one probe of the tester against frame while
1. Remove starter end cover and end cover bracket. placing the other probe against each of the brushes
attached to the field calls.
2. Remove starter motor cable.
2. If either one of the brushes Indicates an open circuit,
3. Remove starter thru bolts. the entire frame and field assembly must be re-
placed.
4. Grasp starter by front and rear end covers, to pre-
vent starter from coming apart, and remove starter. ARMATURE
Disassembly 1. If the armature commutator Is dirty use No. 00 sand·

(Figure 5-2) paper - not emery cloth - to clean It.
2. If commutator Is worn, out of round or has high mica

1. Remove thru bolts (1) washers and lockwashers (2). Insulation between segments, commutator can be
turned down in a lathe.
2. Remove end cover (3).
If the commutator Is badly out of round due to burn·
3. Remove end cover (6), beari ng (7) and armature (5) as ed bars, Indicating open windings, replace the ar·
an assembly. mature.
4. Move brushes (10) out of the way and remove springs 3. If the mica insulation is high between segments, use
1. Thru bolt 7. Drive end ball bearing

2. Washer and lockwasher (2) 8. Brush spring (4)
3. Commutator end cover 9. Terminal and brush assembly
4. Brush plate and holder assembly 10. Ground brush (2)
5. Armature 11. Frame and field coli assembly
6. Drive end cover 12. Cover bushing
Figure 5-2. Starter Motor
5-2
Commutator ~J~~~~== Commutator
Starting groove in mica Undercutting mica with piece
with 3 cornered file of hacksaw blade
Mica ~segments~. Mica
~~;~ ~~:~
Mica must not be left Mica must be cut away J
with a Ihin edge next clean between segments:
to segme nts
Figure 5-3. Recessing the Mica Separators
an undercutting machine to undercut the mica 1/32

in. deep. The slots should then be cleaned to remove
any dirt or copper dust.
If an undercutting machine Is not available, under

cutting can be done satisfactorily using a thin
hacksaw blade. See Figure 5-3. After undercutting,
lightly sand the commutator with No. 00 sandpaper
to remove any burrs.
4. Inspect the bearing (7, Figure 5-2). If it is worn or

loose, replace II.
5. If cover bushing (12, Figure 5-2) Is worn, cover must

be replaced .
BRUSHES
The brushes should be replaced If they are worn close
to 114 in. minimum. Harley-Davidson BRUSH REPLACE· Figure 5-4_ Brush Identification
MENT KIT, Part No. 31541-06, is available from the fac·
tory. Always replace brushes In sets of four.
1. See Figure 5-4. Two of the brushes (2 and 4) are at-

tached to the terminal. To replace these brushes,
remove the terminal assembly and slide the new
assembly on the frame.
2. See Figure 5-4. The other two brushes (1 and 3) are

attached to the field calls. To replace these brushes,
cut the old brushes and leads about 1/2 In. from the
field calls. Solder the new brushes In place making
3
sure the new brushes are in the same position as the
old ones.
Assembly
1. See Figure 5-5. Place the brush holder on the frame
and position the brushes as shown. The holder has a
notch that must line up with the terminal. Figure 5-5. Installing Brush Holder
5-3
""
1. Notch 2. Ridges
Figure 5·6. Holding Brushes in Brush Holder Figure 5·7. Starter Motor Assembly
2. See Figure 5-6. Insert the springs and brushes in the Installation
holder and use clamps to hold them in place while (Figure 5-2)
Installing the armature.
1. With thru bolts installed through starter, install
3. See Figure 5-2. Install the armature (5), bearing (7) starter to housing with terminal to the front. Tighten
and drive end cover (6) as an assembly. Install the thru bolts to 60-80 In·lbs torque.
commutator end cover (3).
2. Install battery cable to starter terminal, tighten
4. See Figure 5-7. The drive end cover has a lip (1) that starter terminal nut to 65·80 in·lbs torque.
must register in a notch on the frame assembly. The
commutator end cover has two ridges (2) that must 3. Install starter cover bracket and starter cover.
line up with the terminal.
5-4
SOLENOID 12V test light
(21 C.P.)
General
See Figure 5-8. The solenoid switch is designed to open
and close the circuil electromagnetically. The switch
consists basically of contacts and a winding around a
hollow cylinder containing a movable plunger. When the
winding is energized by the battery, the magnetism pro-
duced pulls the plunger into the coil. The plunger moves
against two main switch contacts, closing the circuit.
Testing The Solenoid Figure 5·9. Test Circuit for Solenoid
It is not necessary to remove the solenoid to test for

continuity. Use the following procedure:
Removal
WARNING WARNING
Disconnect the battery cables (negative cable first) to Disconnect the battery cables (negative cable first) to
prevent accidental start up of vehicle and possible per· prevent accidental start up of vehicle and possible per·
sonal injury. sonal injury.
1. Disconnect wires from solenoid. 1. Remove the nuts and disconnect the large battery
positive cable and starter motor cable.
2. See Figure 5-9. Connect a 12·Yolt battery to solenoid
terminals A and C. Use a jumper wire between the 2. Remove the nut and disconnect the small starter
plus battery terminal and solenoid terminal B. When relay wire.
connection is made a click should be heard, and if
used the test light should go on. If click or heavy 3. Remove the two mounting bolts and lockwashers.
spark at the terminal does not occur, the solenoid is Remove the solenoid along with the spacer, spring
shorted out and must be replaced. and felt gasket.
Starter motor Disassembly

terminal (Figure 5-10)
Pull·in coil.3 ..... 1. Remove the two co ....er mounting screws (I), raise the
cover (2) and remo ....e the gasket (3).
Starter relay
termln~m!C::~~~~;=-=-:! 2. If the studs are to be replaced, remo ....e the

Remove the stud (5) and copper plate (6).
nuts (4).
Remo ....e
stud (7) and stud (8) by culling the wires as close to
the studs as possible. Solder the wires to the new
Hold·ln coil .6""'- studs.
3. Remove the plunger assembly (9) and disassemble

as follows: Remove the small spring (10), coilar (11),
plastic washer (12), copper washer (13), seat (14),
Figure 5·8. Solenoid Internal Wiring Diagram large spring (15) and collar (11) from the plunger (16).
5·5
1. Screw and washer (2) 14. Seat
2. Cover 15. Spring (large)
3. Gasket 16. Plunger
4. Nut and gasket (3) 17. Solenoid
5. Stud (positive battery) 18. Felt gasket
6. Plate 19. Spring
7. Stud (starter relay) 20. Plunger (outer)
8. Stud (starter motor connection) 21. Pin (large)
9. Plunger assembly (Inner) 22. Rubber boot
10. Spring (small) 23. Spring
11. Collar (2) 24. Collar
12. Plastic washer 25. Pin (small)
13. Copper washer
Figure 5·10. Solenoid
Cleaning, Inspection And Repair 3, Replace the cover (2) and gasket (3) if cracked or
broken.
(Figure 5-10)
Assembly
1. If the copper washer (13) Is grooved or burnt on one (Figure 5-10)
side, turn it around on the plunger. This will double
the life of the washer. 1. lightly coat parts 11-17 with a brake type grease
such as lUBRIPLATE 110. Install the collar (11),
2. Replace the studs If they are pitted, corroded or large spring (15), seat (14), copper washer (13),
burnt. plastic washer (12), collar (11) and small spring (10)
onto the plunger (16). Insert the plunger assembly In· copper jaws In a vise and unscrew from shaft (22)
to the solenoid housing. which has a left hand thread. Remove bearing race
(17). Remove pinion and shifter collar assembly (18).
2. If the studs were removed Install them Into the cover Remove lock ring (19) to separate gear (20) and
and fasten them using the nuls (4). shifter collar (21).
3. Install the gasket (3) and cover (2) and fasten with 5. To remove starter shifter lever (25), It is necessary to
screws (1). either remove starter drive housing (26) or remove
battery and carrier to gain access to screw (24).
CAUTION Remove screw (24) and lever (25) from housing (26).
When Installing the cover, position the Internal wires so 6. Remove starter motor (30) and housing (26) as an
they do not Intertere with the copper washer travel. If assembly by removing two bolts and lock washers
wires are allowed to contact the washer, the wirelnsula· (not shown) from chain housing on left side of
tlon will eventually wear away causing the circuit to re· crankcase.
main constantly open.
Installation 7. Needle bearings (28) and (29) are pressed into hous·
ings at shaft ends. Washer (27) presses out with nee·
die bearing (28).
1. Install solenoid with felt gasket, return spring and
spacer.
2. Install the two moun ling bolts and washers.

Assembly and Installation
3. Connect battery cable to long solenoid stud, starter (Figure 5·11)
cable to short solenoid stud and relay wire to small
solenoid stud.
STARTER DRIVE SHAFT 1. Clean needle bearings (28 and 29) and repack with
grease. If replaced, needle bearing (28) should be
AND HOUSING pressed in flush with outside of housing. Stake
washer (27).
Removal and Disassembly 2. Pinion (20) and shaft (22) should be assembled with
(Figure 5·11) no lubrication on worm threads.
1. Remove solenoid. See SOLENOID Section. 3. Shaft nut (16) should be secured to shaft with
Loctite STUD N' BEARING MOUNT. Clean parts with
2. Remove clutch as described in CLUTCH cleaning solvent before applying adhesive to
OISASSEMBLY, Section 6. threads.
3. Rotate starter shifter lever (25) end forward and 4. Connect battery cable to longesl solenoid terminal
disengage lever fingers from pinion gear shifter col· stud.
lar (21). Pull pinion gear and shaft assembly (14) from
housing (26), then remove gear (23) from drive shaft. CAUTION
4. To disassemble pinion gear and shaft assembly (14), If cables are reversed, the solenoid will remain In
remove thrust washer (15). Place nut (16) between battery circuit.
I~J,r;: l 12 c/9 24
p~.",(' 11 ~ 25 6 4
~:o fjj.~
; ~ ;rJ,JI/
5
3 13
1. Cover I\----Y r
~.. ~- __
@'~23
~
22
2. Terminal nut and lockwasher (2)
3. Terminal nut and lockwasher
4. Retainer cap
30
26
28
r I (f;)
<'~1t
I!
----- ____ ,:?
'-
~
5. Pin ~
9 ~ <Ii "../15
6. Sp"ng 21 20 \, ~1.'!iCb--29
1. Boll and lockwasher (2) 18 ~7 16
8. Spacer bar
9. Boot
10. Gasket 17. Bearing race 14 24. Shifter lever screw
11 . Plunger 18. Pinion & shifter collar 25. Shifter lever
12. Plunger spring 19. Lock ring 26. Starter shaft housing
13. Solenoid 20. Pinion gear 27. Washer
14. Pinion gear and shaft 21. Shifter collar 28. Needle bearing
15. Thrust washer 22. Shaft 29. Needle bearing
16. Pinion shaft nut 23. Drive gear 30. Starter motor
Figure &11 . Starter Shaft, Housing and Solenoid
5..
1981 . 1985
DESCRIPTION clutch gear in the drive housing. The idle gear is sup-
ported by rollers and the clutch gear is part of the over-
The starter Is made up of an armature, field winding running clulchfdri ve assembly.
assembly, solenOid, drive assembly, idle gear and drive
housing. The overrunning clutch is the part which transmits the
rotational torque to the clutch ring gear. II also prevents
The armature speed is reduced by about one fourth the starter from overrunning, The field windings are con-
through gear reduction. The gear reduction consists of nected in series with the armature through brushes and
the drive pinion on the armature, and an idle gear and a commutator segments.
TROUBLESHOOTING
BASIC TYPES PLACE OF

PROBABLE CAUSE REMEDY
OF TROUBLE TROUBLE
Starter does not A. Starting 1. Poor contact condition or 1. Replace
run, or runs at switch or poor connection
considerably low starter
speeds. relay
B. Solenoid 1. Poor contact condition ,. Polish contact surface or
caused by burnt contact replace solenoid assembly
2. Contact plate removed 2. Repair
3. Pull-in winding open or 3. Replace solenoid assembly

short-circu ited
4. Hold-in winding open 4. Replace solenoid assembly
c. Starting 1. Poor contact condition of 1. Check brush spring

motor brushes tension
2. Commutator burnt 2. Correct on lathe or

replace
3. Commutator high mica 3. Correct by undercutting
4. Field winding grounded 4. Replace
5. Armature winding 5. Replace

grounded or shorl-circuit
6. Reduction gears 6. Rep lace

damaged
7. Insufficient brush spring 7. Replace

tension
B. Disconnected lead wire B. Repair or replace lead

between solenoid and wire
field windings
9. Ball bearing sticks 9. Replace bearing
5·9
BASIC TYPE PLACE OF
PROBABLE CAUSE REMEDY
OF TROUBLE TROUBLE
Pin ion does not D. Battery 1. Voltage drop due to 1. Charge battery
engage with ring discharged battery
gear while starter
is running, or 2. Short-circuited between 2. Replace battery
engine cannot be electrodes
cranked
3. Poor contact condition 3. Clean and retighten
of battery terminal
E. Wi ring 1. Disconnection between 1. Repair or replace wire
starter switch and
solenoid terminal
F. Overrun· 1. Overrunning clutch mai- l. Replace
ning function (rollers or
clutch compression spring)
2. Pinion teeth worn out 2. Replace
3. Pinion does not run in 3. Replace

overrunn ing direction
4. Poor sl iding condition of 4. Remove foreign rna-

spline teeth terials, dirt, or replace
5. Reduction gears 5. Replace

damaged
Starter does not G. Solenoid 1. Return spring worn 1. Replace solenoid
stop running
2. Coil layer-shorted 2. Replace solenoid
3. Contact plate melted and 3. Replace solenoid

stuck
H. Ring gear 1. Worn out teeth 1. Replace
I. Starting 1. Unopened contacts 1. Replace
switch or
starter 2. Poor returning 2. Replace
relay
hold-in winding, keeping the main solenoid contacts

OPERATION (Figure 5-12) closed. At this point the starter begins to crank the
engine. After the engine has started, the pinion gear
When the starter button is pushed battery current flows turns freely on the pinion shaft through the action of the
into the pull-in winding and also into the hold-in winding overrunning clutch which prevents overrunning of the
to ground. The magnetic forces of the pull-in and hold·in armature caused by the rotation of the clutch ring gear.
windings in the solenoid push the plunger and cause It
to shift to the left, so that the pinion gear is engaged When the starter button Is released, the current to the
with the clutch ring gear. At the same time, the main hold-jn winding is fed through the main solenoid con-
solenoid contacts are closed and battery current flows tacts and the direction of the current in the pull-in wind-
directly through the field windings to the armature, and ing is reversed. The solenoid plunger is returned to its
to ground . Simultaneously, the pull-in winding is original position by the return spring, disengaging the
shorted. The current continues flowing through the pinion gear from the clutch ring gear.
5-10
STARTER ATMOMENT STARTER SWITCH IS CLOSED
Armature
Field winding
Brush
Idle gear --~

Ball
Pinion bearing
gear
~
CIUIC~
ring gear Battery
Starting L _ _ _- '
switch
STARTER DURING CRANKING

Armature
Field winding
Clutch
ring gear Starting L _ __ ~
switch
Figure 5·12. Starter Operation - 1981 . 1985
5·11
STARTER RELAY 2. Remove the two starter mounting bolts and washers
Figure 5-14.
The starter relay is a non.repairable part and must be
replaced if it is not functioning. 3. Remove rear exhaust pipe.
Figure 5-13. Shows a lest circuit using a 12-volt battery 4. Remove positive battery lead and solenoid wire from
and stop lamp bulb. Contacts should close and bulb starter.
should light when connection is made at positive post
of battery and should go oul when connection is broken. 5. Remove starter and gasket from right side of motor-
cycle.
TESTING ASSEMBLED STARTER

86 Starter Solenoid Tests
NOTE
Do not disassemble solenoid. Before testing discon-

nect field wire from terminal C.
CAUTION
Each test should be performed for only 3 to 5 seconds to
prevent damage to solenold_
Solenoid Pull·ln Test

(Figure 5-15)
Figure 5·13. Starter Relay Internal Wiring Connect test leads from 12-volt battery as shown in
Diagram and Test Circuit Figure 5-15. The starter pinion should pull in strongly If
the solenoid is working properly. If pinion does not pull
in solenoid should be replaced.
REMOVAL
WARNING "C" terminal
Oisconnect battery cables (negative cable first) to avoid

accidental start up of vehicle and possible personal In- "50" terminal
jury.
1. Remove primary chain case cover. See CLUTCH DIS-

ASSEMBLY in Section 6.
Battery
Figure 5-15. Pull-In Test
"c" Terminal
"50" Terminal
Battery
Figure 5·14. Starter Mounting - 1981 . Early 1984 Figure 5-16. Hold-In Test
5·12
Solenoid Hold·ln Test
(Figure 5-16)
Use same setup as Pull·ln Test and disconnect test lead
from C terminal. If pinion remains In pull-in position, the
solenoid is working properly. If pinion does Qot remain
In pull-in position the solenoid should be replaced.
Figure 5-18. Performance Test
Solenoid Return Test (Figure 5-17)

Connect test leads from 12-volt battery as shown In
Figure 5-17. Disconnect the 50 terminal test lead. If pin-
Ion returns to its original position, the solenoid Is work·
Figure 5·17. Return Test
3 2')"
7
'2
(
13. Drive assemblyfoverrunnlng clutch

" 14. Idler gear
15. Idler gear roller (5)
2' 16. Idler gear bearing cage
17. O-ring
18. Return spring
7. Field frame 19. Ball
1. Thru·bolt (2) S. Armature bearings 20. Fell washer
2. End cover screw (2) 9. Drive housing mounting bolt, 21. Gasket
3. End cover washer and lockwasher (2) 22. Front (short) mounting bolt
4. Brush holder 10. Q.ring (2) and washer
5. Brush spring (4) 11. Drive housing 23. Rear (long) mounting bolt
6. Armature 12. Solenoid housing and washer
Figure 5·19. Starter
5·13
Ing properly. If the pinion does not return to its original
position the solenoid should be replaced. ""
Starter Performance Test (Figure 5-18)
Clamp starter securely in vise. Connect 12-voll battery,
ammeter and test leads as shown in Figure 5-18. The
starter should show smooth and steady rotation and
draw less than 90 amps at 3000 rpm minimum. Battery
voltage should not drop below 11.5 volts. If starter does
not meet these specifications see DISASSEMBLY, IN·
SPECTION , REPAIR AND ASSEMBLY.
DISASSEMBLY, INSPECTION,
REPAIR AND ASSEMBLY Figure 5·22. Removing Brush Holder
1. Remove field wire. 4. Use a wire hook to pull up on brush springs and 11ft
brushes out of holder. Remove brush holder (Figure
2. Remove thru·bolts (Figure 5-20). 5-22).
3. Remove the two cover screws and cover (Figure 5. Check brush length. Brushes less than .354 In. long
5·21). should be replaced.
NOTE
"" Replace brushes in sets of four only.
6. Remove armature (6, Figure 5-19) and field frame (7).
7. Place armature in lathe or truing stand and check

runout ot commutator. Armatures with more than
.002 In. of runout should be replaced.
8. Check depth of segment mica on commutator. It

undercut is less than .008 In. armature should be
replaced.
9. Check tor SHORTED ARMATURE with a growler

(Figure 5-23). Place armature on growler. Hold a thin
steel strip (hacksaw blade) against armature core
and slowly turn armature. A shorted armature will
Figure 5-20. Removing Thru-Bolts cause the steel strip to vibrate and be attracted to
the core. Shorted armatures should be replaced .
""
.....
Figure 5-21. Removing End Cover Figure 5.23_ Shorted Arm.ture Te.t Using Growler
5-14
...
,
No continuity (CJC) ohms)
Figure 5-24. Grounded Armature Test

Figure 5-26. Grounded Field Test
10. Check tor a GROUNDED ARMATURE with an ohm-
meter or continuity tester. Touch one prObe to any 1702
commutator segment, and the other probe to the ar-
mature core (Figure 5-24). There should be no can·
tlnulty (00 ohms). If there is any continuity the ar·
mature Is grounded and should be replaced.
Continuity ( 0 ohms)
Figure 5-25. Open Armature Test Figure 5-27. Open Field Test
11 . Check for OPEN ARMATURE with an ohmmeter or 13. Check for OPEN FIELD WINOING with an ohmmeter
continuity tester. Check for continuity between all or continuity tester. Touch one probe to the field
commutator segments (Figure 5-25). There should wire, and the other probe to each of the brushes at-
be continuity (0 ohms) at aU test points. No continui- tached to the field colis (Figure 5-27). There should
ty at any test point Indicates armature Is open and be continuity. If there Is no continuity at either
should be replaced. brush, the field windlng(s) are open and the field
frame shOuld be replaCed.
12. Check lor GROUNDED FIELD WINDING with an

ohmmeter or continuity tester. Touch one probe to 14. Test BRUSH HOLDER INSULATION with an ohm·
the frame, and the other probe to each of the meter or continuity tester. Touch one probe to holder
brushes attached to the field winding (Figure 5-26). plate and the other probe to each of the positive (In-
There should be no continuity (ooOhms). If there Is sulated) brush holders (Figure 5-28). There should
any continuity at either brush, the field wlndlng(s) be no continuity (00 ohms). If there Is continuity at
are grounded and the field frame should be re- either brush holder the brush holder assembly
placed. should be replaced.
5-15
15. Check armature b~arings (8) and replace if
necessary. "'''
No continuity (00 ohms)
Figure 5·28. Brush Holder Insulation Test
Figure 5·30. Drive Assembly

"'"
to reinstall return spring (18) and ball (19).
21. lubricate armature bearings (8) and felt washer (20)

with high temperature grease such as lUBRIPLATE
11()® and Install armature (6) and frame (7) to
solenoid housing (12).
22. Install brushes and brush holder (4).
23. Install end cover (3) with screws (2).
24. Install thru bolts (1).

Figure 5·29. Removing Drive Housing
25. Install solenoid wire to terminal.
16. Remove the two drive housing mounting bolts,
washers and lockwashers, and O·rings (Figure 5·29).
Remove drive housing from solenoid housing. INSTALLATION
17. Remove drive, idler gear and idler gear bearing from 1. Install starter and starter gasket from right side of
drive housing (Figure 5-30). O·ring is in groove in motorcycle.
drive housing.
2. Install positive battery cable and solenoid wire to
18. Clean, inspect and lubricate drive assembly com· solenoid.
ponents (Figure 5-30). lubricate parts with high
temperature grease such as lUBRIPLATE 11()®. 3. Install the two starter mount ing bolls and washers,
long bolt to the rear (Figure 5-13). Tighten mounting
19. When reinstall ing drive assembly components, open bolts to 13·20 ft. Ibs torque.
end of idler bearing cage faces toward solenoid
4. Install primary chain case cover. See CLUTCH
(Figure 5-30).
ASSEMBLY In Section 6.
20. When reinstalling drive housing (11, Figure 5·19) to
solenoid housing (12) use new a·rings (10). Be sure 5. Install rear exhaust pipe.
5·16
(XR·1000)
REMOVAL
WARNING
Disconnect the battery cables, (negative cable first) to

avoid accidental start-up 01 vehicle and possible per-
sonallnjury.
1. Remove the exhaust system including the heat

shield.
2. Drain the oil from the primary chain case, then

remove the gear shifter, left footrest assembly and
the primary chain case cover.
3. Remove the rear master cylinder mounting bolts

and the clip securing the rear brake line to the reaf
chain sprocket cover. Swing the master cylinder
rearward.
Figure 5·31. Starter Mounting
4. Remove the footrest, rear brake pedal, brake ad-
justing screw bracket and the rear chain sprocket Tighten the sprocket cover screws to 90·110 in-Ibs
cover. torque. Tighten the adjusting screw bracket lock-
nut to 50-60 ft·lbs torque.
5. Remove the two starter mounting bolls and
washers Figure 5-31. 5. Position the rear master cylinder assembly over
the mounting holes in the sprocket cover. Be sure
6. Disconnect the battery positive lead and solenoid the push rod is aligned with the master cylinder
wire from the starter solenoid. piston. Secure the master cylinder with screws,
tightening them to 155·190 in·lbs torque.
7. Remove starter and gasket from right side of the
motorcycle. Install brake line retaining clip.
6. Reinstall the footrest.

INSTALLATION
7. Install primary chain case cover. Tighten the
1. Install starter and gasket from right side of the mounting screws to 80-110 in-Ibs torque. Add the
motorcycle. correct amount of specified oil to the chain case.
Refer to TRANSMISSION Section 6.
2. Connect the solenoid wire and battery positive
cable to the starter solenoid. 8. Install the gear shifter and left foot rest assembly.
Tighten the footrest nut to 50 ft·lbs torque. Tighten
3. Install the two starter mounting bolts, long bolt to the gear shifter pinch bolt to 90-110 in-Ibs.
the rear (Figure 5·31). Tighten the mounting bolts
to 13·20 ft·lbs torque. 9. Install the exhaust system and heat shields.
4. Install the rear chain sprocket cover, brake ad· 10. Connect the battery cables to the battery, positive
Justing screw bracket and the rear brake pedal. cable first.
Use a new retaining ring to secure the brake pedal.
5·17
SUBJECT PAGE NO.
1. Generallnformat lon ............. 6-1

2. Speci fi cat ions (1979· Early 1984). . . . . . . . . • . . . ... 6·3
3. Chains (1979 · Early 1984) . ........... .6·5
4. Clutch (1979 · Early 1984) . . . . ........... .. ... 6·9
5. Transmission (1979 · Early 1984) ..... 6-17
6. Kick Starter (1979 XlCH ). ............ . ...... 6·27
7. Specifi cations (Late 1984 and 1985) . . . . . . . . . . . . . . • . . ............. 6-31
8. Chains (Late 1984 and 1985) .. . . .. ....... ,.. . . .... 6·33
9. Clutch (Late 1984and 1985) .. . .. . ................ .. .... 6·35
10. Transmission (Late 1984 and 1985) ..... . . .. . . ............ 6·40
DRIVEl
TRANSMISSION
I
GENERAL INFORMATION
DESCRIPTION Kick Slarier - XLCH
On the XLCH model a kick starter provides a means of
General starting the engine by manual power. When the lever is
moved in a downward stroke, teeth on the starter rat·
The drive/transmission section of this service manual chet gear and starter ratchel are engaged, transmitting
covers the primary chain, rear chain, clutch, kick starter, the force to the clutch, primary drive chain and to the
and transmission. engine sprocket. On the XlH , XlS and XLX models, an
electric starter motor and solenoid activated drive
Clulch pinion engages a ring gear on the clutch to crank the
engine. See STARTER Section 5.
The purpose 01 the clutch is to disengage and engage
the engine from the rear wheel lor starting, slopping
and shifting gears. Transmission
The clutch Is a wet , multiple disc clutch with steel The transmission is a 4·speed constant mesh type, (con-
plates and fiber (frictiOn) plates set alternately In the tained in an extension of the crankcase), that permits
clutch shell. The friction plates are keyed to the clutch the rider to vary the ratio of engine speed to the rear
shell and the sleel plates to the clutch hub and through driving wheel speed in order to meet the varying condi-
ii , to the transmission and rear wheel. The plates driven tions of operation.
by the engine afe called driving plates; those connected
to the clutch hub, the driven plates. The transmission is foot operated by the gear shllter
lever which transmits the force through a gear shifter
When the clutch Is fully engaged, spring(s) force the shaft , actuating a pawl carrier, pawls and gear shllter
plates together and cause them to turn as a unit with cam . The shifter cam moves shifter forks which slide a
the result that the power transmitted through the engine series of gear clutches on the mainshaft and counter·
sprocket, primary drive chain, and clutch is transferred shaft Into mesh with the various gears to obtain the
to the rear wheel through the transmission. desired gear ratios.
6-1
SPECIFICATIONS
(1979· EARLY 1984)
TRANSMISSION KICK STARTER

Minimum clearance between ratchet teeth on starter
General ratchet gear and starter ratchet on clutch shell - .040
In. with starter crank in up position.
Type ..................... Constant Mesh, Foot Shift
Speeds ......................... . .. 4 Forward Crankshaft end play. .001 in.· .007 in.
Number of Sprocket Teeth

GEAR BOX
Engine ..............................••....... 34
Clutch............. . ...... 59 Shifter mechanism must operate freely i n all positions
Transmission .............. . ........ 21
Rear Wheel-
1979-1981 ........... . . ..... 51 MAINSHAFT GROUP
1982- Early 1984 ....... 48
Clutch gear ball bearing
Capacity in access cover (loose) . .001 in.· .0012 in.
Ball bearing on clutch
Power Blend Super Premium Oil (U.S. pints) 1.5 gear(tight) . .0009 in.
Clutch gear bushing
Overall Gear Ratios on mainshaft (loose) . .001 in.· .002 in .
Mainshaft right side
roller bearing assembly (loose) . .001 in . . .0034 in.
1982- Mainshaft end play·
1979-1981
Early 1984 Without axial play (minimum) .003 in.
First (Low) Gear . 10.63 10.02 With axial play. .020 In.
Second Gear. 7.70 7.25 Third gear
Third Gear ........... 5.82 5.49 On shaft (loose) .. .002 In . . .003 in.
Fourth (High) Gear ... ... ... 4.22 3.97 End play. .012 in.· .030 in.
Clearance between faces
Mainshafl fourth gear and
second gear ... .028 in.· .058 in.
CLUTCH Mainshaft third gear and
second gear. .028 in.· .058 in.
Type Wet - Multiple disc
Capacity. 174 ft-Ibs
Spring
Adjustment Fixed spacers sId. length 1.530 in. COUNTERSHAFT GROUP
Free length - Inner. . . 2-25/64 in.
Free length - outer. 2·25164 in. Countershafl end bearings. Retained needle roller
Clutch shell bearing bearing
on clutch gear (loose) . .0000 in.· .0010 in. Bearing fit on shaft ends (loose) .0005 in.· .003 in.
Bearing fit on case press fit
End play.. .004 In ... 009 in.
PRIMARY CHAIN Second gear
On shaft (loose). .001 in ... 0025 in.
Type ............. . 318 in. pitch triple chain low gear
Free play 518 to 7/8 in. slack (cold engine) On shaft (loose). .0005 in.· .0016 in.
318 to 518 in slack (hOt engine) Drive gear
On shaft (loose) . .0005 in.· .003 in.
REAR CHAIN Countershaft low and third gear. .028 In ...058 in.
Countershafl second and third gear . .028 in.·.058 in.
Free play .................•.. . •.•... 1/2 in. slack Countershaft end play. .004 in.· .015 in.
6-3
TORQUES ponents or for measurements not given under SERVICE
WEAR LIMITS, see the foregoing.
Clutch Hub Nut. 110-150 ft-Ibs
Mainshafl Nut ........... .•• . .•.. . 35-65 ft·lbs Clutch spring free length
Access Cover Screws. 13·151t·lbs inner and outer. 2-11132 in.
Drain Plug 14-21 It·Jbs Clutch plate maximum warpage .010 in.
Primary Chain Case Mainshafl - clutch gear ball bearing
Cover Screws ...... .....•. 80tol10in-lbs in access cover (loose) .001 - .0035 in.
Chain Tensioner Stud Nut .. 8-12 ft-Ibs Mainshaft - ball bearing on clutch gear(1005e) .001 in.
Clutch gear bushing
on mainshafl (loose) .001 - .0035 in.
Mainshaft right side
SERVICE WEAR LIMITS roller bearing assembly (loose) .001 .. 0035 in.
Mainshafl - third gear
NOTE
On shaft (loose) .002 in· .004 in.
Countershafl bearing fil
Wear limits are given 8S a guideline for measuring
on shaft ends (lOOse) . . . . . . . • • . .0005· .0035 in.
engine components that are not new. For new com-
6·4
CHAINS
(1979 . EARLY 1984)
FRONT CHAIN NOTE
General If chain tens/on cannot be corrected with chain ad·
juster, then adjuster or chaIn Is worn beyond adjust·
The front chain should be checked every 2500 miles for ment flmits and must be replaced.
correct adjustment. Check chain adjustment through oil
filler opening near the top of the chain cover. A correctly
adjusted fron t chain should have free up·and-down Lubrication
movement, in the upper strand midway between engine
and clutch sprockets, as follows: 518 to 718 in. chain
There Is an opening between the front chain and
slack with cold engine; 3/8 to 5/8 in. chain slack with hot
transmisson compartment, and the same oil supply
engine. automatically lubricates moving parts in both compart.
ments. For complete lubrication service on the front
As chains wear and stretch in service, they will run
chain see TRANSM ISSION, this section.
tighter at one point on the sprocket than another. Chain
free play must be gauged al the lightest point on the
chain.
ReplaCing Chain Adjuster
WARNING (Figure 6·2)
To prevent accidental starter operation, disconnect bat· 1. Remove drain plug (2) and drain 011 from chain
tery cables (negative cable first) before doing any work case.
on the engine, drive or electrical systems.
2. Remove gear shifter lever and left footrest
Adjustment assembly.
(Figure 6·1)
The front chain can be adjusted without removing the
chain cover.
1. Remove the oi l filler plug near the top of the chain

case.
2. Rotate the sprockets to find the tightest point on

the chain.
3. l oosen locknut (1) and turn adjusting screw (2) IN

to reduce freeplay or OUT to Increase free play.
4. When correct tension Is obtained, tighten locknut

(1) and replace oil filler plug.
3 4
1. locknut 4. 011 IIlIer opening
1. Chain adjuster 3. Spring
2. Ch.ln .djuster screw 5. Clutch adjustment
2. Drain plug 4. Chsln
3. Chain cover access plug
Figure 6·2. Replacing Chain and Adjuster
(1979 . Early 1984) (1979 . Early 1984)
6·5
3. Relax chain tension by unscrewing chain adjuster
screw (2, Figure 6-1).
4. Remove chain case cover and gasket.
5. Pull chain adjuster (1, Figure 6-2) and spring (3)

from stud. Transfer spring (3) to new adjuster and
install assembly crankcase stud.
6. Remove foreign material from magnetic drain plug.

Replace and securely tighten drain plug.
7. Reinstall chain case cover and gasket; footrest

assembly, tightening nut to 24·36 ft-Ibs torque; and
gear shift lever, tightening pinch bolt to 90 to 110
in-Ibs torque.
8. Adjust front chain as described previously. Fill

with correct amount of lubricant as described in
TRANSMISSION, this section.
Removal and Installation 1. Axle nut
2. Axle adjuster nut (2)
3. Axle adjuster assembly (2)
Since the front chain runs in an oil bath, little service
will be required other than checking oil level and chain 4. Axle
adjustment every 2500 miles. If through hard usage the
front chain does become worn, it must be replaced Figure 6-3. Rear Chain Adjustment
rather than trying to repair it. This will avert chain (1979· Early 1984)
breakage and possible damage to the crankcases.
either side exactly the same number of turns to
WARNING maintain alignment of wheel.
avoid accidental startup of vehicle and possible per· 3. A properly adjusted chain should have 1/2 in. total
sonal injury. free up and down movement of the lower strand
measured midway between the transmission
1. Remove and install the chain following the sprocket and the rear wheel sprocket. Check rear
disassembly procedure under CLUTCH. wheel alignment. Wheel must run centrally be·
tween rear fork tubes and sprocket must run cen·
trally in the chain. See WHEEL ALIGNMENT.
REAR CHAIN
General 4. When readjustment is completed, be sure to se·
curely retighten rear axle nut (1) to 65-70 fI-lbs
The rear chain should be checked for worn chain links torque.
and correct adjustment. A correctly adjusted rear chain
should have 1/2 in. total free up·and-down movement, in
the lower strand, midway between mains haft and rear NOTE
wheel sprocket. As chains stretch and wear in service,
they will run tighter at one point on the sprocket than Once the chain adjusters have reached their limit and
another; therefore, always rotate rear wheel and check proper chain adjustment can no longer be achieved,
adjustment at tightest point of chain. replace the chain. See REAR CHAIN REMOVAL and IN·
STALLATION.
NOTE
Make rear chain adjustment with the motorcycle upright Lubrication

and the weight of one rider sitting on it.
This motorcycle is not equipped with a rear chain oiler.
Therefore, the rear chain should be checked and lubri·
Adjustment cated manually every 300 miles.
(Figure 6·3)
Under normal operating conditions, brush off the dirt
1. Loosen rear axle nut (1). and lubricate chain. Use Harley-Davidson CHAIN
SPRAY or High Performance CHAIN LUBE PLUS. Apply
2. Turn axle adjuster nut (2) on stud of axle adjuster at room temperature to chain side plates and rollers.
assembly (3) either counterclockwise to loosen Apply with a brush or squirt can to thoroughly cover
chain, or clockwise to tighten chain. Adjust nut on chain. Wipe off surplus lubricant.
6·6
Removal and Installation
(Figure 6·4)
1. locate and remove the spring clip on the chain
connecting link.
2. Using CHAIN TOOL, Part No. HD·95021-29A, press

the connecting link from the side pia Ie.
3. Place transmission In neutral. Connect one end of

the new chain to the old chain using the connect·
ing link and side plate. Run the chain on the
sprockets unlillhe new chain is on both the wheel Spring clip
and transmission sprocket.
4. Disconnect the old chain from the new chain. Figure 6·4. Chain Connecting link
(1979· Early 1984)
5. Using CHAIN ASSEMBLY TOOL, Pari No.
HD·95020-66, connect the ends of the new chain
with a new connecting link, side plate and spring.
CAUTION
Make sure that the spring clip open end trails the dlrec·
tion of chain travel.
6. Adjust the chain tension as described in REAR

CHAIN ADJUSTMENT.
6·7
CLUTCH
(1979 . Early 1984)
GENERAL
Troubleshooting
Effect C. u•• (Check In follow ing order) Remedy
Clutch slips Incorrect clutch release adjustment . Check and adjust clutch release mechan ism
as described under ADJUSTING CLUTCH
RELEASE MECHANISM .
Insufficient clutch spring tension. Check and adjust clutch spring tension as
described under ADJUSTING CLUTCH
SPRING TENSION .
Clutch drags Incorrect clutch release adjustment . Check and adjust clutch release mechanism
as described under ADJUSTING CLUTCH
RELEASE MECHANISM.
Worn clutch release ramps or balls. Replace release ramps and/or balls. See
INSPECTING CLUTCH RELEASE
MECHANISM.
Excessive clutch spring lenslon. Check and adjust clutch spring tension as
described under ADJUSTING CLUTCH
SPRING TENSION .
Warped clutch steel plates. Replace clutch steel plates. See INSPECT·
ING AND REPAIRING CLUTCH.
Badly worn or damaged clutch Replace clutch sprocket. See INSPECTING

sprocket splines. AND REPAIRING CLUTCH .
CONTROLS ADJUSTING NUT WRENCH , Part No. HD·94580·71 ,

and turn screw (5) Inward until it becomes harder
to turn (starts to release the clutch) and continue
General turning (2 more turns) to be sure clutch Is
disengaged.
Periodic adjustment of the clutch and oiling of the
clutch control cable Is required every 2500 miles to com· 4. Adjust all free play out of clutch cable by turn ing
pensate for lining wear. The need for attention to the adjuster (15) outward. Do not put any tension on
clutch and controls will also be indicated by the c lutch cable. With all slack in cable eliminated (no play at
slipping under load, or dragging in released position. In hand lever) tighten the coli adjuster locknut (13).
any case, the first thing to be checked is the adjustment This is the correct cable adjustment.
of the clutch control.
5. The clutch release adjustment should then be
made with the clutch adjusting screw as follows.
Adjusting Clutch Release Mechanism Back off the adjusting screw (5) until the clutch Is
(Figure 6-5) engaged (screw turns eaSier), then, turn screw In·
ward untll the point where free play of adjusting
1. Loosen clutch cable adjuster locknut (13) and turn screw has just been eliminated. From th is point,
adjuster (15) inward unlit there Is a large amount of turn the adjusting screw outward 118 to 114 turn to
free play at hand lever on handlebar. establish correct free play, and tighten locknut (3)
while holding screw (5) stationary.
2. Remove access plug (1) from primary chain cover
using ACCESS PLUG REMOVAL TOOl., Part No. 6. See Figure 6-6. Check free play at clutch
HD-33186. hand lever. There should be 1/16 in. free play be·
tween handle and bracket. If Incorrect, readjust
3. Loosen adjusting screw locknut (3) using CLUTCH sleeve (15, Figure 6·5) and tighten locknut (13).
-
Clutch adjUstl~9
screw locknu
::: ~i:
o :: ferrule
Slot open end

must face toward
Inside of lever
1. Access plug o Washer

2 O·rlng 1 . Ie coupling
3' Locknut 11. Cab an d coil assy.
12. Cable
4' Lockwasher 13. Locknut
S' Adjusting screw 14. Washer eve
6: Retaining ring and lever
7. Release ramp
15. Adjusting
51
7
16. Primary cha n
case cover
8 eall (3) 17. Plug
9: Release ramp 18. 011 level screw
Figure 6'5. Clutch Release Mec hanlsm (1979 • EarIy 1984)
6·10
Outer drive
plate
Releasing
disc
Adjust for 1116 in.

gap between
handle and bracket
Figure 6-6. Adjusting Clutch Free Play - 1979· Earty 1984
NO TE
If the clutch continues to slip under load or drag In Nut

releas ed position, clutch springs may need ad;usting or
release mechanism may not be operating. See subse·
quent sections. 118" M Inlmu m, "I""~l!l!l!l!!llI!llI~!llI~~
Spacer std. length, 1.530 in.

Spacer - .040 length, 1.490 In.
Adjusting Clutch Spring Tension Spacer - .080 length, 1.450 In.
See Figure 6-7. Clutch spring tension Is determined by
the length of six stud spacers. To correct clutch slip· Figure 6-7. Clutch - 1979· Early 1984
page caused by worn clutch drive plate linings, a set of
shorter than standard spacers can be installed. 2. Remove gear shifter lever and left foo trest
assembly.
Under no circumstances should clearance between
releasing disc and outer drive plate be allowed to go 3. Remove access plug (1) from primary cover using
under minimum 118 in. dimension shown. All spacers ACCESS PLUG REMOVAL TOO L, Part No.
should be equal in length. HD·33186.
4. loosen primary chain adjuster.
5. Remove primary chain cover (16).

Disassembling Clutch Release
6. Remove adjusting screw locknut (3), lockwasher (4)
Mechanism and Clutch Cable and screw (5).
(Figure 6·5)
7. Remove retaining ring (6) using a lock ring pliers.
WARNING This will free clutch release ramp lever (7) and
three bails (8). Unless necessary lor replacement,
Disconnect the battery cables (negative cable first) to do not remove release ramp (9) or washer (10)
avoid accidental start·up of vehicle and possible per· which is staked into cover recess .
sonal injury.
8. Remove clutch cable by rotating cable coupling
NOTE 90- from installed position in lever (coupling has a
flat which locks it in place in lever).
On 19 79 models remove exhaust system components
on left side of motorcycle. 9. Unhook cable end (12) from coupling (11). loosen
locknut (13) and unscrew adjusting sleeve (1 5) from
1. Remove drain plug and drain all from chaincase. cover.
6·11
1. Nut, pressure I ~~ . ~r~ven plate (8)
2. Releasing dl pate (6)
12' P nve plate (8)
3. Stud spacer sc 13' Hr·bssure plate
4. Releasing dl (6) . u nut
5. Relaasln Sc collar 14. Hub nut I
6. Spring 19 disc bearing 15. Clutch h ockwasher
75,nner 16. Clutch hUb assy. I.
S' RPrlng, outer 17 s ell
. Retaining rln
9. Outer drive pf~t:u,er drive plate Clut~h ~~!~Ih shell bearing
. 81alnlng rln
18. Bearing,
•. Clutch (1979 • Early 1984)

Figure 68
3. Check fil of
w~~' ra~p
NOTE replace both parts
ramp 11lever (7) hub
T .'cess1v. (9) and
p~~~i
Cable and
rePI8cemen~~~t2)
(14) 8re lo ose p:'t: assembl/'~u~~~ available for
wit h sleeve
S an 3) and washer
4. 0 repl ace
boss and
r eXists
(9), remove stak'ln g .
co,e:~ ~ r~mp
washer (10) wit h old part. Install ne from cover
boss. Stake registered in against
In cover. If clute
cab~
55 In 3 places 0 ch of cover
Inspecting and worn, replace e.cable ends (12) to retain
are ramp
frayed or
Mechanism Repairing Clute
(Figure 6.5) and Clutch Cable h Release
Assembling CI
1. Wash clutch relea sing
. parts in cl . Mechanism utch Release
2. Inspect 3 ba lls ( eanmg solvent. (Figure 6.5) and Clutch Cable
ra mps (7) and (9)
breakdown and wear
8) for bait socket surfaces of
. ' pitt ing or surface
1. Install cable parts (15), (14), (13), and (12) In cover.
6-12
2. Attach cable coupling (1 1) to cable end and Install
in lever (7).
3. Grease ball ramps and install ramp parts (10), (9),

(8), and (7).
4. Use lock ring pliers to install retaining ring (6) in

groove of ramp lever (7).
5. Assemble clutch release adjusti ng screw (5), lock·

washer (4), and locknut (3) In cover.
NOTE
Before installing cover on engine clutch, release lever

must be correctly adjusted so that 3 balls are centered
at bottom of each ramp with no play in clutch cable.
6. Press down on lever (7) to feel when three balls are Figure 6·9. Compressing Clutch Spring to Disassemble
centered in ramps, and adjust cable sleeve (15) to Clutch (1979 . Early 1984)
take all slack out of cable.
plate (9), pressure plate (12) and stud spacers (3)
7. Install chain case cover on engine; tighten cover will come out as a unit by pulling on pressure plate
screws to BO·110 in·lbs torque. Fill with correct studs.
amount of lubricant as described in TRANSM IS·
SION. Adjust clutch as described previously under 8. Use CLUTCH LOCKING TOOL, Part No. 91042, to
ADJUSTING CLUTCH RELEASE MECHAN ISM. hold clutch hub (IS, Figure 6·10). 8end ears of
lockwasher (14) away from hub nul (13). Remove
8. Install access plug in cover. Install gear shifllever, clutch hub nut (13).
tightening pinch bolt to 90 to 110 in·lbs torque. In-
stall left footrest assembly, tightening mounting 9. Remove clutch hub (15) from splines of clutch
nut to 24·36 ft·lbs torque. gear. If necessary, use PULLER, Part No.
HD·97292·61 , and two 1/4·20 x 4 in. long screws, as
shown in Figure 6·11.
DISASSEMBLY
(Figure 6-8) 10. Remove nut securi ng sprocket on engine sprocket
shalt.
WARNING
11. Remove sprocket from splines of shaft usi ng slot-
To avoid accidental start-up of vehicle and possible per· ted portion of PULLER, Part No. HD·97292-61, and
sonal injury, disconnect the battery cables (negative two long boits as shown in Figure 6·11. As
cable first) before performing any of the following pro· sprocket becomes loose on shaft, remove clutch
cedures. shell, front chain and sprocket together.
1. Remove drain plug and drain oil from chain case.
2. Remove gear shifter lever, left footrest assembly INSPECTION AND REPAIR
and front chain cover. (Figure 6-8)
3. Loosen primary chain adjuster. 1. Inspect clutch springs (6) and (7) for damage or col·
lapsed condition. Spring damage usually results
4. Install CLUTCH SPRING COMPRESSING TOOL, from excessive heat. Free length of a new inner
Part No.HO-9717B-71, on crankcase by screwing in· and outer spring is approximately 2-25/64 in. Any
to the crankcase cover screw holes as shown in that check below service wear limit of 2·11132
Figure 6·9. should be replaced.
5. Compress releasing disc (2, Figure 6-8) with tool to 2. Examine the 8 steel drl ....en plates (10) for warpage
take pressure off nuts (1) and remove nuts. and excessive wear, grooving or scoring on run-
ning surface. Replace if necessary. See
6. 8ack off center screw of tool and remove releasing SPECIFICATIONS.
disc (2) and springs (6) and (7). Remove tool.
Steel plates that have turned blue from heat only
7. Remove retaining ring (B) from groove in clutch and are smooth and generally in good condition
shell (16). All clutch plates (10) and (11), outer drive can be used again alter being thoroughly cleaned.
6-13
Figure 6·10. Holding Clutch Hub (1979 . Early 1984)
3. Pay particular attention to the 8 friction drive

plates (11). Plates that have badly worn, grooved,
scored or burned friction surfaces should be
replaced. If oil grooves are worn away, replace fric·
tion plates.
4. Examine bearing (18) in clutch shell (16) lor

roughness or excessive play.
If necessary to replace bearing (18), remove relain·

ing ring (17) with a large lock ring pliers and press
out.
Figure 6·11. Pulling Clutch Hub and Sprocket
From Shafts (1979· Early 1984)
5. Examine bearing (5) In releasing disc (2) for
roughness or excessive play and replace if
necessary. Collar (4) can be reused.
6. Inspect clutch shell (16) for badly worn splines,

loose rivets, worn sprocket teeth or damaged ring 3. Tighten nut to 110-150 ft·lbs torque. Bend ear of
gear teeth. 11 noticeably damaged, replacement washer (14) against hex·head of hub nul. Clutch
clutch shell is recommended. hub must run free on shaft after tightening.
NOTE
ASSEMBLY On kick start models, if starter clutch, clutch shell or
(Figure 6-8) clutch gear have been replaced, it Is absolutely
necessary to check the clearance between teeth on
Assembl y is essentially the reverse order of starter ratchet gear and starter ratchet as described In
disassembly. Be certain that all parts are clean before KICK STARTER.
reassembling.
4. Install SPROCKET LOCKING LINK, Part No. HD-
1. Install spacer, then clutch shell, Iront chain and 97200-55A on engine sprocket. Tighten engine
sprocket in one operation. sprocket nut to 150-165 fI-lbs torque.
2. Install clutch hub on clutch gear splines. Use 5. See Figure 6-8. Remove locking tools and install
CLUTCH LOCKING TOOL, Part No. HD·91042. in· pressure plate (12) over clutch hub splines, against
stall a new lockwasher (14) over clutch gear back side of hub, studs side facing oul.lnstall st ud
spl ines and install hub nut (3). spacers (3) on studs.
6·14
6. Place a drive plate (11) next 10 the pressure plate 10. Adjust clutch release screw as described previously
(12). Place a driven plate (10) over studs into clutch under ADJUSTING CLUTCH RELEASE MECHANISM.
shell and sprocket assembly and push inward
against the friction plate. Alternate plates until 8 11. See Figure 6·5. With motorcycle standing straight
of each are in position. This will leave a driven up, remove plug (l7)and oil level screw (18). Add 24
plate on the outside. Install outer drive plale (9) oz. of oil through plug (17), (use Harley·Davidson
(friction malerial in) and Inslall retaining ring (8) in POWER BLEND SUPER PREMIUM Oil), until it
clutch shell groove. Make sure all plates have free begins to overflow through oil level hole. Allow ex·
movement. cess oil to flow from hole until it ceases to run.
This is correct oil level.
7. Install CLUTCH SPRING COMPRESSOR TOOL,
Part No. HD·97178·71, on crankcase (see Figure 12. Reconnect battery cables, positive cable first.
6·9). Install springs (6) and (7, Figure 6-8) and
releasing disc (2) under tool screw. Compress
parts so that pressure plate (12) studs enter 6
holes In releasing disc to start nuts (1) on threads
(see Figure 6·7). Remove tool. Tighten nuts (1, Fig·
ure 6·8) until releasing disc bottoms on spacers (3).
8. Install primary chain cover using new gasket and

correct length screws in proper holes. Tighten
screws to 80·110 in·lbs torque.
9. Readjust primary chain tension, refer to FRONT

CHAIN
6-15
TRANSMISSION
(1979 . EARLY 1984)
GENERAL
The transmission internal shifter mechanism, main-
shaft and countershaft groups afe an integral part of
the engine crankcase assembly. These groups may be
serviced directly by removing the access cover from the
crankcase as described in REMOVING TRANSMISSION
ACCESS COVER, thereby exposing all transmission
parts for repair.
OISASSEMBL Y
Removing Transmission Access Cover

Unless transmission Is damaged inside so that It can- 1. Access cover
not be shifted from one position to another, shift Into 2. Access coyer cap screws (4)
high gear. Place an oil drain pan under engine and
remove chain case cover, clutch, front chain and Figure 6·13. Transmission Access Coyer
sprocket as described in CLUTCH. (1979 . Early 1984)
Remove rear chain sprocket cover on right side of

motorcycle as described in STRIPPING MOTORCYCLE See Figure 6·13. Remove four access cover cap screws
FOR ENGINE REPAIR. (2).
See Figure 6-12. Remove transmission mainshaft nut (1) Remove access cover (1) from crankcase with transmis-
and lockwasher (2). Remove rear drive chain. If main· sion parts attached to the cover (see Figure 6-14) by tap,
shaft sprocket (3) is tight on shaft use an ALL PURPOSE ping on mainshaft end from right side of motorcycle.
CLAW PULLER, Part No. HD-95635-46, to remove
sprocket. To avoid looth breakage, grasp two teeth with This above method removes the complete transmission.
each end of puller. Remove retainer screws (4), oil seal Remove thrust washer (24, Figure 6-16) and 23 rollers
and retainer (5) and gasket (6). from crankcase.
1. Malnshaft nut
2. Malnshaft lockwasher
3. Malnshaft sprocket
4. all seal retainer screw
and lockwasher (4)
5. 011 seal and retainer
6. 011 seal gasket
Figure 6·12. Transmission Malnshaft Sprocket (1979 ·Early 1984)
6-17
Figure 6·15. Alternate Method of Removing
Transmission Access Cover
(1979 - Early 1984)
Mainshaft and Countershaft Group

(Figure 6·18)
Remove mainshalt (2), from access cover. Remove low
gear (5) from malnshaft splines. Remove retainer ring (6)
from groove In malnshaft using TRANSMISSION SHAFT
RETAINING PLIERS, Part No. J-5586, and discard ring.
Slip washer (7) and third gear (8) from mainshafl.
Remove retaining ring (22), press clutch gear (10) and

bearing (20) from access cover (9). Apply pressure only
to bearing (20) outer race. Press clutch gear (10) from
bearing (20). Remove countershaft assembly from ac·
cess cover. Remove low gear washer (11) and third gear
(12) Irom countershaft. Press drive gear (13) from
Figure 6·1 4. Transmission Removed
countershaft splines and remove gear spacer (14), sec-
(1979 · Early 1984)
ond gear (15) and thrust washer (16). Free countershaft
An alternate method of removing the access cover is to low gear (18) and low gear washer (19). Drift out oiler
pull it out using ACCESS COVER PULLER, Part No. plug (22) from Inside of access cover.
HD-95560-57, as shown In Figure 6·15. The difference be-
tween this method and the one above is that the main·
shaft remains attached to the right crankcase half. In
this case, do not remove sprocket (3, Figure 6-12) from INSPECTION AND
malnshaft. Attach tool as shown in Figure 6·15. REPAIR
Shifter Mechanism Thoroughly clean transmission compartment and all
(Figure 6·16) shifter, malnshaft, and countershaft parts with cleaning
solvent. Be certain malnshaft loose roller all passage Is
To disassemble shllter mechanism, remove cap screw clean. Blow parts dry with compressed air and Inspect
(1) and lock (2). With a snap ring pliers, remove retaining to determine II any must be replaced. Replace all parts
ring (3) and washer (4). Free cam (5), pawl carrier (6), that are badly worn or damaged.
pawl carrier support (7) and pawl carrier support shims
(8) (JI used). Remove pawl carrier springs (9) from pawl
carrier support. To disassemble pawl assembly, remove Transmission Malnshaft Sprocket
retaining rings (13) to free pawls, spacers, and springs (Figure 6·12)
(10), (11), and (12) from pawl carrier (6). To free shifter
forks (14) and linger rollers (15), remove fork shaft (20) Inspect sprocket (3) for badly worn (hooked) or damaged
from access cover. Mark larks so they can be reas· sprocket teet h and splines. Di scard gasket (6). Check all
sembled in same position. seal and retalner (5), lockwasher (2) and malnshaft nut (1).
6-18
/~ 25 ~
~3
,
31 29 W /'1
32 22 1 \ 2 8 L- '" ~~ _ 26
: c£,,'~ 21 29"~ \Wt~ rct-

K~ 7 •
" '®:I' ,J'r \/~~
3
&- 34
J , _ 33
13 \
Q \~" ' ~
· \.//>2.~27
/~ '" ~ .......
,.
I
~ a- ~ /
19
17
30
16
11 J
,/@ oq
,/
~10
6 Available In
standard,+ .020 In.
~~/~ ' .............. '2 or- .02OIn .
............. '3 sizes I
15 '---- r;;) •
~ 14 '-- 'l
'~20
~
<;;/, ~~,,~
/t:2::'':::~__....",.•. -0-:::;;;1---,
15 ~.-l
1. Bolt 13. Retaining ring (2) 25. Pin plwillft.r arm (2)
2. Lockwasher 14. Gelr shifter forb (2) (variable) 26. Upper pawillfler arm
3. Retaining ring 15. Anger rollers (2) 27. lower pawllllt.r arm
4. Thrust wash.r 16. Cam follower 28. CIIrrier spring retainer p(ug (2)
5. Ge.r ,hlft.r cam 17. Cam tollower spring 29. CIIm support p(n (2)
6. Pawl carrier 18. Cam follower retainer 30. Shift shalt bushing
7. Pawl cant.r support 19. Ret.'ner lock 31 . Lever
8. Shim (.010 thick) as required 20. Fork ,halt 32. Shift lever
9. Pawl Clmer .pring. (2) 21. Lever arm ,haft 33. Washer
10. Pawl (2) 22. Shlft.r thalt bUlhlngs 34. 801t
11. Pawl spring 23. Shllt.r ,haft 011 ... ,
12. Pawl spacer (2) 24. Thrust wuher
Figure 6-16. Shlltlng Mech.nlsm (1979 - Early 1984)
Shlfler Mechanism Examine pawl carrier springs (9) for breakage or

damage caused by acids in all. if possible, compare old
(Figure 6,16) springs with new springs. New spring free length is ap-
proximately 2-21132 in.
Discard gear shifter cam retaining ring (3). Carefully ex-
amine gear shifter cam (5) for grooved or worn cam slots
at the various running gear positions. Excessive wear at
thrust points will make the transmission difficult to CAUTION
shift through gear range.
Do not use cadmium plated, 14-<:011 pawl carrier springs.
Inspect gear Shifter pawl carrier (6) lor depressions or Use only cadmium plated, 16-coll springs or black
grooves worn in lingers that engage shifter lever arm phosphatlzed springs, 14 or l&.coll. when reassembling
shaft (21). A badly worn yoke Is caused by rubbing ac- pawl carrier support_
tion of lever arm shaft ball, and will result in transmis-
sion lumping out of gear. Exam ine pawl carrier support Examine shifter pawls (10) for wear, grooves, cracks or
for breakage or minute surface cracks. Loosely as- breakage.
semble shilter cam (5), pawl carrier (6), support (7),
shims (8) (If used), and check bearing action for ap- Check lor wear or damage 10 pawl (10) and carrier (6).
preciable play. Parts that show extremely worn or pitted Free length of new spring (11) Is approximately 1-314 in.
su rfaces should be replaced. between hooks.
6-19
.,,"
lat Gear 2nd Gear
Neutral
3rd Gear 4th Gear
-Power flow
_ - Sliding member
Figure 6-17. Power Flow Chart (1979· Early 1984)

6·20
Check shifter larkS (14) lor bent condition or deep freely in bushings. Remove any high spots from bush·
grooves worn Into fork lingers caused by excessive ings with a hall· Inch reamer. To ensure against oil leak·
thrust action 01 gears. Also examine both shilter larks age, replace all seal (23) when reassembling.
(14) and linger rollers (15) for breakage.
Inspect shifter cam follower (16) and spring (17) lor wear
and damage, especially on thrust face of follower. Mainshaft and Countershaft Group
Check movement of follower and spring In retainer (18). (Figure 6·17)
Free length of new spring is approximately 1-19132 In.
The Illustrations show the transfer of power through
Check shalt (20) for bent or damaged condition by slip· transmission . Note the change in gear position lor each
ping shifter forks on shalt and noting if they have Iree of the four speeds and neutral.
movement on shalt.
Inspect gears for badly battered, chipped or rounded
Inspect gear shifter lever arm shaft (21) for wear or bent dogs and slots at all thrust paints. This condition will be
condition. Temporarily install shalt in crankcase and evidenced by transmission Jumping out of gear. Exam·
check lor appreciable play in bushings (22). If inspec· ine gear teeth for pitting, scoring, cracked, chipped can·
tion indicates replacement of bronze bushings (22), it is ditlon or case hardening worn through . Inspect main·
first necessary to remove gearcase cover as described shalt, countershaft and all gears for pitting, grooving
in GEAACASE, Section 3. Pry oil seal (23) from recess in and excessive wear on bearing surfaces. Slip gears on
shalt hole with screwdriver and drill bushings Irom shalts and check for wear and appreciable play. If not
right case and gearcase cover. Alter pressing in new within service limits as given in transmission
bushings, Install lever arm shalt (21). Shaft must work SPECIFICATiONS, replace worn parts.
1. Malnshat! second gear

2. Transmission mainshaft
3. Malnshaft thrust washer
(yarlable thickness) .
Controls end play of
mainshaft
4. Transmission malnshaft 15. Countershaft second gear
roller (23) 16. Countershaft second gear thrust washer
5. Malnshaft low gear 17. Transmission countershaft
8. Malnshat! third gear retainer 18. Countershaft low gear
ring 19. Countershaft low gear washer
7. Malnshaft third gear washer (yariable thickness) · 25. Clutch gear bushing
8. Malnshaft third gear Countrols end play of 26. Clutch gear needle rolier bearing
9. Access coyer countershaft 27. Malnshaft thrust washer
10. Clutch gear 20. Malnshaft ball bearing 26. Malnshaft rolier bearing race
11. Variable thrust washer 21. Malnshaft ball bearing 29. Malnshaft roller bearing
Controls clearance between shaft ring retainer ring
gears 22. Retaining ring 30. Malnshaft rolier bearing washer
12. Countershaft third gear 23. Countershafl oller plug 31. Countershaft bearing· closed
13. Countershaft driye gear 24. Countershaft low gear end
14. Countershaft gear spacer bushing 32. CountershaU bearing. open end
Figure 6-18. Transmlllion (1979 . Eariy 1984)
.. 21
MAINS HAFT BEARINGS Replace needle roller bearings (31) and (32) if worn and
not within tolerances outlined In transmission SPECIFI·
To replace clutch gear bushing (25, Figure 6·18) and nee· CATIONS. Bearings are a press lit and should be reo
die railer bearing (26), first drift bushing (25) from gear moved for replacement of parts only. Apply pressure to
(10). Drift needle roller bearing (26) and thrust washer printed side of bearing when pressing into position.
(27) from opposite end of gear. Press new bushing into Press needle roller bearing (32) into access cover 5164
clutch gear (10). Insert mainshaft (2) in clutch gear (10) in. from inner side.
and check to be sure shaft is .001 to .002 in. loose in
gear. A new bushing may close up and require reaming NOTE
to size. Use REAMER, Part No. HD·94829·42, for this
operation. Install needle railer bearing (26) and thrust Oller plug (23) must be ins talled with all hole up, as posl·
washer (27), pressing on printed side of bearing only. tioned on access cover, after countershaft end play has
been established.
Position mainshaft (2) in FLYWHEEL TRUING DEVICE
Part No. HD·96650-a0. Rotate shaft and, with a dial in·
dlcator, check shaft for bent condition. Shaft that Is
.003 in. or more out of true must be replaced. Check the
countershaft (17) In the same manner. If countershaft is ASSEMBLY
0.003 in. out of true, replace it.
Lubricate all parts with Harlev·Davldson POWER
Inspect mainshaft ball bearing (20). Tolerances of BLEND SUPER PREMIUM oil before assembly, proceed
clutch gear (10) in ball bearing and ball bearing In ac· as follows:
cess cover (9) are given in transmission SPECIFICA·
TIONS. If bearing is not within specification limits or is
worn to the extent that it has appreciable play or shake, Shifter Assembly
replace it. (Figure 6·16)
To remove ball bearing (20) from access cover (9), first 1. Install cam follower retainer (18) and retainer lock
remove and discard retaining ring (22). Support access (19) Into access cover. Tighten to 17·25 ft·lbs torque.
cover on arbor press and press ball bearing (20) and Bend lock tabs against cam follower retainer (18).
clutch gear (10) from cover. Apply pressure only to bear·
Ing outer race. 2. Position pawls (10) with spacers (12), as shown, on·
to pawl carrier (6) and secure with new retaining
Use press to push clutch gear (10) from ball bearing (20). rings (13). Install pawl spring (11).
Apply pressure only to bearing inner race. Do not drive
bearing from access cover (9) or clutch gear (10) with a 3. Assemble shifter cam (5) into pawl carrier (6),
hammer and drift as damage to bearing is likely to retracting pawls one at a time to do so. Insert
result. assembly Into support (7), with ear of pawl carrier
(6) between springs (9). Secure with thrust washer
To reassemble ball bearing, reverse the order of (4) and a new retaining ring (3).
disassembly. Press bearing (20) flush to shoulder on
clutch gear (10). Install new retaining ring (22). Operate cam (5) to be sure pawls (10) engage cor·
rectly with cam ratchet.
Examine all thrust washers and replace any that are
badly worn or damaged.
Countershaft and Shaft Assembly
MAINSHAFT ROLLER BEARINGS (Figure 6·18)
Inspect railers (4) and roller bearing race (28) and 1. Assemble thrust washer (16), second gear (15) and
replace If badly pitted, scored or worn beyond filling gear spacer washer (14) on countershaft (17).
specifications. Assemble drive gear (13) on shaft. Make sure gear
(15) turns freely.
To remove a badly worn bearing race, remove retainer
ring (29) and roller bearing washer (30). Discard ring (29). 2. Install countershaft group into access cover.
Heat case surrounding bearing and drive race inward
from outside of case. Press new race in until shoulder Is 3. Assemble mainshaft second gear (t) wllh shifter
against case inner surface. See transmission SPECIFI· fork (14, Figure 6·16). Slip shifter fork over fork
CATIONS for correct fit of mainshaft right side roller shaft (20) with finger roller stud toward access
bearing. cover and fork fingers engaged in running slot of
gear.
COUNTERSHAFT BEARINGS
4. Repeat operation with second fork (15) and
To replace countershafllow gear bushing (24), press old countershatt third gear (12). Position finger railer
bushing out and new bushing in. stud away from access cover.
6·22
Countershaft spacing
.028 to .058 In.
41h
Space slid ing gears as

equally as possible
on both sides
Neutral position
Malnshaft spacing
.028 to .058 in.
Figure &19. Gear Spacing - 1979· Early 1984

5. Install finger rollers (15) on shifter forks (14). Insert gear washer (7), and retainer ring (6) onto main·
cam follower (16) and spring (17) in follower reo shaft (2). Use MAINSHAFT THIRD GEAR RETAIN·
tainer (18). Be sure cam follower (16) is free in cam ING RING SLEEVE, Part No. HD·96396·52, to install
follower retainer (18). retainer ring (6) into groove in mainshaft (2). This
tool prevents the retainer ring from spreading out
6. Assemble pawl and cam assembly to access cover. of shape during assembly. NEVER reuse a retainer
install shims (8) as removed; secure with bolt (1) ring.
and lockwasher (2), tighten to 20·30 ft·lbs torque.
Bend lock tab against bolt (1). 8. Insert assembled mainshaft group in second gear
(1) and clutch gear (10). Install the low gear variable
7. Install low gear (5, Figure 6·18), third gear (8), third washer (11) and position against shoulder on
countershaft. Install low gear (18) onto counter·
shaft.
Establishing Proper Gear Spacing
1. See Fig ure 6·20. Using a feeler gauge, check
clearance between clutch faces and gears, as
shown. See SP ECIFICATIONS for clearance
tolerances.
See Figure 6-19. Clearance between a sliding gear
and its mating members must be equal on both
sides.
2. Adjust spacing by:
a. Changing shift forks (14, Figure 6-16) size (- .020

In., standard and + .020 in. sizes are available).
Changing forks will move individual sliding gears.
b. See Figure 6·16. Changing pawl carrier support

shims (8). Adding or deleting shims will move
both shaft forks, the same distance in the same
Figure &20. Measuring Gear Spacing - 1979· Early 1984 direction.
25% Engagement
50% Engagement
Figure 6-21. Gear Engagement - 1979· Early 1984
Gear Engagement
1. After correct gear spacing has been achieved

mechanical gear engagement must be checked.
With complete transmission assembled to access

door observe gear dog/pocket engagement:
2. See Figure 6·22. Slowly rotale pawl carrier until

pawl carrier contacts lifter arm. Use hand pressure
on shifter cam to prevent cam follower from com·
pleting shifts.
3. See Figure 6·21. Shift transmission Into all four

gears (upshift and downshift), as instructed above.
Observe, In each shift, gear dog/pocket engage·
ment. Engagement of gear dog into pocket must be
Figure 6·22. Checking Gear Mechanical Engagement at least 50% in every gear except low gear which Is
- 1979· Early 1964 25%.
See Figure 6·16. Filing or replacing lifter arms (26

c. Changing gear shaft thrust washer (11) (.065, .075,
and 27) will produce changes in gear dog/pocket
.085, .100 In. thick sizes are available). This can be
engagements.
used In conjunction with shift forks and pawl
shims 10 establish proper counlershaft 3rd gear 4. Releasing hand pressure will allow cam follower to
spacing. further rotate shifter cam. This motion combined
with the action of gear back angles will draw gear
NOTE dogsfpockets into complete engagement.
If gear shaft thrust washer(11) is changed, countershaft See Figure 6·16. Filing or replacing lifter arms (26
end play wfll have to be checked and may require and 27) will prOduce changes in gear dog/pocket
reshlmmlng. engagements .
.. 24
Establishing Malnshall and screws (4). Do not Ughten screws (4). Temporarily posl·
tlon sprocket (3) on malnshalt to correctly locate reo
Countershall End Play tainer (5). Remove sprocket (3) and securely tighten
(Figure 6·18) screws (4). Reassemble sprocket, lock washer (2) and
mainshaft nut (I). Tighten nut (1) to 35-65 It·lbs torque.
Temporarily select the thinnest variable low gear Bend ears ollockwasher (2) against head of nut (I).
washer{s) (19, Figure 6-18) and malnshafl thrust washer
(3) and InstaH In their respective positions. On early Install rear drive chain. See REAR CHAIN, REMOVAL
1983 and prior vehicles, the mainshaft thrust washer AND INSTALLATION.
has a tang. Install thrust washer (3) with tang down as
positioned In transmission compartment. CAUTION
Temporarily install access cover to crankcase with all Make sure that rea r chain spring clip open end traUs the
transmission parts. Carefully align cover on dowel pins, dlractlon of cha in t ravel.
and, with a rawhide maliet, genlfy tap cover inlo posi-
tion. Secure access cover with four cap screws, (2, Install starter as described in STARTER, Section 5.
Figure 6·13).
Install clutch as described in this section, under
USing a dial indicator, check end play 01 mainshaft (2, CLUTCH.
Figure 6·18) gaugIng from sprocket side of shaft. Press
against clutch gear (10) so that bearing (20) seats Fill transmission compartment with all as described In
against lock ring (21) In access cover. Move shaft back this section, under LUBRICATION.
and forth and measure end ptay while holding clutch
gear in. With access cover sUlI in place, measure end
play of countershaft from access cover side using a dial Crankcase and Transmission
Indicator. Bend a discarded spoke and wedge In
countershaft end hole. Pull and push counlershaft and The following assembly procedure should be followed
al the same time, measure amount of end play. If end only if the crankcases have been separated, an opera·
play of transmission malnshaft (2) is not within .003 tlon normally performed In conjunction with a complete
minimum or countershaft (17) is not within .004 to .009 engine overhaul.
in. limits, II is necessary to remove access cover and In·
stall correct size variable thickness thrust washers (3) Position left crankcase side on workbench with
and (19) to obtain correct fit. Variable thickness main· transmission compartment facing up. Proceed to
shaft thrust washers (3) are availabie in four sizes, 0.098 assemble transmission shifter mechanism, mainshaft
In., 0.107 in., 0.116 in., and 0.125 in. for 1979 and up and countershaft groups as described in TRANSMIS·
vehicles, and in ten thicknesses 0.030 in. to 0.085 In. for SION ASSEMBLY.
1978 and earlier vehicles.
To establish correct transmission malnshaft and
Countershaft thrust washers (19) are available In nine countershaft end play, temporarily assemble right and
thicknesses 0.020 In. to 0.075 In. for ail vehicles. left crankcase sides, less flywheel assembly, together
with two upper and two lower case bolls. Then, lollow
With mainshaft and countershaft end play established, the procedure lor establishing correct end playas
center the gear shifter lever arm shaft (21, Figure 6·16), described in ESTABLISHING MAINS HAFT AND COUN·
so thai it will engage with gear shifter pawl yoke when TERSHAFT END PLAY. Disregard instructions pertain·
access cover Is in place. Make sure lever arm Is correct· Ing to removing and Installing access cover.
Iy engaged with shifter pawl yoke by IighUy rotating
countershaft and testing for engagement. When transmission Is completely reassembled and cor·
rect tolerances establ1shed, continue to reassemble
With transmission and access cover assembled, install crankcase as described in ASSEMBLING CRANKCASE,
23 malnshalt rollers (4, Figure &-18). Install roller bear· Section 3. Fill transmission compartment with 011 as
ing washer (3O)and roller bearing retainer ring (29). described below.
CAUTION
Roller washer must be Installed between roller. and r. LUBRICATION

t al n l ~
ring or engine damage may result.
With motorcycle standing straight up, remove 011 filler
plug using PLUG REMOVAL TOOL, Part No. H0.J3186,
Malnshafl Sprocket, and 011 level screw. The 011 filler plug is located near the
lOp of the chain case cover and the oil level screw Is
Starter and Clutch Assemblies located near the bottom of the chain case cover.
(Figure 6·12)
Refill transmission with Harley·Davidson POWER
Instal\loot shifllever and shift transmission Into fourth BLEND SUPER PREM IUM OIL. If POWER BLEND
gear. Install gasket (6), 011 seal and retainer (5) and SUPER PREMIUM OIL is not available, use grade 20150
6-25
above 40· F., and grade 58W below 40· F. (approximate· Drain transmission and refill 10 correct level with fresh,
Iy 24 oz.). Add 011 until II begins to overflow through 011 clean 011 once each year or every 5000 miles, whichever
level hole. Permit excess oil to flow from oil level hole comes lirst.
until il ceases 10 run. This Is Ihe correcl oil level. Re·
insert and tighten 011 level screw and oil filler plug.
6·26
KICK STARTER
1979 XLCH
worn slarler ralchelleelh (18 and 6), damaged spring (8)
GENERAL or ralchel gear (6) binding on spacer m.
The kick starter Is designed for rugged service and will
seldom require attention. However, If any irregularity OISASSEMBL Y
should develop It is of utmost Importance that the (Figure 6-23)
engine be turned off and starter mechanism serviced
Immediately.
Remove slarter crank clamp boll and relalnlng ring (1).
See Figure 6-23. A service problem will be indicated by a Remove starter crank (2). Remove right footres t
ralchetlng (clicking) sound with engine running and assembly. Remove rear brake master cylinder mounting
starler crank upright as positioned on motorcycle. Rat- bolls and move master cylinder up, out of Ihe way. Do
cheUng Is caused by the starter ratchet gear (6) teeth not disconnect brake line. Remove acorn nut and lever
making partial contact with starter ratchet (18) teeth, as from rear brake pivot shaft. Loosen the exhaust pipe
the result of either a loose kick starter shaft nut (9), ex- and muffler. Remove sprocket cover screws and
cessive kick starter crankshaft (11) end play or a loose sprocket cover (5).
starter c rank gear cam plate (20).
Remove clutch as described in CLUTCH DISASSEMBLY.
If the kick starter crank (2) slips or partially engages
when crank Is rolaled Ihrough lis cycle, check for badly Rotate kick starter crank gear (12) to free starter ratchet
1. Crank clamp bolt, retaining ring 8. Ratch.t aprlng 18. Shaft bushing (2)
2. Crank and pedal ••••mbly 9. Shaft nut 17. Spring stud
3. Cr.nk .pring 10. Crank g.ar lockw.aher 18. St.rter r.tchet
4. Cr.nk clamp .nd boll (2) 11 . Crank.haft 19. Crank g.ar cam pl.t. rivet (5)
5. Sprocket cover 12. Crank gear 20. Crank gear cam pl.te
8. Starter ratch.t gear 13. Crank 041 a•• 1 21. Crank gear slop pin
7. Clutch aprock.t apacer (avail.bl. 14. Crankshaft shim · .007" 22. Crank gear stop pin w.sher
In v.rtoua I.ngtha) 15. Shaft thrust pl.t. 23. Bushing
24. Gre... fitting
Figure &-23. Kick Starter
6-27
gear (6), spacer (7) and spring (8). Remove crank nut (9)
and lockwasher (10). Tap end of kick starter crankshaft
(11) with a soft mattet to loosen from gear (12). Remove
crankshaft (11), oil seal (13), thrust plate (15), and shims
(14), if used.
NOTE
Shims (14) are only used to establish correct crankshaft

end play when crankshaft and thrust washer are worn.
INSPECTION AND REPAIR

(Figure 6-23)
Clean all parts in cleaning solvent and blow dry with

compressed air.
Inspect and replace starter ratchet gear and starter rat·

chet (6 and 18), if necessary. Especially check lor badly
worn or damaged ratchet teeth that may cause partial
or no engagement of ratchel (18) and gear (6). Examine
gear (6) bushing face for burred or damaged condition
affecting free movement of gear on spacer (7). Recheck
lor binding by assembling gear on spacer and note ac·
tion of two paris.
Examine starler ratchet spring (8) for collapsed condi·

lion or breakage, and compare with new spring, il pos·
sible. New spring free length is approximately 1 in.
1. Starter crankshaft shim· .007"
Inspect kick starter crankshaft (11) for bent condition or 2. Starter shaft thrust plate
badly worn bearing surfaces and particularly for wear 3. Starter crank gear stop pin washer
on thrust plate (15) and shaft collar faces. Temporarily
position shaft (11), seal (13) and plate (14), gear (12), Figure 6·24. Installing Starter Crankshaft
washer (10) and nut (9) in left case and check crankshaft
end play with dial indicator. If end play is not within
specified limits of .001 to .007 in. it is absolulely Slarter gear stop pin (21) and washer (22) ordinarily will
necessary to shim crankshaft. Use .007 in. thickness not require replacement, and it is recommended pro·
shim, Pari No. 6802, between crankcase and thrust cedure to inspect and replace stop pin only with engine
washer to obtain correct fit as shown in Figure 6·24. removed from chassis. Stop pin is a press fit in
crankcase. Washer is locked in place by peening stop
Examine starter crank gear assembly (12) for wear and pin end.
damage. Pay particular attention to cam plate (20) ears
for wear or bent condition. Check for loose cam plate ASSEMBLY
rivets (19) that may result in cam plate separating from
crank gear. Cam plate may be replaced providing gear (Figure 6-23)
(12) is in good condition. When riveting new cam plale to
crank gear, insert rivets from gear side. Install oil seal (13) in left crankcase. Slip crankshaft
through hole in motor mount~ Slip thrust plate (15) on
Check lockwasher (10) and oil seal (13), if worn or starter crankshaft (11), flat side of plate up as position·
damaged, replace parts. ed on motorcycle. Insert steel shims (14) on crankshaft
if needed, as described under INSPECTION AND
Bronze bushings (16) are a press fit in transmission REPAIR, and install crankshaft In left case engaging
sprocket cover (5) and left crankcase. Bushings are long notched thrust plate (15) with stop pin washer (22) using
grease to hold in place (see Figure 6·24).
life parts and will seldom require replacement, however,
if shaft (11) is not badly worn and excessive starter
crankshaft radial play is noled, bushings should be Turn starter crankshaft until notch (A, Figure 6·23) is to
replaced when installing sprocket cover bushing be the rear as positioned on motorcycle. Place starter
sure to correctly align hole in bushing with cover grease crank gear on squared end of shaft, recessed portion of
fitting channel. cam plate facing down, end of slot against stop pin as
6·28
shown in Figure 6·25. When positioning crank gear (12)
on shaft (1 1) be extremely careful that thrust plate does
not become dislocated from stop pin washer (see
Figure 6·25).
Slip lockwasher (10) over crankshaft end (11) engaging

prong of washer with hole In crank gear face. Install and
securely lighten crank nut (9) to 55·65 ft·lbs torque, with
flat side of nut against washer.
Slip starter ratchet gear (6) over spacer (7), grooved side
of gear bushing against lip of spacer collar. Position
small end of spring (8) in clutch gear bushing groove.
Place starter ratchet gear assembly on clutch gear,

compressing spring (8) and at the same time turning
starter crank gear to permit meshing of gear teeth.
Return starter crank gear to original position as shown

In Figure 6·25, with clutch ratchet held against cam
plate by spring tension. Figure 6·25. Positioning Starter Crank Gear
On Starter Shaft
Check gear (6) and crank gear (12) to see that there is a
gear lash (play) through range of engagement.
Install transmission sprocket cover (5) and screws. In·
CAUTION stall exhaust pipe and muffler. Reinstall master cylinder
and adjust as described under REAR BRAKE.
See Figure 6·23. If clutch sprocket spacer only (7), Is
replaced, the new spacer must be exactly the same Slip spring (3) over squared end of shaft (11), end of
length as the old spacer. spring and notch (A, Figure 6·23) up as positioned on
motorcycle. Using a screwdriver rotate spring clockwise
Reassemble clutch as described in CLUTCH and engage with stud (17). Install starter crank (2) and
ASSEMBLY. bolt and retaining ring (1).
6-29
SPECIFICATIONS
(LATE 1984 AND 1985)
TRANSMISSION Second gear

On shaft (lOOSe). . . . . . . . . . • . .001 in.· .0025 in.
Low gear
Capacity On shaft (loose). .0005 in.· .0016 in.
Drive gear
Chain case lubricant. 1.5pts. On shaft (lOoSe) . .0005 in . · .003 in.
Countershaft low and third gear. .028 in.· .058 in.
Countershaft second and third gear .. 028 i n.· .058 in.
Overall Gear Ratios Countershaft end play. . ... 004 in.· .015 in.
First (LOw) gear. 10.01
Second gear 7.25 TORQUES
Third gear 5.49
Fourth (High) gear ..... .... .•.. 3.97 Mainshaft n ut locking SGrew . 50·60 in·lbs
Mainshaft nut .. . .. .. ......... • • . 35·65 ft·lbs
Access cover screws. 13-15 ft·lbs
Drai n plug 14·21 ft·lbs
CLUTCH Front chaincase
Cover screws 80 t0 11 0in·lbs
Type Wet· Mult iple disc Chain tensioner st ud nut . 8·12 ft·lbs
Capacity. 174 ft-Ibs Stator screws (4 slotted) 20·35 in·lbs
Spring Force (engaged). 3041bs Stator mounting
(disengaged) . 260lbs Screws (4 hex·socket) 20·35In·lbs
Clutch shell bearing Torx fasteners .... .. ....... . 30 to 40 in·lbs
on clutch gear(IOOSe) . .0000 in. - .0010 in.
SERVICE WEAR LIMITS

MAINSHAFT GROUP
NOTE
Clutch gear ball bearing
in access cover (lOOse) . .001 in . . 0012 in. Wear limits are given as a guideline for measuring
Ball bearing on clutch engine components tha t are not new. For new com·
gear (light) . .0009 in. ponents or for measurements not given under SERVICE
Clutch gear WEAR LIMITS, see the foregoing.
on mainshaft (loose) .001 .. 002 In.
Mainshaft right side retained Clutch plate stack. .025 in.
roller bearing (loose). .001 in. - .0034 in. Friction plate. .0025 In.
Mainshaft end play' Intermediate plate. .001 in.
(minimum) .009 in. Mainshaft - clutch gear ball bearing
(maximum) . .015 in. in access cover (loose) .001 ..0035 in.
Third gear Mainshaft - ball bearing on clutch gear (loOSe) .. 001 in.
on shaft (loose) . .002 in . . 003 in. Clutch gear bearing
end play. ..... . . . ...... .012 in.· .030 in. on mainshaft (loose) . .001 ..0035 in.
Clearance between clutch faces Mainshaft right side retained
mainshaft fourth gear and roller bearing (loose) . .001 .. 0035 in.
second gear. .028 i n.' .058 In. Mainshaft - third gear
mainshaftthlrd gear and on shaft (loose) . .002 i n.· .004 in.
second gear. .028 i n. · .058 in. Countershaft bearing f it
on shaft ends (loose) . .0005· .0035 in.
COUNTERSHAFT GROUP
Cou ntershaft end bearings . Retained needle
roller bearing
Bearing f it on shaft ends (loose) .. .0005 in . · .003 In.
Beari ng f it on case press fit
6·31
CHAINS
(LATE 1984 AND 1985)
8. Remove foreign malerial from magnetic drain plug

FRONT CHAIN (2). Replace and securely tIghten draIn plug to
14·21 It·lbs torque.
Replacing Chain Adjuster 9. Reinstall chain case cover and gasket; footrest
(Figure 6·26) assembly, tightening nul to 24-36 fI-lbs torque; and
gear shift lever, tightening pinch boll to 90 to 110
WARNING in-Ibs torque.
10. Adjust Ironl chain as described previously. Fill
Di sconnect the battery cabl es (negative cable first) to with correct amount of lubricant as described in
avoid accidental startup of vehicle and possi ble per· TRANSMISSION, this sectIon.
sonallnjury.
11. Install the clutch adjusting screw nut (12, Figure
1. Remove drain plug and drain all from the chain- 6-28) turning the adjusting screw counterclockwise
case. until the nut fits Into the hexagon recess in the
cover.
2. Remove gearshifter lever and left footrest
assembly. 12. Adjust the clutch as described under CLUTCH in
this section, then Install the lockplate (13), spring
3. Relax chain tension by loosening locknut (1) and (14) and access plug (16).
unscrewing the chain adjuster screw (2).
13. Connect the negative battery cable to the battery.
4. Remove the clutch adjustment access plug (5). spr-
ing and lockplate from the front chain cover.
5. Turn the clutch adjusting screw clockwise until the

adjusting screw nul can be removed.
6. Remove the screws securing the Irani chain cover

and remove the cover and gasket.
2. Drain plug 5. Engine sprocket nut

3. Spring 6. Clutch assembly
Figure 6·27. Replacing Chain and Adjuster

(Late 1984 and 1985)
Figure 6·26. Front Chain Tension Adjustment

(Late 1984 and 1985)
7. Pull chatn adjuster (1, Figure 6·27) and spring (3) REAR CHAIN
from stud. Transfer spring (3) 10 new adjusler and
install assembly on Ihe crankcase stud. See CHAINS (1979 - EARLY 1984), REA R CHAIN.
..33
CLUTCH
(LATE 1984 AND 1985)
GENERAL
Troubleshooting
Effec t Ca use (Check in foll owi ng ord er) Remedy

Clutch slips Incorrect clutch release adjustment. Check and adjust clutch release mechanism
as described under CLUTCH RELEASE
MECHANISM.
Clutch drags Incorrect clutch release adjustment. Check and adjust clutch release mechanism
as described under CLUTCH RELEASE
MECHANISM.
Worn clutch release ramps or balls. Replace release ramps and lor balls. See
CLUTCH RELEASE MECHANISM .
Warped clutch sleel plates. Replace clutch sleel plates. See CLUTCH.
Badly worn or damaged clutch

sprocket splines. Replace clutch sprocket. See CLUTCH.
Clutch Release Mechanism DISASSEMBLY

(Figure 6·28)
(Figure 6·28)
WA RN ING
ADJUSTMEN T
1. loosen control cable adjuster locknut (3) and turn
avoid accidental startup of vehicle and possible per·
adjuster (2) inward until there is a large amount of
sona l Inj ury.
free play at hand lever or handlebar.
1. Remove the drain plug and drain the oil from the
2. Remove access plug (16) from the front chain cover
Iront chain case.
using ACCESS PLUG REMOVAL TOOL, Part No.
HO·33186.
2. Remove the gear shUter lever and left footrest
assembly.
3. Remove the adjusting screw lockplate (13) and spr·
ing (14). Turn the clutch adjusting screw (15)
3. Remove the access plug (16) from the chain cover
counterclockwise until free play has been removed
clutch adjustment opening, then remove the spring
from the screw.
(14) and lockplate (13). Remove the clutch adjust·
ing nut (12).
4. Turn the clutch adjusting screw (5) clockwise 1/4
turn, t hen install the lockplate (13) and spring (14)
4. Loosen the locknut and back off the front chain ad·
on the adjusting screw flats. If the hex on the
justing screw.
lockplate does not match up with the recess in the
primary cover, rotate the adjusting screw clock·
5. Remove the front chain cover.
wise until the match·up is achieved, then install
the access plug (16).
6. Remove the screws (6) securing the release me·
chanism and lift the mechanism from the cover.
5. Turn the cable adjuster (2) counterclockwise until
all slack in the cable (1) is eliminated, then use
cable adjuster (2) to obtain 1116 in. free play be· NOTE
tween the hand lever and bracket.
Hold the release ramps (8) and (10) together to prevent
6. Tighten t he cable adjuster locknut (3). the bafls (9) from falfing 8nd becoming lost.
6·35
1
-------~5
~6
10
1. Cable 8. Screw 12.. Nut
2. Cable adJust.er 7. Lockplate 13. Lockplate
3. Locknut 8. Inner ramp 14. Spri ng
4. Washer 9. Ball (3) 15. O-rIng
5. Clutch adjusting 10. Quter ramp 18. Plug
screw assembly 11 . Coupling
Figure 6·28. Clutch Release Mechanism - Late 1984 and 1985
7. Disconnect the clutch cable (1) from the coupling 2. Install the cable coupling (11) on the cable end,
(11). then position the coupling in the ramp (10).
CLEANI NG, INSPECTION AND REPAIR 3. Apply mu lti·purpose grease to the balls (2) and
ramps (8) and (10), then Insert the balls in the ball
1. Wash the clutch releasing mechanism compon- sockets between the ramps.
ents In cleaning solvents.
4. Position the ramp assembly on the chain cover and
2. Inspect the three release mechanism balls (9) and secure with lockptate (7) and hex head screws (6).
ball socket surfaces on ramps (8) and (10) for wear, Tighten the screws to 22-30 in·lbs, then bend the
pitting, surface breakdown and other damage. Re- lock tabs on the lockplate to secure screws.
place damaged parts.
5. Adjust cable sleeve (2) to take all slack out of
3. Check fit of the hub on ramp (10) In ramp (8) and cable.
replace both parts If excessive wear exists.
6. Install front chain cover on engine, tightening cov·
4. Check clutch cable ends for frayed or worn ends er screws to 80·110 in·lbs torque.
and replace cable (1) if damaged or worn.
7. Refill the transmission with approxim ately 1.5
ASSEMBLY pints of Harley·Davldson FRONT CHAIN CASE
LUBRICANT, Part No. 99887-84. Add 011 until it
1. Install the locknut (3) and flat washer (4) on the begins to overfl ow through t he oil level hole with
cable adjuster (2), then Insert the adjuster and the vehicle In an upright posit ion. Allow excess oi l
cable Into the front chain cover. to flow from the 011level hole until It ceases to run.
6·36
This is the correct level. Insert and tighten the oil Installation (Figure 6·29)
level screw and all filler plug.
1. Install the engine sprocket, clutch shell and front
8. Instal l the clutch adjusting nut (12). chain as a unit. With the clutch shell installed on
the clutch gear, install space (23) and new retain-
Adjust clutch as previously described under Ing ring (24).
ADJUSTMENT, then install the locking plate (13)
and spring (14). 2. Install the guide and adjusting screw assembly in
the pressure plate and secure with a new retaining
9. Install access plug in cover. Install gear shift lever, ring (6).
tightening pinch bolt to 90-110 in-Ibs torque. Install
left footrest assembly, tightening mounting nut to 3. Install the engine spro cket nut and tighten it to
24-36 ft-Ibs torque. 150-165 fI-lbs torque.
10. Connect the battery negative terminal to the bat- 4. Install a new gasket on the front chain cover, then
tery. assemble the cover to the chain case. Tighten Ihe
cover mounting screws to 80-11 0 in-Ibs torque. Be
sure the correct length screws are installed in the
Clutch
proper holes.
REMOVAL
5. Install the gearshaft lever, tightening the pinch
WARNING boll to 90-110 In·lbs torque, then install the left
footrest, tightening the nut to 24-36 ft-Ibs torque.
To avoid accidental start·up of vehicle and possible per-
sonal Injury, disconnect the battery cables (negative 6. Install the clutch adjusting screw nut and adjust
cable first) before performing any of the following pro· the clutch as described in CLUTCH ADJUSTMENT.
cedures. Instalilockplate and spring, and install the access
plug.
1. Remove drain plug and drain oil from chain case.
7. Readjust front chain tension as described under
2. Remove gear shifter lever and left footrest as- FRONT CHAIN in this section.
sembly.
B. With motorcycle standing straight up, remove plug
3. Loosen front chain adjuster until chain is com- and oil level screw. Add 24 oz. of Harley-Davidson
pletely slack. FRONT CHAIN CASE LUBRICANT, Part No.
99887-84 until it begins to overflow through oil
4. USing ACCESS PLUG REMOVAL TOOL, Part No. level hole. Allow excess oil to flow from hole until
HD·33186, remove the clutch adjusting access il ceases to run. This is correct oil level. Replace
plug, then remove locking plate (4, Figure 6·29) and the access plug and oil level screw.
spring (3).
9. Reconnect battery cables, positive cable first.
5. Turn the clutch adjustment screw clockwise and
remove the adjusting screw nut (5), then remove
the front chain cover. DISASSEMBLY
6. Remove the engine sprocket nut. WARNING
7. Remove the retaining ring (6) securing the guide To avoid accidental start·up of vehicle and possible per·
and adjusting screw assembly (Items 7 through 10) sonal Injury, disconnect the battery cables (negative
in the pressure plate (26), then remove the guide cable first) before performing any of the following pro·
and adjusting screw assembly. cedures.
8. Remove retaining ring (24) and spacer (2~), then NOTE

remove the clutch assembly, front chain and en-
gine sprocket as an assembly. Disassembly of the clutch assembly should only be
accomplished with the clutch on the vehicle.
If necessary, use the slotted porti on of PULLER,
Part No. HD·97292-61 and two bolts to loosen the 1. Remove drain plug and drain oil from chain case.
eng i ne sprocket.
2. Remove gear shifter lever and left footrest
NOTE assembly.
Res/stance to clu tch shell removal is due to the mag- 3. Loosen front chain adjuster until chain is com-
netic attraction of th e alternator rotor magnets. pletely slack.
6-37
1. Access plug 10. Adjusting screw 19. Clutch shell
2. 0·rlng 11. Snap ring 20. Bearing
3. Spring 12. Spring seat 21. Retaining ring
4. Locking plate 13. Spring seat 22. Clutch hub
5. Nut 14. Spring 23. Spacer
6. Retaining ring 15. Friction disc 24. Retaining ring
7. Retaining ring 16. Drive plate 25. Spring seat
8. Guide 17. Retaining ring 26. Pressure plate
9. Be.rlng 18. Spring plate
Figure 6·29. Clutch, Exploded View - Late 1984 and 1985
6·38
4. Using ACCESS PLUG REMOVAL TOOL, Part No. netic attraction of the alternator rotor magnets.
HD-33186, remove the clutch adjusting access
plug, then remove locking plate (4, Figure 6·29) and 9. Remove re taining ring (17) and separate the clutch
spring 13). hub (22) and shell (19).
5. Turn the clutch adjustment screw clockwise and INSPECTION AND REPAIR
remove the adjusting screw nut (5), then remove
the front chain cover. 1. Examine the steet driven plates (16) and (18) for
warpage and excessive wear, grooving or scoring
WARNING or running surface. Replace if necessary. See
WEAR LIMITS.
Do not attempt removal of snap ring (3, Figure 6-30)
without using SPRING COMPRESSION TOOL, Part No. 2. Pay particular attention to the friction drive plates
HD·34761. The snap ring is under high spring tension (15). Plates that have badly worn, grooved, scored
and can cause personal injury if tension on it is not or burned friction surfaces should be replaced. If
relieved prior to removal. oil grooves are worn away, replace friction plates.
5. Install SPR ING COMPRESSION TOOL, Part No. 3. Examine bearing (20) In clutch shell (19) for
HD·34761 as shown in Figure 6-30 and secure with roughness or excessive play. If necessary to reo
nut (1). Turn adjusting screw (2) counterclockwise place bearing (20), remove retaining ring (21) and
until the tool relieves pressure on snap ring (3). press bearing (20) from the shell.
Remove the snap ring, then turn adjusting screw
clockwise and remove nut and the tool (4). 4. Examine bearing (9) in the lifter guide (8) for
roughness or excessive play and replace if
7. See Figure 6·29. Remove the outer clutch spring necessary.
seats (12) and (13), clutch spring (14) and inner
clutch spring seat (25), pressure plate (26) and the 5. Inspect clutch shell (19) for badly worn splines,
lifter guide and adjusting screw assembly (7 thru loose rivets, worn sprocket teeth or damaged ring
10). The entire clutch pack can now be removed. gear teeth. It noticeably damaged, replacement
clutch shell is recommended.
ASSEMBLY (Figure 6·29)
Assembly is essentially the reverse of disassembly. Be

certain that all parts are clean before assembly.
1. If removed, press bearing (20) in the clutch shell

(19) and secure with a new retaining ring (21).
2. If separated, install clutch hub (22) in shell bearing

(20) and secure with new retaining ring (17).
3. Install the engine sprocket, clutch shell and front

chain as a unit. With the clutch shell installed on
the clutch gear, install spacer (23) and new retain·
Ing ring (24).
4. Instal l the engine sprocket nut and Ughten it to

150·165 ft·lbs torque.
2. Adjusting screw 5. Install a frlctton disc (15), a drive plate (16), then
alternately instal l the remaining friction discs and
Figure 6·30. Clutch Spring Compression Tool dri ....e plates. The spring plate (18) is installed be-
(late 1984 and 1985) tween the third and fourth friction discs from the
8. If it is necessary to remove the clutch shell, clutch shell (19).
remove the engine sprocket nut (5, Figure 6-27).
Use slotted po.rtion of PULLER, Part No. 6. If removed, assemble bearing (9) and adjusting
HD·97292-61 and two bolts to loosen the engine screw (10) in guide (8) and secure with new retain-
sprocket. Remove the clutch shell retaining ring ing ring (7). Install adj usting screw assembly In the
(24, Figure 6-29) and spacer (23). Then pull the pressure plate (26) and secure with a new retaining
engine sprocket, clutch shell and front chain as a ring (6).
unit.
7. Position the pressure plate (26) In the clutch shell.
NOTE Slip the Inner spring seat (25) over the pressure
Resistance to clutch shell removal is due to the mag· plate hub, concave side toward the pressure plate.
6·39
8. Position the clutch spring (14) on the hub, then in- to90-110 in·lbs torque, then install the left footrest,
stall the U-shaped outer spring seat (13), concave tightening the nut to 24-36 ft·lbs torque.
side out, and the flat spring seat (12) in the pres-
sure plate (26). 12. Install the clutch adjusting screw nut and adjust
the clutch as described in CLUTCH ADJUSTMENT.
9. Install SPRING COMPRESSION TOOL, Part No. Install lock plate and spring, and instatlthe access
HD-34781 on the adjusting screw assembly and se- plug.
cure with nut(s). Turn the adjusting screw counter-
clockwise until the clutch spring is fully com· 13. Readjust front chain tension as described under
pressed, then install a new snap ring (11). With the FRONT CHAIN in this section.
snap ring fully seated in the groove, remove the nut
and compreSSion tool. 14. With motorcycle standing straight up, remove plug
and oil level screw. Add 24 oz. of Harley-Davidson
10. Install a new gasket on the front chain cover, then FRONT CHAIN CASE LUBRICANT, Part No.
assemble the cover to the chain case. Tighten the 99887-84 until it begins to overflow through oil
cover mounting screws to 80·110 in·lbs torque. Be level hole. Allow excess oil to flow from hole until
sure the correct length screws are installed in the it ceases to run. This is correct oil level. Replace
proper holes. the access plug and oil level screw .
11. Instatlthe gearshift lever, tightening the pinch bolt 15. Reconnect battery cables, positive cable first.
TRANSMISSION
(LATE 1984 AND 1985)
Access Cover Removal 4. Remove the rear chain sprocket cover from the
right side of the motorcycle. Refer to STRIPPING
1. Unless transmission is damaged inside so it can· MOTORCYCLE FOR ENGINE REPAIR, Section 3.
not be shifted from one gear to another, shift into 5. See Figure6-31. Remove the lockscrew (1) from the
high gear. sprocket, then remove the mainshaft sprocket nut
2. Place a drain pan under the engine and drain the (2). Remove the rear chain and sprocket.
chaincase. 6. See Figure 6-32. Remove the four screws (1) secur-
3. Remove the chaincase cover, clutch, front chain ing the alternator stator (2) to the stator mount (3).
and engine sprocket as described in CLUTCH Swing the stator away from the access door and
REMOVAL, in this secUon. remove the stator spacer (4).
ON LATE 1985 MODELS:

See Figure 6·33. Remove the four screws (1) securing
the alternator stator (2) to the access door. Swing the
stator away from the access door.
NOTE
It is not necessary to completely remove the stator

from the crankcase for access door removal.
7. Remove the three bolts (1) and bolt (4) securing Ihe
access cover to the chalncase, Figure 6-34.
8. See Figure 6-35. Place the stator on the clutch gear

to gain access to the lower slot in the access
cover. USing an alignment tOOl , SNAP-ON 1650 or
MAC LF·12, pry alternately at the removal slots 10
draw access cover from the locating pins.
NOTE
1. Lock screw 2. Mainshaft sprocket nut
It may be necessary to heat cover around pins to ease
Figure 6·31. Malnshaft Sprocket - Late 1984 and 1985 cover removal.
6·40
1. 8011(3) 3. Stator
2. Access cover 4. Bolt
1. Screws (4) 3. Access cover
2. Stator 4. Spacer Figure 6-34. Transmission Access Cover Hardware _
Late 1984 and 1985
Figure 6-32. Stator Removal - Late 1984 and 1985
gear shifter cam follower (16) and springs (17) will
remain on the access cover, or they may fall free.
2. USing a snap ring pliers remove retaining ring (3)

and washer (4). Free the cam (5), pawl carrier (6),
pawl carrier support (7) and pawl carrier support
shims (8) (If used).
1. Tont fastener (4) 3. Access cover

2. Stator
Figure 8·33. Stator Removal - Late 1985
9. Remove the stator from the clutch gear, then Figure 8·35. Removing Transmlnlon Access Cover _
remove the transmission as a unit, Figure 6·36. Late 1984 and 1985
Shifter Mechanism Removal 3. Remove the pawl carrier springs (9) from the pawl
and Disassembly carrier support.
(Figure 6·37)
4. To disassemble the pawl assembly, remove the reo
1. Remove shifter mechanism from the access door talnlng rings (13) to free pawls (10), spacers (12),
by removing capscrew (1) and lockplate (2). The and springs (11) from the pawl carrier (6).
...,
cleaning solvent. Blow parts dry with compressed
air and Inspect to determine if any must be re-
placed. Replace all parts that are badly worn or
damaged.
2. Inspect the mains haft sprocket for badly worn or
damaged sprocket teeth and splines.
3. Check the mainshaft oil seal In the crankcase for
damage. Replace seal.
4. See Figure 6·37. Carefully examine gear shifter
cam (5) for grooved or worn cam slots at various
running gear pOSitions. Excessive wear at thrust
points will make the transmission difficult to shift
through gear range.
5. Inspect gear shifter pawl carrier (6) for depressions

or grooves worn in fingers that engage shifter lever
arm shaft (21). A badly worn yoke is caused by rub·
bing action of lever arm shaft ball, and will result in
transmission jumping out of gear. Examine pawl
carrier support for breakage or minute surface
cracks. Loosely assemble shifter cam (5), pawl car-
rier (6), support (7), shims (8) (if used), and check
bearing action for appreciable play. Parts that
show extremely worn or pitted surfaces should be
replaced.
F~ure 6-36. Transmission Removed - late 1984 and 1985 6. Examine pawl carrier springs (9) for breakage or
damage caused by acids in oil. If pOSSible, com·
pare old springs with new springs. New spring free
Mainshaft and Countershaft length is approximately 2-21/32 in.
(Figure 6-38)
CAUTION
1. Remove the mainshaft assembly from the clutch
gear (10), then slide the mainshaft second gear (1)
Do not use cadmium plated, 14-coll pawl ca"ier springs.
from the malnshaft (2).
Use only cadmium plated, 16·coil springs or black
2. Remove the retaining ring (6) and washer (7), then phosphatlzed springs, 14 or 16-coll, when reassembling
slide the mainshaft third gear (8) from the main· pawl carrier support.
shaft.
7. Examine shifter pawls (10) for wear, grooves,
3. Remove the end play thrust washer (3) from the cracks or breakage.
malnshaft, then use a press to remove the main·
8. Check for wear or damage to pawl (10) and carrier
shaft first gear (5) and bearing inner race (26) from
(6). Free length of new spring (11) is approximately
the mainshaft If removal is needed. Support the
1-3/4 in. between hooks.
first gear when pressing against the mains haft.
4. Remove the countershaft assembly from the ac· 9. Check shifter forks (14) tor bent condition or deep
cess cover. Slide the countershaft fourth gear (13), grooves worn In to fork fingers caused by ex·
spacer (14) and countershaft second gear (15) from cesslve thrust action of gears. Also examine both
the countershaft (17), then slide thrust washers shifter forks (14) and finger rollers (15) for
(19), countershaft first gear(18), thrust washers (11) breakage.
and countershaft third gear (12) from the counter-
shaft. 10. Check shaft (20) for bent or damaged condition by
Slipping shifter forks on shaft and noting if they
5. Remove the retaining ring (21), then remove the
have free movement on shaft.
clutch gear and bearing as an assembly from the
access cover (9). Remove the retaining ring (28) and 11. Inspect gear shifler lever arm shaft (21) for wear or
press clutch gear (10) from bearing (20), if bearing bent condition. Temporarily install shaft in
replacement is required. crankcase and check for appreciable play in
6. Press out or drift roller bearings (27), (24), (23), (22) bushings (22). If inspection indicates replacement
and (4) only if replacement Is needed. of bronze bushings (22), it is first necessary to
remove gearcase cover. Pry oil seal (23) from
recess in shaft hole with screwdriver and drift
Cleaning, Inspection and Repair bushings from right case and gearcase cover.
After pressing in new bushings, install lever arm
1. Thoroughly clean transmission compartment and shaft (21). Shaft must work freely In bushings.
all shifter, malnshalt, and counters haft parts with Remove any high spots from bushings with a half-
6·42
1. Bolt 12. Pawl spacer (2) 23. Shifter shaft 011 seal
2. Lockplate 13. Retaining ring (2) 24. Thrust washer
3. Retaining ring 14. Gear shllter forks (2) (variable) 25. Pin pawl lifter arm (2)
4. Thrust washer 15. Finger rollers (2) 26. Upper pawl lifter arm
5. Gear shifter cam 16. Cam follower 27. Lower pawl lifter arm
6. Pawl carrier 17. Cam follower spring 28. Carrier spring retainer plug (2)
7. Pawl carrier support 18. Washer 29. Cam support pin (2)
8. Shim (.010 thick) as required 19. Bolt 30. Shift shaft bushing
9. Pawl carrier springs (2) 20. Fork shaft 31. Lever
10. Pawl (2) 21. Lever arm shaft 32. Shllt lever
11. Pawl spring 22. Shifter shaft bushings
Figure 6·37. Shifting Mechanism - Late 1984 and 1985
inch reamer. To ensure against oil leakage, replace 14. See Figure 6·38. Position mainshaft (2) in
oil seal (23) when reassembling. FLYWHEEL TRUING DEVICE, Part No.
HD-96650-80. Rotate shaft and, with a dial in·
12. Inspect gears for badly battered, chipped or round· dicator, check shaft for bent condition. Shaft that
ed dogs and slots at all thrust points. This condi· is .003 in. or more out of true must be replaced.
tion will be evidenced by transmission jumping out Check the counterShaft (17) in the same manner. If
of gear. Examine gear teeth for pitting, scoring, countershaft is 0.003 in. out of true, replace it.
cracked, chipped condition or case hardening
worn through. Inspect mainshaft, countershaft 15. Examine all thrust washers and replace any that
and all gears for pitting, grooving and excessive are badly worn or damaged.
wear on bearing surfaces. Slip gears on shafts and 16. See Figure 6-37. Inspect the gear shifter cam
check for wear and appreciable play. If not within follower (16) for wear. Also check the cam follower
service limits as given in transmission SPECIFICA· springs (17). Replace badly worn cam follower.
TIONS, replace worn parts.
17. Refer to transmission SPECIFICATIONS for in·
13. Inspect all roller bearings for wear, pitting, scoring spection criteria of parts not specifically covered
and other damage. Press or drive damaged bear· in the inspection procedures.
ings from their respective housings.
Assembly
NOTE
Lubricate all parts with Harley·Davidson FRONT CHAIN
All roller bearings are press fit in their bores. Do not CASE LUBRICANT, Part No. HD-99887·84.
remove roller bearings unless their replacement is
necessary. 1. See Figure 6-39. If removed, install a new main·
6·43
1. Malnshaft second gear
2. Transmission malnshaft
3. Malnshaft thrust washer
(variable thickness) . controls
malnshaft end play 12. Countershaft third gear
4. CountershaH bearing closed end 13. Countershaft fourth gear
5. Malnshaft first gear 14. Countershaft gear spacer
8. Malnshaft third gear retainer 15. Countershaft second gear 20. Malnshaft ball bearing
ring 16. Countershaft second gear 21. Mainshaft ball bearing snap ring
7. Malnshaft third gear washer thrust washer 22. Countershaft low gear bearing
8. Malnshalt third gear 17. Transmission counterahaft 23. Clutch gear bearing
9. Access cover 18. Countershaft first gear 24. Clutch gear bearing
10. Clutch gear 19. Countershaft IIrst 25. Mainshaft thrust washer
11. Yariable thrust washer gear washer 28. Mainshaft roller bearing
Controls clearance between (variable thickness) . 27. Countershaft bearing . open end
gears Controls countershaH end play 28. Retaining ring
Figure 6·38. Transmission - Late 1984 and Later
shaft roller bearing, using MAINS HAFT BEARING against the right crankcase hall. This will properly
INSTALLATION TOOL, Part No. HD·34810 and locate the bearing .005· .015 in. below the surface
UNIVERSAL DRIVER HANDLE, Part No. HD·33416 of the crankcase.
as shown. Drive the bearing in until the tool seats
See Figure 6-41. Install a new mainshaft seal using
a suitable Instaliation tool. Seal is installed flush
to .010 in. below surface of right crankcase.
2. See Figure 6·38. If removed, press a new clutch

gear ball bearing (20) onto the clutch gear. Press
only on the bearing inner race. Install a new retain·
ing ring (28) on the clutch gear.
3. Install a new retaining ring (21) in the access cover

(9), then install the clutch gear and bearing
assembly in the access cover.
ON LATE 1985 MODELS:
See Figure 6·40. Install the clutch gear and bearing

assembly in the access cover until it contacts door
shoulder. Install a new retaining ring (21) with
beveled side facing transmission and flat side next
to bearing.
4. If removed, press new roller bearings (27), (24), (23),

Figure 6-39. Malnshaft Bearing Installation - (22), or (4) into their respective bores. Press only
Late 1984 and 1985 against the lettered side of the bearings.
6·44
Retalnlg rIng
/
Flat side toward

bearing
1. Cover
2. Screw
3. Retaining ring
4. Malnshalt fourth gear
bearing assembly
5. Stator
Figure 6·40. Transmission Cover Assembly - late 1985
NOTE lainer plugs (28) in the pawl carrier support (7). If

removed, install the upper and lower pawl Iilter
The countershaft bearing in the access cover must be arms (26) and (27) and secure them with pins (25).
pressed Into the cover .030 In. (1/32 In.) be/ow the cover
3. Assemble shifter cam (5) onto pawl carrier (6),
Inner surface.
retracting pawls one at a time to do so. Insert
assembly Into support (7), with ear of pawl carrier
(6) between springs (9). Secure with thrust washer
Shifter Mechanism Assembly (4) and a new retaining ring (3).
1. See Figure 6-37. Position pawls (10) with spacers Operate cam (5) to be sure pawls (10) engage correctly
(12) onlo pawl carrier (6) and secure with new reo with cam.
talning rings (13). Install pawl spring (11).
Countershaft and Mainshaft Assembly
2. Install the pawl carrier springs (9) and spring re- (Figure 6·38)
1. Assemble thrust washer (16), second gear (15) and
gear spacer washer (14) on countershaft (17).
Assemble drive gear (13) on shaft. Make sure gear
(15) lurns freely.
2 Inslall countershaft group into access cover (9).
Also Install shifter fork shalt to access cover.
3. See Figure 6-37. Assemble mainshalt second gear
with shllter fork (14). Slip shifter fork over fork
shalt (20) with finger roller stud toward access
cover and fork fingers engaged in running slot of
gear.
4. Repeat operation with second fork (15) and
countershaft third gear (12). Position finger roller
stud away from access cover.
5. Install finger rollers (15) on the shifter forks (14).
6. Instatl the cam follower springs (17) on the access
cover pins, then install the cam follower (16) mak-
Ing sure It is Inserted In the springs.
7. Assemble pawl and cam assembly to access cover.
Figure 6-41. Mainshaft 011 Seal and Bearing Raca- Install shims (8) as removed; secure with bolt (1)
Lata 1984 and 1985 and 10ckwaSher (2), tighten to 20-30 ft-Ibs torque.
6·45
Bend lock tab against bolt (1). in., - .0tO in. and - .020 in. Changing forks
moves individual Sliding gears.
8. See Figure 6·38. If removed, install mainshaft first
gear (5) on the mainshaft (2) seating it against the b. See Figure 6·37. Changing pawl carrier support
shaft shoulder, then press the mainshali bearing shims (8, Figure 6-36). Adding or deleting shims
inner race (26) onto the mainshafl against the first will move both shift forks, the same distance in the
gear (5). Press the race on with the lettered side same direction.
out.
c. See Figure 6·38. Changing gear shaft thrust washer
9. Install the mainshafi third gear (8), third gear (11) (.047 in., .056 i~., .066 in. and .OBO in. thick
washer (7) and relaining ring (6) onto the mainshaft. sizes are available). This can be used in conjunc·
Use MAINSHAFTTHIRD GEAR RETAINING RINGS tion with shift forks and pawl shims to establish
SLEEVE, Part No. HO-96396-52 to instatithe retain- proper countershaft 3rd gear spacing.
ing ring (6) into the groove in the mainshaft. This
tool prevents the retaining ring from spreading out NOTE
during installation. NEVER reuse retaining rings.
If gear shaft thrust washer ( 11) is changed, countershaft
10_ Insert assembled mainshaft group in second gear end play will have to be checked and may require
(1) and clutch gear (10). Install the low gear variable reshlmming.
washer (11) and position against shoulder on
counters haft. Install low gear (18) onto counter- Gear Engagement
shaft.
1. After correct gear spacing has been achieved
mechanical gear engagement must be checked.
Figure 6-42. Measuring Gear Spacing -

Late 1984 and 1985
Figure 6-43. Checking Gear Mechanical Engagement -
Late 1984 and 1985
Establishing Proper Gear Spacing
With complete transmission assembled to access
1_ See Figure 6-42. Using a feeler gauge, check door observe gear dog/pocket engagement.
clearance between clutch faces and gears, as
shown. See SPECIFICATIONS for clearance 2. See Figure 6-43. Slowly rotate pawl carrier until
pawl carrier contacts lifter arm. Use hand pressure
tolerances. The gear spacing dimensions .028 -.058
on shifter cam to prevent cam follower from com·
in. for both mainshaft and countershaft gears, In-
dicate absolute maximum and minimum distances pleting shifts.
between gears. These dimensions include slider 3. Shift transmission into all four gears (upShift and
gear and shifter fork side play when the slider downshift), as instructed above. Observe, In each
gears are loaded to 4 - 6 Ibs. in either direction. shift, gear dog/pocket engagement. Engagement
Check the gear spacing with the mainshaft third of gear dog into pocket must be at least 50% in
gear and countershaft first gear loaded with 4 - 6 every gear except low gear which is 25%. See
Ibs. towards the access cover. Figure 6-44 and 6·45.
Clearance between a Sliding gear and its mating 4. Releasing hand pressure will allow cam follower to
gears must be as equal as possible on both sides. further rotate shifter cam. This motion combined
with the action of gear back angles will draw gear
2. Adjust gear spacing by:
dogs/pockets into complete engagement.
a. Changing shifter fork size. Forks are available in
+.005 in. +.010 in., +.020 in., standard, -.005 See Figure 6·37. Filing or replacing lifter arms will
6·46
Countershaft spacing
.028 to .058 in.
41h
1st
Space sliding gears as
equally as possible
on both sides
Neutral position
Mainshaft spacing
.028 to .058 In.
Figure 6·44. Gear Spacing - Late 1984 and 1985
produce changes in gear dog/pocket 4. USing a dial indicator, check end play of malnshaft
engagements. gauging from sprocket side of shaft. With bearing
(20) seated against retaining ring (21) in access
cover, move shaft back and forth and measure end
Establishing Mainshaft and play.
Countershaft End Play
5. With access cover st ill in place, measure end play
(Figure 6-38) of counlershaft from access cover side using a dial
indicator. Bend a discarded spoke and wedge in
1. Temporarily select the thinnest variable counter-
countershaft end hole. Pull and puSh counters haft
shaft low gear washer(s) (19) and mainshaft thrust
and at the same time, measure amount of end play.
washer (3) and install in their respective positions.
It end play of transmission mainshaft (2) is not
within .003 minimum 10 .020 in. maximum or
2. Temporarily install access cover to crankcase with
countershaft (17) is not within .004 to .015 in. limits,
all transmission parts. Carefully align cover on
it is necessary to remove access cover and Install
dowel pins, and, with a rawhide mallet, gently tap
correct size variabfe thickness thrust washers (3)
cover into position. See Figure 6-34. Secure access
and (19) to obtain correct tit. Variable thickness
cover with four bolts. Tighten the bolts to 14 -19 ft·
mainshaft thrust washers (3) are available in six
rbs torque.
sizes.
Refer to the following chart for correct thrust
3. 1979 TO EARLY 1985:
washer selection.
See Figure 6·32. Install alternator stator spacer
ring. Position stator on access cover, aligning four MAINS HAFT END PLAY THRUST WASHERS
counter bored holes in stator mount with four tap·
ped holes on access door. Apply 2-3 drops of LOC· Use thrust Thrust washer
TITE 242 to threads of 4 new Allen socket·head If end play is: washer thickness Part No.
screws. Secure access cover to crankcase with . 114 - .108 in . .099 - .Og4 in . 35380-84
screws. Tighten screws to 30-35 in-Ibs torque. .107 - .102 in. .093 - .088 in . 35381·84
. 101 - .097 in . .087· .082 in . 35382-84
LATE 1985: .096 - .092 in. .082· .077 in . 35383·84
.091 .. 086 in. .081 - .070 in . 35384·84
Position stator on access door. Align the four .085· .079 in. .070· .065 in . 35385·84
holes in stator with four tapped holes on access
door. Install tour new Torx fasteners securing Countershaft thrust washers (19) are available In twelve
stator to door. Tighten fasteners to 30 - 40 in·lbs. thicknesses from .020 in. to .075 in.
6·47
25% Engagement
50% Engagement
Figure s..S. Gear Eng",ement - late 1984 and 1985
Installation 6. Install the rear chain. See REAR CHAIN REMOVAL

ANO INSTALLATION.
1. With malnshaft and counters haft end play
established, check the ge8f shifter lever arm for CAUTION
proper engagement with the gear shifter pawl yoke
with the access cover in place. Make sure of Make sure tha' rear chain spring clip open end trails the
engagement by lightly rOlatlng the lever arm shaft , direction of chsln travel.
Resistance to movement Indicates proper engage·
ment. 7. Fill transmiSSion compartment with oil as de·
scribed In this section, under LUBRICATION.
2. If removed for end play adjustment, install access
COlier bolts and lighten them to 14·19 ft·lbs lorque.
LUBRICATION
3. Apply 2·3 drops of LOCTITE 242 to threads of" new
Allen socket·head screws, Secure access cover 10 With motorcycle standing straight up, remove 011
crankcase screws. Tighten screws 10 30-35 in·lbs IlIIer plug using PLUG REMOVAL TOOL, Part No.
torque. HD·33 t86, and 011 level screw. The oilliller plug Is
located near the top of the chaincase cover and the
4. Install the clutch as described under CLUTCH IN· 011 level screw is located near the bouom of the
STALLATION In this section. chaincase cover.
Reflll the transmission wUh approximately 24 oz.

5. Install the drive sprocket, on the malnshaft and of Harley·Oavidson FRONT CHAIN CASE LUBRI·
secure with the sprocket nul. Tighten the nut to CANT, Part No. HO·99887-84. Add 011 until it begins
35-65 ft·lbs torque, then Install the locking screw to overflOW through 011 level hote. Permit exceSS 011
and tighten II to SO-60 In·lbs torque. The locking to 1I0w from 011 level hote until It ceases to run.
screw must be installed to the clockwise side of This is the correct oil level. Reinsert and tighten oil
the sprocket nut flat. Additional lightening of the level screw and 011 filler plug.
sprocket nul may be needed to move any nut cor·
ner past one of the three locking screw holes. Max· Drain transmission and reWI to correct level with
Imum allowable torque on the sprocket nut is 90 ft· fresh, clean 011 once each year or every 5000 miles,
Jbs. whichever comes first.
S.4.
SUBJECT PAGE NO.
1. Specifications. . .. . .......... 7·1

2. Ignition System 1979..... ........ . . ..... 7·3
3. Ignition System 1980 ·1982 .............. . ........... • ............ ... 7·9
4. IgnitionSystem1983·1985............ . .... . 7·15
5. Ignition - Light Switch ..... 7·21
6. Spark Plugs ....................•................... 7·23
7. Ignition Coil...... . .. .... ..... ... ... ... . . ... .. 7·25
8. Generator(1979· Early 1984). . ... 7·27
9. Regulator (1979· Early 1984) .....................•................... 7·35
10. Charging System (Late 1984 and 1985) .. 7·39
11. Battery ...... 7·45
12. Lamps ...... ................ . ..... . .... • . ......... 7·47
13. Horn ............................ . . ..... 7·49
14. Specilications{XR·1000j.. . ..... 7·51
15. Ignition System (XR·1000) .... . .. ..................... .. .......... ... 7·53
16. Ignition·Light Switch (XR·l000) ...... 7·59
17. Horn (XR·1000) .. ...... ... ........... • ...... .....•. . ..... 7·59
18. Spark Plugs (XR·1000) . . ............ . .. .7·59
19. Wiring Diagrams
ELECTRICAL I
SPECIFICATIONS
IGNITION TIMING Tightening torque. 18-28 ft -Ibs
Ignition timer air gap (1979 only) . 0.004-0.006 in.

1980-1982 spark occurs at NOTE
Fully advanced. 40 ± 2.5 BTDC
0 0
Fully retarded. . ......... Approximately 8 0 BlOC Plug nos. 4-5 and 4R5 can be used in place of the NO.4
1983-1985 spark occurs at plug providing they are gapped at .038-.043 in.
fast idle. 40° BTDC
Fully retarded .............. . .• . . 10° BTDC
GENERAL
SPARK PLUGS Battery 12 v. 19 amp.
Generator - Two brush shunt, external regulator control
Standa rd. . . . . . . . (1979) Harley·Davidson No.4 1979·1981 10amp .
(1980·1981) Harley·Davidson No. 4·5 1982-early 1984. 13 amp.
Resistor type . (1980 and later) Harley·Davidson No. 4R5 Regulator
Size. 14mm 1979-early 1984 solid state current and voltage control
Gap- NO. 4. .060 in. Horn . . ..... . .... .. . . .' ....... Electric, vibrating type
No. 4-5, 4R5 . 0.038-0.043 in. Armature end play (1982·early 1984) .004·.010 in.
BULB CHART
The chart below gives the light bulb locations and requirements.
CANDLE HARLEY·
NUMBER POWER DAVIDSON
LAMP DESCRIPTION OF BULBS OR PART
(ALL LAMPS 12 V.) REQUIRED WATIAGE NUMBER
Headlamp 1
High Beam 50 Watts 67717·65A (1979·1981)
Low Beam 35 Watts 67698·81A (1982·1985)
Tail and Stop Lamp 1 68165·64

Tail Lamp 3 C.P.
Stop Lamp 32 C.P.
High Beam Indicator light 1 2 C.P. 71090-64 (1979·1982)

Generat or Signal light 1 4 C.P. 68597·83 (1983·
early 1984)
68466·84 (late 1984
·1985)
Oil Pressure Signal light 1 4 C.P. 68536·75 (1979·1982)
68489-83 (1983-1985)
Speedometer, Tachometer lights 1 2 C.P. 71090-64
Turn Signal Lamps 4 32 C.P. 68572·64A
7·1
IGNITION SYSTEM
1979
The advance mechanism is an extension on the cam·
DESCRIPTION shaft and operates at half crankshaft speed. The trigger
The ignition system is a breakerless inductive dis- rotor is advanced automatically as engine speed in·
creases and retarded as speed decreases through the
charge ignition system. II has two circuits, the primary
action of flyweights in the advance mechanism. This en·
circuit and the secondary circuit. The primary circuit
consists of the battery, switch, primary coil winding, ig- sures correct spark tlmlng to suit starting, low and high
speed requirements.
nition timer and associated wiring. The secondary cir-
cuit consists of the secondary coil, the spark plugs and
associated wiring. See schematic diagram, Figure 7·1 .
OPERATION
The ignition timer is located in the gearcase cover on (Figure 7-1)
the right hand side of the motorcycle. II has two func-
tions. First, it opens and closes the low voltage circuit The trigger rotor (1) has two lobes. The small lobe fires
between the battery and Ignition coil causing the call to the front cylinder and the large lobe fires the rear
produce high voltage discharge 10 the spark plugs. Sec- cylinder. The sensor (2) consists of a number of turns of
ond, the ignition timer limes discharge for proper fine wire wound on a core and is mounted on the timer
engine firing. plate so that the lobes on the trigger rotor pass in close
proximity. The air gap must be adjusted to specified
The ignition timer includes a trigger rotor, sensor, elec· limits.
tronic control module and advance mechanism. A
single ignition coil fires both spark plugs at the same The electronic control module (3) contains all of the
time, but one spark occurs in the exhaust stroke of one solid state components used in the ignition system.
cylinder and the other spark fires the combustible Within the control module Is an integrated circuit chip
gases in the other cylinder to produce the power stroke. (4) which contains oscillator and demodulator circuits.
8
r-------------------4W~----------~
9
BE~~'
w
2
4
9
7 1. Trigger rotor
2. Sensor
3. Control module
4. Integrated circuit chip
3 5. Ignition switch
6. Battery
7. Transistor
8. Ignition coil
9. Spark plug
10. Main circuit breaker
11. Ignition circuit breaker
= 12. Engine stop switch
Figure 7·1 . Breakefless Inductive Discharge Ignition System Schematic Diagram - 1979
7·3
The control module is fully enclosed in a silicone 4. Remove the timer case cover and position ignition
material to protect it from vibration, dust, water or oil. module to one side. Check the air gap between both
The unit is a non-repairable item. If it fails, it must be trigger lobes and the sensor. Air gap must be be-
replaced. tween 0.004 and 0.006 in. If this gap cannot be held
on both rotor lobes, timer mechanism shaft and/or
trigger rotor have excessive runout and should be
replaced or straightened. Check to make sure that
control module ground black lead is securely fasten-
ed to timer plate and that wires are in good condi-
tion.
Note whenever sensor air gap is adjusted, the igni-

tion advanced timing should be checked and ad-
justed if necessary. See CHECKING ADVANCED
Front cylinder Rear cylinder TIMING WITH STROBE TIMING LIGHT. If spark is
(narrow lobe) (wide lobe) still not evident, continue with the following
voltmeter checks.
Figure 7·2. Trigger Rotor Position for Ignition Timing
5. Position trigger rotor so that the center of the sensor
When the ignition switch (5) and eng i ne stop switch (12) is between two lobes .
are on, current flows from the battery (6) to the control
module (3). An oscillator section in the integrated circuit Connect voltmeter between ignition positive coil ter-
chip (4) sets up a signal in the sensor (2). This creates a minal (white wires) and engine ground. With ignition
field around the sensor. When a trigger rotor (1) lobe and engine stop switches on, the voltmeter reading
leading edge enters the sensor's field, it reduces the should equal battery voltage within 0.5 volt. If not,
strength of the oscillating signal. The weakened sensor trouble lies in circuit between battery and ignition
signal is detected by demodulator circuit in the inte- coil. Check the connections at or in circuit breakers
grated circuit. The demodulator controls a transistor (7) and ignition switches.
which turns off the current in the ignition coil (8) primary
circuit. This causes a high voltage to be induced in the 6. Disconnect blue wire from coil negative terminal.
secondary of the coil which in turn causes a spark at the Connect voltmeter between coil negative terminal
spark plug gap . and ground. With ignition and engine stop switches
on, the voltmeter reading should equal battery
The time of spark plug firing occurs when the leading voltage. It not, ignition coil primary is defective.
edge of each lobe aligns with the center of the sensor Replace coil. Retest for spark after corrections are
as shown in Figure 7-2. made.
7. Reconnect blue wire to coil negative terminal. Con·

nect voltmeter between coil negative terminal and
TROUBLESHOOTING ground . Reading should be 1 to 2 volts. Place the
blade of a screwdriver against the face of the sen-
Refer to Figure 7-4 and to the appropriate vehicle wiring
sor. If the voltmeter reading switches up to 11.5 to 13
diagram .
volts, proceed to step 8. If the voltmeter does not
When the engine will not start or when hard starting or switch up and down or does not read 1 to 2 volts, the
missing indicates a faulty ignition system, proceed as ignition module is faulty and must be replaced .
follows:
8. Reestablish the 3/16 in gap between spark plug
1. Disengage spark plug cables. Check condition of cable and ground. Check for a spark discharge each
time the screwdriver blade is placed against the
plugs and cables. Clean or replace as necessary.
face of the sensor. If sparks are not observed , the
2. Insert an extension adapter into spark plug nipple coil secondary is faulty and the coil must be reo
and establish a 3116 in. gap between adapter and placed.
cylinder head. Turn on ignition and engine stop
CAUTION
switches. Crank engine. Check to see if a spark is
obtained across the gap. If a spark is obtained, the
Coil wires must be connected correctly! Both white
problem is not the electronic system or coil. Check
wires must be connected to the same coil primary ter-
carburetion, choke, spark plugs, and advance mech- minal or ignition control module will be permanently
anism.
damaged.
3. If no spark is obtained, check battery voltage and
battery connection. Turn on ignition and engine stop ADJUSTING SENSOR AIR GAP
switches and with a voltmeter across the battery
and current flowing, voltage should be 11.5 or above.
(See Figure 7·3)
If voltage is low, battery needs charging. Ignition timer sensor air gap should be checked every
7·4
2500 miles. Remove spark plugs to permit engine to turn
easily and rotate flywheels so that the wide lobe on the
trigger rotor (1) Is centered in the sensor (2). Check the
gap between the rolor and sensor using a narrow 0.004
in. feeler gage. If gap Is not correcl, loosen screws (3)
and move sensor as required. Repeal for narrow tobe
setting so that gap for both lobes is between 0.004 and
0.006 In. Tighten screws (3) to 5 to 7 in·lbs torque.
CHECKING ADVANCE TIMING

WITH STROBE TIMING LIGHT
(Figure 7 -3)
Ignition liming should be checked initially at 500 miles
and thereafter every 2500 miles.
Before checking timing, check sensor air gap as

described above.
Use a strobe flash liming light (timing gun) to view ad·

vanced liming (7) on flywheel through accessory
PLASTIC VIEW PLUG, Part No. HD·96295-65, screwed In·
to timing inspection hole (9). Make sure view plug does
not touch flywheels. Timing light leads should be con·
nected to the front spark plug, ground and battery
positive terminal. Start engine and set engine speed at /" ~
~~
2000 rpm. light will flash each time spark occurs.
Loosen timer plate screws (5) just enough so that plate
(4) can be shifted using a screwdriver in nolch (6) as
light aimed inlo inspection hole (8) stops timing mark (7)
In center of hole. Timing will retard 30" automatically
when engine Is at Idle speed or is stopped. 89~ ir'ln. 9 7
/" ~
SETTING RETARDED TIMING
WITH CIRCUIT TESTER
(See Figure 7 -3) -'=-----"'-~.l\~
NOTE 8
1. Rotor 7. Front cylinder advance 40 0
This procedure wffl result In approximate timing and
2. Sensor timing mark on flywheel
engine can be opera ted In an emergency for a short
3. Sensor screws (2) 8. Front cylinder retard timing
period of time. Advanced timing should be checked and mark on flywheel
4. Timer plate
set under running conditions as soon as possible using
5. Plate screw (2) 9. Timing Inspection hole
a strobe timing fight 8S described in preceding section. 10. Cover plate
6. Plate adjusting
notch
Whenever ignition components have been disassembl·
ed, such as during engine disassembly and reassembly, Figure 7·3. Ignition Timer and Flywheel Timing Marks
or if a strobe timing light Is not available, approximate
timing can be obtained by using the following pro·
cedure.
With timer rotor advanced (turned fully counterclock·
Remove screw plug from timing inspection hOle (9) in wise) the leading edge of the narrow rotor lobe should
left side of crankcase. Then remove front push rod cover be aligned with the center of the sensor body as shown
so that opening and closing of valve can be observed. In Figure 7·2. At this point the advanced front cylinder
ignition spark occurs. A circuli tester, such as a 12·volt
Turn engine until front piston Is on compression stroke light bu lb (No. 57) can be used to determine the exact
(just after front Intake valve closes), and contin ue turn · point of Ignilion firing as follows: Disconnect the blue
ing engine very slowly (less than 1/2 revolution) until wi re from the Ignition coil primary terminal and connect
front cylinder advanced timing mark (7) on flywheel is test light to this terminal and to end of removed blue
aligned In the Inspection hole as shown. wire.
7·5
Loosen timer plate screws (5, Figure , 7-3) so they are just Route wires as shown in Figure 7·5.
snug and shift timer plate (4) so that center line of the
sensor body is aligned with the leading edge of the nar-
row lobe on the timer rotor as shown in Figure 7-2.
REMOVING IGNITION TIMER
COMPONENTS (Figure 7-4)
Turn timer rotor (1 , Figure 7·3) counterclockwise as far
as it will go and hold in the fully advanced position. Remove ignition timer cover screws (1), cover (2) and ig-
Shift timer plate (4) using a screwdriver in notch (6) so nition module (3). Remove timer plate screws (4) and
that light goes on or off. Tighten timer plate screws to washers (5). Remove trigger rotor bolt (6) and pull trigger
12 to 16 in·lbs torque. rotor (7) from advance assembly (8). Remove advance
assembly from gearcase cover. To remove sensor (9)
CAUTION and screw (10) from timer plate (11), remove screws and
washers (12).
When reinstalling timer cover, be careful not to pinch
any wires. To disassemble advance mechanism , unhook spring
1. Cover screw (2)

2. Ignition timer cover
3. Ignition module
4. Timer plate screw (2)
5. Washer (2)
6. Trigger rotor bolt
7. Trigger rotor
8. Advance assembly
9. Sensor
10. Screw
11. Timer plate
12. Screw and washer (2) 21
13. Flyweight spring (2)
14. Flyweight (2)
15. Advance assembly base
16. Flyweight roll pin (2)
17. Cam stop roll pin
18. Register roll pin
19. Camshaft 011 seal
20. Ignition coli
21. Spark plug cable
22. Ignition coil terminal
Figure 7·4. Ignition System Components - 1979
7·6
upper looped end grips groove in pin tigh.tly. See Figure
ROute wires between screw 7·6. Check for looseness of rotor (7, Figure 7·4) on shaft
(15) and wear on sides of flyweight ears which engage
slots in rotor.
Reassemble advance assembly and lubricate moving

parts with Loctite ANTI·SEIZE. Check operation by mov·
ing rotor in direction required to advance weights to
their fully extended position. Then release the rotor and
see if springs return to the fully retarded position. Cor·
rect causes of faulty action by cleaning and lubricating
the shaft and flyweights with ANTI·SEIZE and replace
weak springs. Lubrication of the advance assembly
should be performed at 5000 mile intervals.
ASSEMBLING IGNITION TIMER

COMPONENTS (Figure 7-4)
Assemble ignition timer parts in reverse order of
disassembly with the following exceptions:
Advance assembly must seat squarely and firmly on

end of camshaft.
Install trigger rotor (7) in correct position so that it

engages both flyweights and flat side is next to roll pin
(17). Tighten trigger rotor bolt to 20 to 24 in·lbs.
Screw
Route wires
between screw Adjust sensor air gap and set retarded ignition timing
and housing as described in previous section. Check advanced igni·
Cable strap tion timing under running conditions as described in
previous section.
Tighten screw (4) and screw (1) to 12·20 in·lbs torque.

Figure 1·5. Ignition Timer Wire Routing
CAUTION
(13) from grooves in pivot and slip flyweights (14) with When installing module, make sure wires are not
spring from pivot pins on advance base (15). Do not pinched.
remove springs from flyweights unless they are to be
replaced. Roll pins (16,17,18) are pressed in and can be
replaced if necessary. Loop tightly in
pin groove Spring
INSPECTION AND REPLACING
PARTS (Figure 7-4)
Inspect lip of seal (19) and replace it if worn or rough.
Also replace the seal if there is any evidence of oil
leakage into the timer compartment. Hook spring end
through bottom
Check flyweight springs (13), and if bent or stretched, of hole
replace them. When installing, be sure that bent end of
each spring is hooked through bottom of hole, and that Figure 1-6. Advance Unit Flyweight Spring Assembly
7·7
IGNITION SYSTEM
1980·1982
DESCRIPTION module is mounted on the bottom of the battery car·
rier/oil tank. On 1982 models the computer module is
The ignition system is a breakerless inductive mounted to the frame. It is located under the side cover
discharge ignition system. It has two circuits, the next to the battery. The computer has two functions.
primary circuit and the secondary circuit. The primary First, it computes the spark advance for proper ignition
circuil consists of the battery, switch, primary coil wind- firing. Second, it opens and closes the low voltage cir-
ing, computerized ignition timer and associated wiring. cuits between the battery and ignition coil to produce
The secondary circuit consists of the secondary coil, high voltage discharge to the spark plugs.
the spark plugs and associated wiring.
The ignition timer includes a rotor, sensor plate, and a
computerized microprocessor control module. A single
The computerized ignition system consists of two ignition coil fires both spark plugs at the same time, but
assemblies, the rotor and sensor plate and the com- one spark occurs with no effect in the exhaust stroke of
puter microprocessor module. The rotor and sensor one cylinder, while the other spark fires the combustible
plate are located in the gearcase cover on the right side gasses in the other cylinder to produce the power
of the motorcycle. On 1980-1981 models the computer stroke.
___ '0
~------~Wr---------~ 5
~+±-L:;/ /6
o
Y ~6
1. Sensor plate
2. Computerized control module
3. Ignition switch
4. Battery
5. Ignition coil
6. Spark plug
o 8. Ignition circuit breaker
9. Engine stop switch
10. Rotor
Figure 7·7. Ignition System Components - 1980·1982

7·9
The rotor is bolted on to the camshaft and operates at (black lead) is securely fastened to the frame and
one-half crankshaft speed_ The computer module auto- that the ground wire from the battery to the frame is
matically advances the spark as the engine speed in- in good condition. If spark is still not evident, con-
creases, and retards as the speed decreases without tinue with the following voltmeter checks.
the action of flyweights, or an advance mechanism.
This ensures correct spark timing to suit starling, low NOTE
and high speed requirements.
Voltmeter should have a resistance of 20,000 ohmlvolt
As the rotor turns, slots in its external edge break the or more in order to obtain correct readings.
magnetic field of a Hall-effect device mounted on the
sensor plate. The output of the Hall-effect device is a 5. Position rotor so that the center of the sensor is be-
logic-type signal that corresponds to the timing infor- tween the two slots.
mation from the spinning rotor. This technique gives ac-
curate timing information down to "0" speed. Connect voltmeter between ignition coil positive
terminal (white wires) and engine ground. With igni-
Basically, the system gives a spark near top dead center lion and engine stop switches on, the voltmeter
for starting, and at rpm's above this gives a spark ad- reading should equal battery voltage within 0.5
vance between 8 G and 40 G _ The whole timing program volts. If not, trouble lies in circuit between battery
can be shifted by mechanical rotation of the sensor and ignition coil. Check the connections at or in cir-
plate. See CHECKING ADVANCE TIMING WITH cuit breakers and ignition switch.
STROBE TIMING and SEITING RETARDED TIMING.
6. Disconnect blue wire from coil negative terminal.
Connect voltmeter between coil negative terminal
The dwell time for the ignition coil is calculated in the and ground. With ignition and engine stop switches
microprocessor and is dependent upon engine speed. on, the voltmeter reading should equal battery
The programmed dwell Is an added feature to keep bat- voltage. If not, ignition coil primary is not functional.
tery drain to a minimum and yet charges the coil ade- Replace coil. Retest for spark after corrections are
quately at all speeds. (The microprocessor control made.
module has added protection against transient volt-
ages, continuous reverse voltage protection, and dam- 7. Disconnect sensor plate from ignition module at
age due to jump starts.) The system will operate down connector. Connect a voltmeter from pin #1 (red
to 5.7 volts DC. The control module Is fully enclosed In a wire) to pin #2 (black wire) of the module connector
polyurethane material to protect it from vibration, dust, (Figure 7-8). With the ign ition and engine stop
water or oil. This unit is a non-repairable item. If it fails, switches on, the voltmeter should read 5.0 ± .5
it must be replaced. valls. If not, the computer module is not functioning
and must be replaced.
NOTE
Use IGNITION TEST ADAPTER Part No. HD·94465·81 or

fabricate a jumper cable (Figure 7-8) to test module and
TROUBLESHOOTING sensor.
When the engine will not start, or when hard starting or CAUTION
missing indicates a faulty ignition system, proceed as When using Jumper cable extreme care must be used
follows: not to touch exposed wire terminals, Figure 7-8, to each
other or ground which could result In damage to ignition
1. Disconnect spark plug cables from spark plugs. module.
Check condition of plugs and cables. Clean or
replace as necessary. 8. Reconnect sensor plate using IGNITION TEST
ADAPTER, Part No. HD-94465-81 (Figure 7-8).
2. Insert a 3/16 diameter (No. 10) screw into spark plug Recheck voltage from pin #1 to pin #2. Connect the
cable nipple and establish a 3/16 in. gap between voltmeter from pin #3 to #2 to check sensor output.
screw and cylinder head. Turn on ignition and This output should be 5.0 ± .5 volts when the slot is
engine stop switches. Crank engine. Check to see if not present at the sensor and should be 0 to 1 volt
a spark is obtained across the gap. If a spark is ob- when the slot is at the sensor. A screwdriver blade
tained, the problem is not in the electronic system or can be used to check the sensor output. If these
COil. Check carburet ion, choke and spark plugs. voltages are not present, the sensor plate must be
replaced.
battery connection condition. Turn on ignition and CAUTION
engine stop switches to crank engine with voltmeter
across the battery. Voltage should be 11.5 or above. Coli wires must be connected correctly. Both white
If voltage is low, battery neeeds charging. wires must be connected to the same coil primary ter-
minal or ignition control module will be permanently
4. Check to make sure that ignition module ground damaged.
7-10
TIMING ADVANCE
Range.
Start. . ....... 8°BTDC
Green (3)
Red (1) JiC

d J--- Black (2)
Fast Idle.
2000 rpm and Up .
.20° BTDC
... 40° BTDC
I (f f~ Vollmele' SETTING RETARDED TIMING
LJjj (Figure 7-9)
CAUTION
Ignition Module Check This procedure will result In approximate timing and
engine can be operated in an emergency for a short
period of time. Advanced timing should be checked and
a strobe timing light as described in preceding section.
Red (1)
\ .........- Black (2) Whenever ignition components have been disas-

sembled, such as during engine disassembly and
Green (3) reassembly, or if a strobe timing light is not available,
Voltmeter approximate timing can be obtained by using the
fOllowing procedure:
1. Set sensor plate (8) so that sensor plate screws (6)

are centered in the slots. Snug down the screws (6).
Sensor Output Check
2. Engine can now be started.
Figure 7·8. Testing ignition System 3. Adjust the advanced timing with timing light follow-
ing procedure in the preceding section as soon as
possible.
CHECK ADVANCE TIMING WITH REMOVING IGNITION

STROBE TIMING LIGHT COMPONENTS (Figure 7-10)
Figure 7-9) WARNING
Ignition timing should be checked every 2500 miles. To avoid accidental start·up of vehicle and possible per-
sonal Injury, disconnect the battery cables, (negative
Use an INDUCTIVE TIMING LIGHT, Part No. HD·33813 cable first) before performing any of the following pro·
(liming gun) to view advanced liming of flywheel cedures.
through TIMING MARK VIEW PLUG , Pari No.
HD·96295·65, screwed into timing inspection hole. Make 1. Using a 318 in. drill bit, drill out outer cover rivets (1)
sure view plug does nol touch flywheels. Timing light and remove outer cover (2).
leads should be connected to the front spark plug cable,
ground and battery positive terminal. Start engine and 2. Remove inner cover screws (3) and remove Inner
sel engine speed at 2000 rpm. light will flash each time cover (4) and gasket (5).
spark occurs. Loosen sensor plate screws just enough
so that plate can be shifted using a screwdriver in notch 3. Remove sensor plate screws (6) and washers (7).
as light aimed into inspection hole stops timing mark in
center of hole. Timing will retard automatically when 4. To remove sensor plate (8) from gearcase, discon·
engine is at idle speed or is stopped. See table. The nect connector (12) and remove connector from sen-
small dot (early 1980) or lazy 00 (late 1980 and later) sor plate wires. Pull wires through gearcase hole
mark indicates rear cylinder advanced timing. one at a time.
7-11
~
~
~.
2
I
3 2
I ,
2
I ~ ,
Early 1980 Models
3
7
z~ 2
I
4
Late 1980 and later Models

before crankcase No. 780·108·001 after crankcase No. 780·10S'()()1
1. Front cylinder top dead center (TOC) 3. Front cylinder advance timing mark
2. Timing Inspection hole 4. Rear cylinder advance timing mark
Figure 7·9. Ignition Timing Mark 1980 And later
5. Remove rotor screw (9) and rotor (10). On 1982 models assemble ignition module to frame.
Make sure that the black ground wire is secured. In-
6. Seal (11), jf not functioning, can be pried out from jg- stall sidecover.
nitlon side 01 gearcase. Use care not to damage cam·
shaft end while prying. 2. Connect ignition module wires to ignition coil as
shown in the wiring diagrams.
7. Disconnect ignition module wires from coil.
3. JI seal (t 1) was removed, install new seal (11) in gear-
8. On 1980 and 1981 models, to remove ignition module case, lip side to flywheel side of gearcase.
(13) from the battery carrier, remove two mounting
bolts, and the screw securing the ground wire. CAUTION
On 1982 models remove ignition module side cover Seal (11) must be pressed Into gearcase until it is flush.
located next to the battery. Remove two mounting A seal that is not all the way in may leak.
bolts securing ignition module and the screw secur-
ing the ground wire. Remove ignition module from 4. Apply Loctite LOCK 'N SEAL to rotor bolt (9). Install
frame. rotor (10) with rotor bolt (9). Torque bolt (9) to 75·80
in·lbs (6 ft·lbS).
INSPECTION AND REPLACING CAUTION

PARTS Use only the grade of Loctlte specified.
Inspect lip of seal and replace It If worn or rough. Also 5. Install sensor plate (8) with sensor plate screws (6)
replace the seal if there is any evidence of oil leakage and washers (7). Tighten screws (6) to 12·17 in-Ibs
into the timer compartment. torque.
NOTE
If sensor plate (8) was completely removed it may be

INSTALLING IGNITION necessary to install new wire pins, sockets and body
COMPONENTS (Figure 7-10) receptacle.
1. On 1980 and 1981 models assemble ignition module 6. Set retarded ignition timing as described in previous
(13) to bottom of battery carrier. Make sure that the section. Check advanced ignition timing under run·
black ground wire is secured. ning conditions as described In previous section.
7-12
1. Outer cover rivet (2) 13. Ignition module
2. Outer cover 14. Ignition coil
3. Inner cover screw (2) 15. Spark plug cable (2)
4. Inner cover 16. Ignition coil terminal
5. Gasket
6. Sensor plate screw (2)
7. Washer (2)
8. Sensor plate
9. Rotor screw and star
washer
10. Rotor
11. Camshaft oil seal
12. Connector
Figure 7·10. Ignition Components - 1980·1982
7. Inslall gasket (5) and Inner covef (4) with screws (3).
1113
Tighten screws (3) to 12·20 In·lbs lorque.
8. Alvet outer cover (2) to Inner cover (4) with rivets (1).
CAUTION
Use only rivets Part No. 8699 to secure outer cover. (See
Figure 7·11.) Timing cover rivets are specially designed
so there Is no rivet end to fall off Into timing compart·
ment as with regular rivets. Use of regular rivets could
Incorrect Correct
cause damage to Ignition components.
Figure 7·11. Special Timing Cover Rivet
7·13
IGNITION SYSTEM
1983·1985
DESCRIPTION frame. It is located under the side cover next to the bat-
tery. The V.D. E.S. is located above the intake manifold.
The Ignition system Is a breakerless Inductive The computer has two functions. First, It computes the
discharge Ignition system. It has two circuits, the spark advance for proper Ignilion firing. Second, It
primary circuit and the secondary circuit. The primary opens and closes the low voltage circuits between the
circuli consists of the battery, switch, primary coli wind- battery and ignition coli to produce high voltage
ing, computerized ignition Ilmer and associated wiring. discharge to the spark plugs.
The secondary circulI consists of the secondary call,
the spark plugs and associated wiring. The vacuum operated electric switch (V.D.E.S.) senses
intake manifold vacuum through an opening in the car·
The computerized Ignition system consists of three buretor body. The V.D.E.S. is connected to the car·
assemblies, the rotor and sensor plate, the computeriz- buretor with a vacuum hose. The switch is open under
ed microprocessor module, and the vacuum operated acceleration and high engine load conditions (lOW
electric switch (V.O. E.S.), The rotor and sensor plate are vacuum) and closed under low engine load conditions
located in the gearcase cover on the right side of the (high vacuum). The computer modu le is prog rammed
motorcycle. The computer module Is mounted to the with two spark advance curves to meet varying engine
10
6
r - - - - - { W} - - - - - " '
+
o
1 . Sensor plate
2. Computerized control module
3. Ignition switch
4. Battery
5. Ignition call
6. Spar1< plug
o 9. Engine stop switch
10. Rotor
11 . Vacuum operated electric switch
Figure 7·12. Ignition System Components - 1983·1985

7·15
loads. The 'high vacuum curve selected for maximum screw and cylinder head. Turn on ignition and
spark advance under normal light load cruising condi- engine stop switches. Crank engine. Check to see if
tions provides improved fuel economy and perform- a spark is obtained across the gap. If a spark is ob-
ance. The low vacuum curve (retarded spark) minimizes tained, the problem is not in the electronic system or
spark knock, while maintaining performance, under coil. Check carburetion, choke and spark plugs.
high load conditions (acceleration and highway driving).
The computer module selects the proper curve when it battery connection condition. Turn on ignition and
receives an open or closed electrical signal from the engine stop switches to crank engine with voltmeter
V.O.E.S. This system ensures correct timing to suit across the battery. Voltage should be 11.5 or above.
starting, low and high speed requirements. If voltage is low, battery neeeds charging.
The ignition timer includes a rotor, sensor plate, and a 4. Check to make sure that ignition module ground
computerized microprocessor control module and a (black lead) is securely fastened to the frame and
V.O.E.S. A single ignition coil fires both spark plugs at that the ground wire from the battery to the frame is
the same time, but one spark occurs with no effect in in good condition. If spark is still not evident, con·
the exhaust stroke of one cylinder, while the other spark tinue with the fallowing voltmeter checks.
fires the combustible gasses in the other cylinder to
produce the power stroke. NOTE
Voltmeter should have a resistance of 20,000 ohmlvolt

The rotor is bolted on to the camshaft and operates at
or more in order to obtain correct readings.
one-half crankshaft speed. As the rotor turns, slots in
its external edge break the magnetic field of a Hall-
5. Position rotor so that the center 01 the sensor is be·
effect device mounted on the sensor plate. The output
tween the two slots.
of the Hall-effect device is a logic-type signal that cor-
responds to the timing information from the spinning
Connect voltmeter between ignition coil positive
rotor. This technique gives accurate timing information
terminal (white wires) and engine ground. With igni ·
down to " 0" speed.
tion and engine stop switches on, the voltmeter
reading should equal battery voltage within 0.5
Basically, the system gives a spark near top dead center
volts. If not, trouble lies in circuit between battery
for starting, and at rpm's and loads above this gives a
and ignition coil. Check the connections at or in cir·
spark advance that varies between 10- and 55-. The
cuit breakers and ignition switch.
whole timing program can . be shifted by mechanical
rotation of the sensor plate. See CHECKING ADVANCE
6. Disconnect blue wire from coil negative terminal.
TIMING WITH STROBE TIMING and SETIING RETARD·
Connect voltmeter between coil negative terminal
ED TIMING.
and ground. With ignition and engine stop switches
on, the voltmeter reading should equal battery
The computerized control module contains all of the
voltage. If not, ignition coil primary is not function-
solid state components used in the ignition system. The
ing. Replace coil. Retest for spark after corrections
dwell time for the ignition coil is also calculated in the
are made.
microprocessor and Is dependent upon engine speed.
The programmed dwell is an added feature to keep bat·
7. Disconnect sensor plate from ignition module at
tery drain to a minimum and yet charges the coli at all
connector. Connect a voltmeter from pin #1 (red
speeds. (The microprocessor control module has added
wire) to pin #2 (black wire) of the module connector
protection against transient voltages, continuous
(Figure 7-8). With the ignition and engine stop
reverse voltage protection, and damage due to jump
switches on, the voltmeter should read 5.0 ± .5
starts.) The system will operate down to 5.7 volts DC.
volts. If not, the computer module is not functioning
The control module is fully enclosed in a polyurethane
and must be replaced.
material to protect It from vibration, dust, water or oil.
This unit is a non.repairable item. If it fails, it must be
replaced. To perform module and sensor checks of early 1983
components fabricate a Jumper cable as shown. The
parts needed are:
TROUBLESHOOTING
When the engine will not start, or when hard starting or
missing indicates a faulty ignition system, proceed as PART NO. QTY.
follows:
Pin connectors 74539-83 3
1. Disconnect spark plug cables from spark plugs. Socket connectors 72028-83 3
Check condition of plugs and cables. Clean or
replace as necessary.
Socket housing
Pin housing
72051-83
74521-83 ,
Wire ring terminals 9857 3
2. Insert a 3116 diameter screw (No. 10) into spark plug 18 gauge insulated wire (4 ft.)
cable nipple and establish a 3116 in. gap between Electrical tape
7·16
Use IGNITION TEST ADAPTER Part No. HD-9446S-81 or when the slot is not present at the sensor and
fabricate a jumper cable as shown in Figure 7-8 to test should be 0 to 1 volt when the slot is at the sensor. A
late 1983 sensors and modules. screwdriver blade can be used to check the sensor
output. If these voltages are not present, the sensor
plate must be replaced.
CAUTION
Electrical tape
Coil wires must be connected correctly. Both white
\
wires must be connected to the same coil primary ter-
minal or ignition control module will be permanently
damaged.
Black Pin housing
Socket housing
CHECK ADVANCE TIMING WITH
-
Wire ring terminals
Sensor -Module
STROBE TIMING LIGHT
(Figure 7·9)
Ignition timing should be checked every 2500 miles.
Use an INDUCTIVE TIMING LIGHT, Part No. HD-33813

(timing gun) to view advanced timing of flywheel
through TIMING MARK VIEW PLUG, Part No.
Black (2) HD·96295·65, screwed into timing inspection hole. Make
............. ____ Red (1)
sure view plug does not touch flywheels. Timing light
".""'[iIE ..,.-
ground and battery positive terminal. Make sure
vacuum hose is properly installed at carburetor and at
vacuum operated electric switch. Start engine and set
engine speed at 1300 rpm. Light will flash each time
spark occurs. Loosen sensor plate screws just enough
so that plate can be shifted using a screwdriver in notch
as light aimed into inspection hole stoos timing mark in
Ignition Module Check center of hole.
WARNING
When checking advance timing, always check V.O.E.S.

Red (1)~ _ _ Black (2) operation. Failure to do so may result in running engine
with too much spark advance, and may cause extreme
Green(3)~ engine knock and engine failure.
r'- + Voltmeter
The lazy 00 indicates rear cylinder advanced timing.
TIMING ADVANCE
1000cc 4-SPEED
Sensor Output Check Range ......... .
Start .. . ... 10" BTDC
Figure 7·13_ Fabricating and Using Jumper Cables - Fast Idle. . ............. . . .40" BlDC
1983-1985 Models 1800-2800 rpm and Up
CAUTION
When using jumper cable extreme care must be used

not to touch exposed wire terminals (6, Figure 7-8) to
VACUUM OPERATED
each other or ground which could result in damage to ig· ELECTRIC SWITCH (V.O.E.S.)
nitlon module.
8. Reconnect sensor plate using the fabricated jumper Checking Operation

cable (Figure 7-8). Recheck voltage from pin #1 to pin
#2. Connect the voltmeter from pin #3to #2 to check After engine has been timed with a strobe timing light,
sensor output. This output should be 5.0 :t .5 volls perform the following check:
7-17
With the engine idlin-g, remove vacuum hose from car-
buretor and momentarily plug carburetor fitting. Timing
will retard and engine speed should decrease. Reinstall
vacuum hose to carburetor. Timing mark should reap·
pear and engine speed should increase to preset speed.
If speed does not decrease and increase as described,

check vacuum operated electric switch (V.O.E .S.) wire
connection to computer module and ground wire.
The vacuum operated electric switch (V.O.E.S.) can also

be checked using an ohmmeter and a Harley-Davidson
VACUUM PUMP, Part No. HO-23738.
See Figure 7-14 . Remove the air cleaner. Disconnect the

switch wire from the computer module connector under
the fuel tank and remove the switch vacuum hose from
the carburetor.
Figure 7·15. Checking V.O.E.S.

NOTE
Removal and Installation
Rear of fuel tank may have to be raised to disconnect
1. Disconnect wire from vacuum operated electric
switch lead connector from computer module connec-
switch (V.O.E.S .) to computer module.
tor.
2. Disconnect V.O.E.S. ground wire from engine.
3. Remove V.O.E .S.
4.lnslall new V.O.E.S. reversing the removal pro·

cedure.

(Figure 7-9)
CAUTION
This procedure will result In approximate timing and

engine can be operated in an emergency for a short
period of time. Advanced timing should be checked and
a strobe timing light as described in preceding section.
Whenever ignition components have been disas-

sembled, such as during engine disassembly and
Figure 7·14. V.O.E.S. Wire Connector and Vacuum Hose reassembly, or if a strobe timing light is not available,
approximate timing can be obtained by using the
following procedure:
See Figure 7·15. Attach ohmmeter leads to switch wire
and to ground. Attach vacuum pump hose to switch 1. Set sensor plate (8) so that sensor plate screws (6)
vacuum hose. are centered in the slots . Snug down the screws (6).
2. Engine can now be started.

Ohmmeter should indicate switch closed with 3.5 to 4.5
in. of mercury vacuum applied. If more or less vacuum is 3. Adjust the advanced timing with timing light follow-
required to close the switch, replace it using Part No. ing procedure in the preceding section as soon as
26557-83. possible.
7·18
IGNITION COMPONENT 2. Remove inner cover screws (3l and remove inner
cover (4) and gasket (5).
REMOVAL (Figure 7·16)
3. Remove sensor plate screws (6) and washers (7).
WARNING
4. To remove sensor plate (8) from gearcase, discon-
To avoid accidental start·up of vehicle and possible per- nect connector (12) and remove connector from sen-
sonal injury, disconnect the battery cables, (negative sor plate wires. Pull wires through gearcase hole one
cable first) before performing any of the following pro- at a time.
cedures.
5. Remove rotor screw (9) and rotor (10).
1. Using a 318 in. drill bit , drill Qut outer cover rivets (1)
and remove outer cover (2). 6. Seal (11), if damaged, can be pried out from ignition
1. Outer cover rivet (2) 13. Ignition module

2. Outer cover 14. Ignition coil
3. Inner cover screw (2) 15. Spark plug cable (2)
4. inner cover 16. Ignition coil terminal
5. Gasket 17. V.O.E.S. wire
6. Sensor plate screw (2) 18. Vacuum operated electric switch
7. Washer (2)
8. Sensor plate
9. Rotor screw and star washer
10. Rotor
11. Camshaft oil seal
12. Connector
' - -14
Figure 7·16. Ignition Components - 1983·1985
7·19
side of gearcase. Use care not to damage camshaft 5. Apply Loctite LOCK 'N SEAL to rotor bolt (9). Insta ll
end while prying. rolor (10) with rotor bolt (9). Torque bolt (9) to 75·80
in·lbs (6 ft.lbs).
7. Disconnect ignition module wires from coil, and
V.O.E.S. CAUTION
8. To remove ignition module (13), remove Ignition Use only t he grade of Loctlte specified .
module side cover. Remove two mounting bolts, and
the screw securing the ground wire.
6. Install sensor plate (8) with sensor plale screws (6)
and washers (7). Tighten screws to 12·20 In·lbs torq ue.
INSPECTION
NO TE
Inspect lip of seal and replace it if worn or rough. Also
replace the seal if there Is any evidence of oil leakage 11 sensor pla te (8) was completely remo ved it may be
into the timer compartment. necessary to install wire pins, sockets and receptacle
body.
IGNITION COMPONENT
INSTALLATION (Figure 7·16) 7. Set retarded ignition timing as described In previous
section. Check advanced Ignition t iming under run·
1. Assemble ignition module (13) to frame. Make sure ning condit ions as described in previous section.
that the black ground wire is secured.
8. Install gasket (5) and inner cover (4) with screws (3).
2. Connect ignition module wires to ignit ion coil and Tighten screws to 12·20 in·lbs torque.
V.O.E.S as shown In the wiring diagrams.
9. Aivel outer cover (2) to inner cover (4) with rivets (1).
3. Install ignition module side cover.
4. If seal (11)was removed, inslall new seal (11) in gear· CAUTION

case, lip side 10 flywheel side of gearcase.
Use only rivets Part No. 8699 to secure outer cover. (See
CAUTION Figure 7·11 ,) Timing cover rivets are specially designed
so there is no rivet end to fall off into timing compart·
Sea l (11) must be pressed Into gearcase until It is flu sh. ment as with regular riVets. Use of regular rivets could
A seal that i s not all the way in may leak. cause damage to ignition components.
7·20
IGNITION - LIGHT SWITCH
(Figure 7-17)
The combination ignition - light switch is a three posi-
tion switch. The vertical position is OFF. For U.S.A.
operation, the nexllwo clockwise positions are ignllion Off
and head light. Key will lock Ignition in OFF position I Ignition
~~~;
only. Switch must be replaced as a unit.
Figure 7·17. Ignition - Ught Switch
7·21
SPARK PLUGS
GENERAL
Spark plugs should be replaced every 5000 miles. Use
only the replacement spark plugs listed in SPECIFICA·
TIONS page 7·1.
The 4R and 4R5 plugs have a resistor element to reduce

radio interference originating in the motorcycle ignition
system. Only resistor type plugs should be used with
1980 and later Ign ilion systems.
INSPECTING SPARK PLUGS

(Figure 7-18)
Examine plugs as soon as they have been remove d. The
deposits on the plug base are an Ind ica tion of the plu g
eff iciency and are a guide to the general condition of
rings, valves, carburetor and ignition system.
A. A wet black and shiny deposit on plug base. elec-

trodes and ceramic insulator tip indicate an all foul·
ed plug. The condition may be caused by worn rings
and pistons, loose valves, weak battery or fault y ig-
nition.
B. A dry fluffy or sooty black deposit Indicates a too Figure 7·18. Type. of Plug Bas. Depo.lt.
rich carburetor air-fuel mixture or long periods of
engine idling.
C. An overheated plug can be idenUlled by a light

brown, grassy deposit. This condition may be ac-
compa nied by c racks In the insul ator or by eros io n soflen depOSits wi th penetrat ing all and clean out
of the elect rodes. This condit ion Is caused by too with a thread chaser.
lean an air-fuel mixture, a hot running engine, valves
2. Apply engine oil to plug threads and Install spark
not seating or improper Ignition timing. The glassy
plug finger tight. Torque to 18-28 ft·lbs. If a torque
deposit on the spark plug Is a conductor when hot
wrench is not available, tighten finger light and
and may cause high speed misfiring.
then, using a spark plug wrenCh, tighten an addi-
tional 1/4 tu rn .
A plug wit h eroded electrodes, heavy deposits o r a
cracked Insulator shoul d be replaced.
3. Check engine idle speed, and adjust if necessary.
D. A plug with a white, yellow or light tan to rusty

brown powdery deposit indicates balanced combus-
lion. The depoSits may be cleaned off at regular in-
tervals If desired.
CLEANING SPARK PLUGS
SETTING SPARK GAP NOTE
Use only a wire-type gauge. Bend the outs ide of the Spark plugs should be replaced at every tune-up. Should
electrode so only a slight drag on the gauge Is felt when the plugs require cleaning bBtween tune-ups, proceed
passing It between electrodes. Never make adj ustments as fol/ows.
by bending the center electrode. See SPECIFICATION
Page 7·1 for correct gaps. 1. Degrease the firing end of t he plug with CLEAN ING
SO LVENT. Dry the plug with compressed ai r.
INSTALLING SPARK PLUGS 2_ Use a thin file to file the electrodes flat before set·
ting the spark plug gap. A plug with sharp edges on
1. Before Installing spark plugs, check condition of the electrodes requires twenty·five to forty percent
thread$ In ~Iinder head and on plug. If necessary less firing voltage than one with rounded edges.
7·23
IGNITION COIL
grounded). Transfer terminal wires to new coil as shown
DESCRIPTION in wiring diagram for that particular model.
The ignition coi l is a pulse type transformer that
transforms or steps up low battery voltage to the high CAUTION
voltage necessary to j ump the electrode al the spark
plug in the cylinder head. Internally the coil consists of Connect Ignition coil wires as shown in wiring
primary and secondary windings with a laminated iron di agrams. Revers ing polarity to the ignition control
core and sealed In water-proof insu lating compound. module will permanently damage the control module.
The ignition call cannot be laken apart or repaired. If the
ignition coil is defective, it must be replaced . Attach new spark plug cables to coil and plugs. If igni·
tion trouble is elim inated by the temporary installation
CAUTION of new coil, carefully inspect old coil and cables. The in·
sulation on cables may be cracked or otherwise dam·
On 1980 and later models, use only Ignition coils marked aged allowing high tension current to short to metal
ELECTRONIC ADVANCE. On 1979 and earlier models, pa rts . This is most noticeable in wet weather or when
use the old style coils. Interchanging these coils could motorcycle has been washed .
cause 8 failure In the electronic components.
REPLACING SPARK PLUG CABLE

TROUBLESHOOTING
Resistor type high tension cables are used. Th is type
When eng ine will not start or when hard starting or has a carbon impregnated fabric core instead of sol id
missing indicates a fau lty Ignition system, follow the wire for radio noise suppression and improved reliabi li·
troubleshooting procedure listed under the respective ty of electronic components. For this reason, it is neces·
ignition system sections. If condition persists, check sary that the exact replacement cable is used.
primary and secondary resistance of ignition coil with
an ohmmeter. Resistances should be within the follow· Remove old cable from coil terminal and install new
ing limits: cable. Always be certain that cable boot or cap is
securely tightened to the coil tower to prevent moisture
1979 and dirt from contacting the high tension lead. Replace
Primary . ...... . . •. .......... . .4.5t05.70hms boot or cap if damaged or loose fitting.
Secondary ... 16,500 to 20,000 Ohms
1980 and Later CAUTION
Primary . . ............. , .... 3.3t03.70hms
Secondary . . . ..... 16,500 to 19,500 Ohms When dlsconnectlng ca ble connector from spark plug
terminal, do not pull on the cable itself because the
If an ohmmeter is not available, temporarily substitute a cable carbon core will be damaged. Always pull on the
new ignition coil by attac hing it at any convenient point rubber boot as close as possible to the spark plug ter·
near old coil (coi l will function without bei ng securely mlnal.
7·25
GENERATOR
(1979 . Early 1984)
GENERAL Maximum Output
The generator is a direct current, two pole, shunt (Figure 7·20)
wound, two brush unit, driven by the engine liming
gears. 1. Remove both "A" and "F" terminal wires.
The generator output is regulated by the vOltage 2. Adjust voltmeter to read on a 50 volt DC scale.
regulator to meet the requirements of the motorcycle
and to keep the battery fully charged. 3. Connect positive voltmeter lead to the "A" terminal
and the negative lead to ground.
NOTE
4. Start motorcycle and run at 2000 rpm.
The generator should be tested prIor to removal to
evaluate performance and necessity of repair. See 5. MOMENTARILY connect a jumper lead from ground
GENERATOR OUTPUT TEST following for specific test to the " F" terminal. Voltmeter should read 25·30
procedures. volts DC.
If correct voltage is read generator is in good condi·

GENERATOR OUTPUT TEST tion.
Residual Magnetism If zero or very little voltage Is read disassembly and

(Figure 7·19) repair will be required. See GENERATOR TEST to de·
termlne source of problem.
1. Remove both "A" and "F" terminal wires.
2. Adjust voltmeter to read on a 10 volt DC scale. '--
3. Connect positive voltmeter lead to the "A" terminal

and the negative lead to the ground.
25·30 VDC
"'-
0
- I IA ,(.
1":·Momentarlly"
-
1 i T Jum~ erWlre
2·2VJ VDC I iiI,
0
- I'
,. Figure 7·20. Testing Maximum Output
1 i r CAUTION
I II-
DO NOT ground the generator field terminal for longer
than 10 seconds when the engine Is running as this may
Figure 7·19. resllng for Residual Magnetism damage the generator.
4. Start motorcycle and run at 2000 rpm. Voltmeter REMOVAL

should read a minimum of 2·2.5 volts DC.
1. Remove two hex screws securlng.generator to gear·
If correct voltage is read proceed to maximum out· case.
put test.
2. Disconnect and tag wires from generator "F" and
If Improper voltage is read polarize the generator "A" terminals.
and repeat test. See POLARIZING procedure.
3. Raise shaft end of generator, over idler gear and
If after polarizing the generator no voltage Is read remove from left side of motorcycle Care must be
disassembly and repair will be required. See taken to avoid damaging the generator slinger
GENERATOR TEST to determine source of problem. washer.
7·27
2. Remove gear shaft nut and washers .
DISASSEMBLY
3. Remove generator drive gear, use GEAR PULLER,
Part No. HD-95715-19A or ALL PURPOSE CLAW
1979-1981 PULLER, Part No. HD-95635-46 and WEDGE AT-
(Figure 7-21) TACHMENT, Part No. HD-95637-47.
Remove generator from engine gearcase as described 4. Remove through bolts (15) and carefu l ly pull off com-
in GENERATOR REMOVAL. mutator end cover (7).
1. Remove gasket (1). NOTE
2. Remove gear shaft nut (2) and washers (3 and 8), Thrus t washers (11) are positioned between bearing (12)
and commutator end cover. Retain all thrust washers
3. Remove generator drive gear (4). Use GEAR PULLER, for reassembly.
Part No. HD-95715-19A or ALL PURPOSE CLAW
PULLER, Part No. HD·95635·46, and WEDGE AT- 5. Lift body assembly (4) and brush holder mounting
TACHMENT, Part No. HO-95637-46. Slip drive end oil plate (9) from drive end cover (2).
deflector (5) off armature shaft.
NOTE
4. Remove brush cover strap (6).
Complete the following disassembly steps only if re o
quired to replace a damaged or worn part.
5. Turn off commutator end cover nuts (7). Pull frame
screws (9) out of frame . Tap commutator end cover
6. Press seal (1) from drive end cover (2).
(10) gently with small mallet and remove.
7. Pull bearings (12 and 14) from armature, using an
6. Remove nuts (11) and washer (12) 10 free positive
ALL PURPOSE CLAW PU L LER, Part No .
brush cable and brush leads.
H D-95635-46.
7. Remove brush holder mounting plate assembly (13).
8. Remove two pole shoe screws (5). Remove pole
shoes and coils (3) from body (4).
8. Press armature (14) out of bearing (26) with press .
9. Remove terminal screw nuts (15), lockwashers (16), GENERATOR TEST

and insulating washers (17). Remove terminal
screws (22) from inside generator frame and remove
terminal insulator (18), terminal bolt clip (19), ter- Field Coil Test
minal screw bushings (20), bracket insu lator (21) and
positive brush cable (23). NOTE
10. Tap drive end cover (28) off frame and remove bear- An ohmmeter should be used to perform the following
ing retainers (25). Use INTERNAL LOCK RING tests:
PLIERS, Part No. HD-96215-49.
GROUNDED FIELD
11. Remove bearing (26) and tolerance ring (24).
1. Remove or insulate brushes from commutator.
12. Remove seal (27).
2. Touch one probe to any part of generator frame and
NOTE other probe to the "F" terminal. There should be no
continuity (ooohms).
Do not remove pole shoe screws, pole shoes and field
coils unless necessary to replace faulty parts. If no continuity (00 ohms) was read continue by
checking for SHORTED or OPEN FIELD, procedures
13. Remove two pole shoe screws (30). Screws are following.
turned extremely tight. Remove pole shoes (31) and
field cal ls (32) from frame (33). If cont inuity was read continue with test.
3. Disconnect "A" and "F" terminals from frame and

1982 and Later again check continuity by touchi ng probes to "F"
(Figure 7-22) wire terminal and frame. There should be no conti nu-
ity (00) ohms. If there is no continuity Inspect insu-
Remove generator from engine gearcase as described lators and replace as needed.
in REMOVING GENERATOR.
If there was continuity field cOi l(s) is grounded and
1. Remove gasket. must be replaced .
7-28
1, Mounting g.lket 18. Termln.1 insul.tor 35. Nut
2, Ge.r Ihaft nut 19. Terminal bolt clip 36. Brulh (2)
3, Ge.r Ih.ft w.lherl 20. Terminal Icrew bUlhlng (2) 37. Brush spring (2)
4. Drive ge.r 21. Br.cket Insul.tor 38. Brush holder plate
5. Drive end 011 dellector 22. Terminal screw (2) Icrew (2)
6. Brulh cover Itrap 23. Po.lllve brUlh c.ble 39. Brulh holder plate Icrew
7, Commut.tor end cov.r nut (2) 24. Toler.nce ring washer (2)
8, Slinger w.lh.r 25. Be.rlng retainer 40. Brush holder plate screw
9. Frame screw (2) 26. Arm.ture bearing washer (3)
10. Commutator end cov.r 27. Se.1 41. Bracket
11. Brulh cable nut (2) 28. Drive end cover 42. Speed nut
12. Brulh c.ble w.sh.r (2) 29. Generator mounting bolt (2) 43. Cover
13. Brush holder mounting pl.te ....mbly 30, Pole Ihoe screw (2) 44. End cover bearing
14. Armature 31. Pole Ihoe (2) 45. Screw
15. Terminal Icrew nut (2) 32, Field coli (2) 46. Brulh cover screw, lock-
16. Termlnallcrew lockwalher (2) 33. Fr.m. washer and nut
17. Inlulatlng w.lher (2) 34, Lockwalher 47. End locating pin (2)
Figure 7·21. Generator - 1979·1981
7·29
(
I 1.
L~~
1.011 ••• 1 8. Brush spring 16. Spring washar
2. Drive end cover 9. Brush holder ...y. 17. Screw
3. Field coil assy. 10. Bru,h 18. Inauillting tube
4. Body 11. Thrust washer 19. Inaulatlng washer
5. Screw 12. Ball bearing (rear) 20. Plain washer
6. Terminal Insulator 13. Armatur.... y. 21. Spring wa,he,
7. Commutator end cover 14. aall bearing (front) 22. Nut
15. Through bolt 23. Locating pin
Figure 7·22. Generator - 1982 & later
SHORTED OR OPEN FIELD GROUNDED ARMATURE
1. Remove or insulate brushes from commutator. 1. Remove armature from generator frame. Work on a
bench with a nonconductlve top.
2. Touch one probe to the "F" terminal and Ihe other to
the "A" terminal. A small resistance (5.0-6.5 ohm) 2. Touch one probe to any commutator segment and
should be read. the other to armature core. There should be no con-
tinuity ( OJ ohms). If there is continuity, the arma-
If no resistance (0 ohms) is read coi ls are shorted ture is grounded and must be replaced.
and must be replaced. If there is no continuity (OJ
ohms) there is an open circuit and coils must be OPEN ARMATURE
replaced.
1. Remove armature from generator frame. Work on a
Armature Test bench with a nonconductlve top.
NOTE 2. Check for continuity between all commutator

An ohmmeter should be used to perform the following segments. There should be continuity (0 ohms) at all
tests. test points.
7·30
No continuity between any two commutator seg- COMMUTATOR REPAIR
ments Indicates an armature coil Is open and ar-
mature must be replaced. A generator that has been In extended service may lall
to deliver enough current to keep the battery In a
SHORTED ARMATURE charged condition although Its field coil and armature
windings are in serviceable condition. In such cases the
1. See Figure 7-21. Place armature on a growler. Hold a commutator and/or brushes are usually at fault. II the
thin steel strip (hacksaw blade) against armature commutator has been worn down until the mica separa-
core. tions between segments are no longer undercut or re-
cessed, the commutator probably is grooved noticeably
2. Slowly rotate armature. A shorted armature will in path of brush travel and no slot between commutator
cause the steel strip to vibrate and be attracted to segments exists, causing the brushes to ride high and
the core. A shorted armature must be replaced. make only Intermittent contact with commutator.
CLEANING, INSPECTION The commutator may be turned down in a lathe and

smoothed with crocus cloth until true and smooth.
AND REPAIR When turning armatures, grip shaft on bearing surfaces.
1. Clean all parts except gasket, armature, field colis

and brushes In cleaning solvent and blow dry with CAUTION
compressed air. Wipe rest of parts clean with cloth
dampened In white gas and blow dry with com· Never sand a commutator with emery cloth. Particles
pressed air. will embed themselves In the copper surface, holding
the brushes off the commutator far enough to cause
2. Examine all parts carefully for wear. Give close ai- heavy arci ng and burning.
tention to condition of insulators, armature wind·
Ings, field coil wrapping and surfaces of pole shoes
Alter commutator has been turned down, the mica In-
nearest armature. If armature had oily appearance
sulation between segments must be recessed or under-
before cleaning, replace oil seal. Replace any part of
cut approximately .025 In. Undercutting is usually done
brush holder mounting assembly that is bent.
with a special undercutting machine. If one is not
available, satisfactory undercutting may be done with a
3. Check play in armature ball bearing. If any play can
piece at hacksaw blade. Carefully thin down blade
be detected replace the bearing.
width, If necessary, until offset saw teeth are the same
width as slots In commutator. Slots must be square-
4. Clean and Inspect brush holders, Brushes must
bottomed for good results. See Figure 7-24.
move freely In holder.
5. Inspect brush springs. Springs must provide even

and constant pressure on brushes. Replace as re-
quired.
ASSEMBLY
6. Measure longest side of brushes, if length Is 112 In. 1979·1981
or less replace brushes as a set. (Figure 7·21)
2222 1. Assemble the brushes (36), brush springs (37) and
other related parts to the brush holder mounting
plate (13).
2. Position pole shoes (31) In field colis (32) and insert

In frame. Turn in pole shoe screws (30) until snug.
Place frame in vise and use very large screwdriver to
securely tighten screws. Use a wrench to turn
screwdriver while bearing .down with considerable
force to keep screwdriver from slipping out of slots.
Shoes will align themselves In frame.
3. Place tolerance ring (24) in drive end plate (28). Push

bearing (26) Into tolerance ring. Compress bearing
retainers (25) with needle nose pliers and insert In
grooves.
4. Press seal (27) Into cover (28) from inside, with lip
toward beari ng.
Figure 7·23. T•• tlng Arm.ture for Short 5. Insert armature (14) drive end shaft in beari ng (26)
7-31
and press In until shoulder seats on the bearing. Be generator ends are not seated properly or pole
sure to support bearing Inner race while pressing In shoes are not drawn up tightly.
shaft.
11. Slip drive end 011 deflector (5), drive gear (4) and
6. Slip "A" terminal field coli lead on positive terminal washers (8 and 3) over shaft and turn on nut (2) until
screw (22), followed by positive brush cable (23), a gear is seated against 011 deflector. Install brush
terminal screw bushing (20), bolt clip (19) and the ter· cover strap (6) with connection at bottom as posl·
minallnsulator (18). Insert the assembly through "A" tloned on motorcycle. Position gasket (1) onto the
terminal frame hole from Inside. Assemble the In· generator and Install In reverse order of removal.
sulatlng washer (17), lockwasher (16) and nut (15)
over terminal screw.
7. Slip "F " terminal screw (22) Into "F" terminal field 1982 · Early 1984
call lead, bracket insulator (21) and screw bushing (Figure 7·22)
(20). The assembly Is then slipped Into "F" terminal
frame hole through the bolt clip and terminal In· 1. Assemble springs (8) and brushes (10) Into brush
sulator. An insulating washer (17), lockwasher (16) holder assembly (9). Attach field and "A" terminal
and nut (15) are assembled over terminal screw. wire with corresponding brush lead to Insulated
post, on brush holder assembly (9).
8. Slip frame assembly over armature, locating pin (47)
In hole In drive end plate. Bend loose end of positive 2. Install field coli assembly and shoes, if applicable.
brush cable out commutator end of generator. Push Secure with Loctlte LOCK N'SEAL.
brushes back in brush holders to clear commutator
and assemble brush holder mounting plate over 3. Carefully press seal (1) Into front cover (2).
commutator so pin (4n registers In small slot and
brush cable passes through large slot almost direct· 4. Press bearings (12 and 14) onto armature (13), If ap·
Iyopposlte. plicable.
9. Connect positive brush cable and positive brush 5. Push armature assembly (13) through front cover (2),
lead to Insulated brush holder terminal with washer bearing (14) Is a light hand press fit in cover.
(12) and nut (1 1). Connect grounded (negallve) brush
to Its terminal In same manner. 6. Align terminal Insulator (6) over terminal holes in
body (4) and push terminals through. Inslall In·
10. Install commutator end cover (10) over armature sulators and other hardware as shown .
shaft end so notch in edge registers over pin (47) in
frame. Slip internal tockwashers over frame screws 7. Carefully slide body assembly (4) over armature,
(9) and feed them through generator from drive end . align locating pin (23) In body with hole in front cover
Assemble nuts (7) to frame screws and tighten (2) and push into place.
securely. Turn armature shaft to see If if is bound or
If armature core strikes pole shoes. Shaft should be 8. Slide rear cover (7) over rear bearing (12) and brush
reasonably difficult to turn, but there should be no holder assembly (9). Position slot in brush holder
tight spots. If armature core strikes pole shoes, over locating pin (23).
Starti ng groove in mica Undercutti ng mica with piece

with 3 cornered file of hacksa w blade
Mica ~
__ ' Segments ~ Mica
% 0 ' .
Wrong way
~ Right way
Mica must not be left Mica must be cut away
wit h a thin edge next clean between segments
to segments
Figure 7·24. R.c... lng Mic. Separator.
7·32
9. Push rear cover (7) into position, aligning hole in of the battery. This restores the magnetism. Remove
cover with locating pin (23). Secure with through jumper.
bolts (15) and lockwashers (16).
NOTE
10. Adjust armature end play to 0.004-0.010 in.
It /s recommended to polarize the generator whenever
wIres have been removed or when installing a new
generator to ensure correct pOlarity.
POLARIZING GENERATOR
(Figure 7-25)
After a generator has been repaired and assembled It
must be repolarized to make sure that it has the correct
polarity for charging in the right direction. A generator
that is put into service with the wrong polarity will not
----
charge the battery and may cause damage to the
regulator.
1. With generator on bench, connect the positive ter·

n +
.dt
minal of a battery to the armature terminal of the 12v Battery
generator. Then , momentarily "flash" the negative I ,A
battery terminal to the generator field terminals.
2. Wlth generator on motorcycle and connected to

1 :M!:J arily"
regulator, connect one end of a jumper wire to the
generator armature terminal. Momentarily touch the
other end of the jumper wire to the positive terminal Figure 7·25. Polarizing Generator
7·33
REGULATOR
(1979 . Early 1984)
GENERAL CHECKING CHARGING SYSTEM
The solid state voltage regulator controls the output of
the DC generator. II Incorporates the electronic equiva- General
lents of the cut-oul relay and the current relay of its
electromechanical predecessor. It Is, however, Insen- When the charging system falls or Is not charging at a
sitive to dust, dirt or vibration but has a more sensitive satisfactory rate, as is visually evidenced by a weak bal·
electronic circuit which holds the output to closer tery, dim lights, or excessive battery water usage. It Is
tolerances than before possible. recommended that the following checks be made.
Figure 7·26 and 7-27 shows a simplified schematic

diagram. Preliminary Checks
Diode D, prevents current !low from the battery into the Battery: Check for weak or bad battery. See BATIEAY
regu lator and generator, but permits charging current to section. Battery must be fully charged for
pass from the generator to battery and load. following electrical tests.
Transistor Q,. through the voltage divider consisting of Wiring: Check for corroded or loose connections in
charging circuit. Particularly check for worn
R" Z, and A2. senses the generator output Yoltage.
When the output voltage rises: 0, draws more current or pinched wires in the generator·le-regulator
through AS causing the voltage at the base of 03 to harness. Also check for corroded or loose ter·
drop. The generator field current IF which flows Into the mlnals at generator. Remove rubber regulator
collector of 03 Is thus reduced. This in turn causes the connector plug and check for burned or cor·
generator output voltage to drop. An equilibrium condi· roded terminals. Regulator base must have a
tion is reached whereby the generator supplies Jusl good, clean, tight connection for proper
enough current 10 the electrical load to maintain a con· grounding.
stant pre·sel output voltage.
When the output voltage drops through increased load Electrical Checks
or reduced rpm the reverse happens. 0, draws less cur·
rent which causes 03 to draw more, which increases If the preliminary Inspection shows components 10 be In
the output voltage. good condition, make the following electrical checks:
Transitor 02 senses the voltage across A3 which is a REGULATING VOLTAGE CHECK:

measure of the generator current. When the current ex· (See Figure 7·28)
ceeds a predetermined value 02 turns on. This turns on
0, which turns 011 03' The field current is reduced and Connect an ammeter in series with the regulator output.
so Is the output current. Connect load rheostat (carbon pile) and \loltmeter
Regulator
Dt
R3
R5
+ Q2' ~--~
Load
. tl Rl
ZI
Regulator Qt R2
side
plug
Flgure 7·26. Schematic Diagram - 1979·1981
7·35
Regulator
Ign. Indicator
switch light D1
R3
R5
+ 02!)!---~
Load R1
Z1
Regulator 01 R2
0
side 1
plug -23-
Figure 7·27. Schematic Diagram - 1982 & Later
across battery. Check regulating voltage while running OUTPUT CHECK:

engine at 2000 rpm.
Run engine at 2000 rpm and adjust load rheostat (car·
Adjust load rheostat (or carbon pile) to 2·7 amperes out- bon pile) to obtain a constant 12.5 volts . The output cur-
put The voltage readings then should conform to the rent should be 10 amperes minimum. 11 amperes max-
values given by the curves shown in Figure 7-29 at the imum, for 1979·1981; 13 amperes minimum 14 amperes
temperature measured at the time of testing. For exam- maximum, for 1982 and later.
ple, if the regulator temperature was + 75°F, the upper
voltage (from upper curve) would be 15.0 volts and the If no generator output current is obtained in the output
lower voltage (from lower curve) would be 13.8 volts. check, polarize generator (see POLARIZING GENERA-
TOR).
If voltage exceeds upper limit of curve, check for ground
Again check output at 2000 rpm per OUTPUT CHECK. If
in field circuit of generator (see GENERATOR) or in
still no generator output current is obtained, momen·
regulator to generator field wire (green). If no ground is
tarily ground generator "F" terminal with engine run-
found, defect is probably in regulator - replace with
ning at 2000 rpm.
known good unit.
CAUTION
If voltage is below lower limit on curve, proceed with
output check. If system passes output check, regulator Do not ground "F" terminal for longer than 10 seconds
is out-of-specification - replace with known gOOd unit - damage to generator or regulator can occur.
- 0 Voltmeter Ammeter
o 0·20 0·20
o R
o
o Battery
Reconnect red ganerator

Rheostat wire from main circuit
15 ohm Junction breaker to junction
250 watt
Figure 7·28. Test Arrangement with Individual Components
7·36
generator (see GENERATOR). If no output current is ob-
tainable, problem could be in regulator or generator.
Temperature Compensation Curve
Check regulator as follows: Disconnect rubber regula-
tor connector and connect ohmmeter between battery
16.0
and generator wires (orange and tan wires on regulator).
Up"_
,..",r lImits Reverse ohmmeter connections. Ohmmeter should
..
:l
>
~
15.0
14.0
show continuity (low resistance) with the other connec-
tion. If regulator checks OK, check generator (see GEN·
ERATOR). If regulator does not pass ohmmeter test,
replace with a known good regulator and retest.
~ L.o loVerlJ
•
aI 13.0
nUts
If charging system operates properly and generator
warning light sti ll glows, check diode in wiring harness.
12.0 Also check for missing or bad regulator ground.
·25 o +25 +50 +7 S +100 .f12S
Air temperature of REGULATOR CHECK:
If the regulator appears to be the defective component,

check it by replacing it with a unit that is known to be
Figure 7·29. Regulating Voltage good and check agai n. Electrically disconnect the unit
to be checked, then temporarily connect in the new unit.
With '·F" terminal grounded, generator output should be If the output is now okay, the original rectifier·regulator
18 Amps min imum. If output is OK with " F" terminal was defective and should be replaced. If the output is
grounded, problem is most likely in regulator - replace still unsatisfactory, the original unit was probably okay
with known good unit and re·test. If output is low, check and the problem lies elsewhere.
7·37
CHARGING SYSTEM
(Late 1984 and 1985)
and accessories turned off, maximum reading should be
GENERAL one mill iamp (1m). A higher reading indicates a malfunc-
tioning regulatorlrectifier which must be replaced.
Alternator
NOTE
The alte rn ator consists of two main com ponents: the
rot or which i s mounted on the rear of the clutch shel l, Make sure accessories are not wired so they stay on at
all times. Check for this by connecting ammeter as
and the stator, which is bolted to the transmi ssi on ac-
shown in Figure 7-31 . With ignition switch and aI/lights
cess cover.
turned off, there should be no more than 1 milliamp (1m).
Regulator
The regulator is a series regulator with shunt control.
The circuil combines the functions of rectifying and
regulating . oAMP
+
12V
TROUBLESHOOTING battery
To ground
Preliminary Checks
When the charging system fails or does not charge at a
satisfactory rale, it is recommended that th e following Figure 7·31_ Total Output and Current Draw Test
chec ks be made: If battery runs dow n during use, the current draw of the
motorcycle components and accessories may exceed
Battery: Check for a wea k or dead battery. See the BAT- output of the charging system. To check for this condi-
TERY Section . Battery must be fully charged in order to tion, connect an ammeter between the battery negative
perfo rm any electrical tests . terminal and ground as shown in Figure 7-31.
Wiring: Check for corroded or loose connections in the With ignition and al l continuously running lights and ac-
charging circuit . The regulator base must have a clean, cessories turned on (headlamp on high beam), read the
tight connection for proper grounding. Make sure star total current draw. Compare this reading to the output
washers (if used) are between regu lator and mounting given in SPECIFICATIONS. The output should exceed
bracket. current draw by 3.5 amps minimum . If not, there may be
100 many accessories for the charging system to handle.
If battery runs down when motorcycle is not being used,
the problem could be in the regulator / rectifier. With ig- Charging System Output Test
nition switch off, connect an ammeter between the
regulator wire and the battery positive terminal as Using Ammeter (Figure 7-31)_
shown in Figure 7-30. With ignition switch and all lights
1. With engine running at 2000 rpm, connect am-
meter between· ground and battery negative ter-
minal , then disconnect battery ground wire. Leads
should be reverse of previous draw test.
CAUTION
oAMP
Do not disconnect battery ground wire before connec·
ting ammeter. Also, do not try to start engine with am·
meter connected. In either case, damage to com-
+ 1 milliamp
ponents could result.
12V
battery 2. With all continuous ly running lights and ac-
To regulator cessories turned on (headlamp on high beam),
Ignition "OFF" reading should be 3.5 amps or more. If reading is
less than 3.5 amps, problem may be in charginq
Figure 7·30. lesting Regulator/Rectifier system.
7-39
- u Voltmeter Ammeter Regulator
a 0-20 0-20 rectifier module
a
a
o Battery
0+
R~ta~I------------~C::::::::::::::::::'--------)
15 ohm
To alternator
250 watt
Figure 7·32. Test Arrangement with Load Rheostat
Charging System Output Test Stator Check

Using Load Rheostat (Figure 7·32)
1. To check for a grounded stator, turn off ignition
NOTE and disconnect the regulator/rectifier from the
stator at the plug below the crankcase on the left
Use this test procedure In place of above procedure If side.
load rheostat is available.
2. See Figure 7·34. Connecl an ohmmeter on the RX1
Connect an ammeter In series with the alternator out· scale between ground and with stator pin or
put. Connect a load rheostat (carbon pile) and voltmeter socket. There should be no conlinuity (infinite
ohms) across either test point. Any other reading
across the battery. Check the regulating lIoltage while
indicates a grounded slator which must be replac·
running the engine at 3600 rpm. ed.
3. Check the stator resistance with an ohmmeter set

Output Check on the RX1 scale. The stator coil resistance should
be 0.2 . 0.4 ohm (very low) when measured across
Run the engine at 3600 rpm and adjuslthe load rheostat
the stator pins. If the resistance is higher or no
(carbon pile) to obtain a constant 13.0 volts. The alter·
needle movement (co) is detected the stator must
nator current output should be 19 amperes minimum to
23.0 amperes. See Figure 7·33. be replaced.
Output Check (Figure 7·35)

•
1. To test AC output, disconnect the regulalor/rec·
..
"
~
tifier and connect an AC voltmeter across both
stator pins or sockets. Run the engine at 3000 rpm.
If the AC output is not at least 60 volts, the rotor
" must be replaced.
t "" 2. If stator and rotor are good, charging problem can

~ ", be assumed to be a faulty regulator/rectifier.
8 ' Replace the regulator as described under REPLAC·
ING TH E REGULATOR.
I "• 3. Check the output again as described under
I •
•
CHARG ING SYSTEM OUTPUT TEST given earlier.
, Disassembly (Alternator)
,
1000 2000 300D ~ 600D eooo WARNING
EngJM SpHcI RPM
avoid accidental start·up of vehicle and possible per·
Figure 7·33. Alternator Ouput Curve sonal Injury.
7·40
2. Remove retaining ring, Figure 7·36 and separate
.~, Grounded Stator Test
the clutch assembly from the clutch shell.
NOTE
A portion of the clutch shell functions as the alternator
rotor, Resistance to clutch shell removal is due to the
magnetic attraction of the rotor magnets.
""
FIgure 7·34. Testing for Grounded Stator
AC Output Test 1. Clutch hub

"" 2. Retaining ring
3. Rotor
Figure 7·36. Removing Clutch Hub Retaining Ring
3. Replace rotor and clutch shell as a unit.

4. Reassemble clulch assembly and clutch shell and
secure with new retaining ring.
5. Inslall the clulch assembly, Irani chain and engine
sprockel as a unit. Refer 10 CLUTCH INSTALLA·
TION , Section 6.
REPLACING STATOR
LATE 1984 TO EARLY 1985:
1. Remove the four slotted screws securing the

stator to the stator support.
2. Disconnect the stator from the regulator at the
connector beneath the crankcase. If stalor reo
placement is needed, pry the grommet from the
crankcase, pu i lihe connector through the opening
and remove the stator.
Figure 7·35. Checking Alternator Output
LATE 1985:
GENERAL
Remove the drain plug and drain the all from the chain- 1. Using a T-27 Torx drive socket, remove the four
case, then remove the gear shift lever, left footrest Torx fasteners securing the stator to the access
assembly and the front chain cover as described under door.
CLUTCH REMOVAL in Section 6.
NOTE
REPLACING ROTOR Tone screws contain a locking compound in pellet form

1. Remove the clutch assembly, front chain and on the threads. When the screw is started, the pellet
engine sprocket as a unit. Reier to CLUTCH breaks, releaSing the compound. As 8 result, the screws
REMOVAL, Section 6. cannot be reused.
7-41
2. Disconnect the stator from the regulator at the remove them with emery cloth so that stator will seat
connector beneath the crankcase. If stator replace· properly on the stator mount.
ment is needed, pry the grommet from the
crankcase, pull the connector through the opening
and remove the stator. 3. To install the replacement stator leads, thread a
light flexible wire (18 gauge) between the stalor
CLEANING, INSPECTION AND REPAIR leads behind the connector.
1. Remove all foreign particles from the rotor
magnets, then clean the rotor with a petroleum 4. Insert the ends of the flexible wire through the hole
base solvent. in the crankcase and downward.
CAUTION
5. Grasp the ends of the flexible wire and gently route
Do not strike or drop alternator rotor, or magnet the connector into position.
adhesive may be damaged, resulting in rotor failure.
2. Clean the stator by wiping it with a clean cloth. 6. Place a few drops of oil or CHAINCASE LUBRI-
CANT on the grommet surface that contacts the
3. Examine the stator leads for cracked or damaged hole in the crankcase and press grommet inward
insulation. until it seats in the crankcase hole. Reconnect the
stator/voltage regulator connector.
4. The rotor and stator can be replaced individually if
either is damaged or defective.
ASSEMBLY
1979· EARLY 1985
1. See Figure 7-37. Place the slator mount in position

on the access door. Align the four counter bored
holes in the stator mount with the four tapped
holes on the access door.
Figure 7·38. Tightening Stator Mount Screws
7. See Figure 7-39. Position the stator on the stator

Figure 7·37. Stator Mount in Position mount and align the holes indicated in Figure 7-39
with the tapped holes in the stator mount. Apply
2-3 drops of Loctite 242 to the threads of the four
2. Apply 2·3 drops of Loctite 242 (blue) to the threads slotted head screws, Part No. 2653, and tighten
of the four Allen socket head screws, Part No. these screws to 30-35 in·lbs torque.
2647. Insert the screws thru the recessed (counter-
bored) holes and tighten the screws to 30-35 in-Ibs 8. Install clutch, engine sprocket, and front chain as
torque. See Figure 7-38. described in CLUTCH INSTALLATION , Section 6.
CAUTION
9. Install front chain cover, left footrest assembly,
Inspect the replacement stator mounting holes iden· and gear shift lever as described in CLUTCH IN·
tified In Figure 7·39 tor burrs. If burrs are present. STALLATION, Section 6_
7·42
Figure 7-39. Stator Mounting Holes
1. Torx fastener
2. T·27 Torx driver
Figure 7·38a. Stator Torx Fasteners REPLACING REGULATOR
LATE 1985
1. See Figure 7-38a. Position stator on access door. The regulator is a non-repairable item and must be
Align the four holes In stator with four tapped replaced if it fails.
holes on the access door. Install 4 new Torx
fasteners securing stator to door. Tighten
fasteners to 30-40 In·lbs torque. 1. Unplug the regulator from the alternator lead
beneath the crankcase.
2. To Install the replacement stator leads, thread a
light flexible wire (18 gauge) between the stator
leads behind the connector. 2. Cut the cable straps securing the regulator wires
to the left side frame member. Remove the seat
3. Insert the ends of the flexible wire through the hole and disconnect the regulator lead from the main
In the crankcase and downward . circuit breaker.
4. Grasp the ends of the flexible wire and gently route
the connector Into position.
3. Remove the mounting bolts and replace the old
regulator with a new one. Reinstall the mounting
5. Place a few drops of all or CHAIN CASE LUBRI·
CANT on the grommet surface that contacts the bolts.
hole in the crankcase and press grommet Inward
until It seats in the crankcase hole. Reconnect the
statorlvoltage regulator connector. 4. Route the wires along the inside of the bottom
frame member and connect it to the circuit
6. Install clutch, engine sprocket , and front chain as breaker. Install the seat , then secure the wires to
described in CLUTCH INSTALLATION, Section 6. the frame with cable straps.
7. Install front chain cover, left footrest assembly,

and gear shift lever as described In CLUTCH iN· 5. Plug the regulator Into the alternator lead beneath
STALLATlON , Section 6. the crankcase.
7·43
BATTERY
GENERAL BATTERY CARE
The battery produces electrical energy to start the Prompt and correct battery care determines the life
motorcycle, to operate accessories when the engine is span of the unit. Therefore, for a longer useful life, the
not running and to provide additional current, when battery solution level must be checked at regular Inter-
necessary, over the amount being generated. For a bat- vals, see the REGULAR MAINTENANCE INTERVAL
tery to remain in good condition, the currect draw must Chart in Section 1.
be balanced by a current Input. All Harley-Davidson bat-
teries have lead plates and sulphuric acid electrolyte CAUTION
units of capacities suitable for load requirements under
Intended use. Add only pure distilled or approved water. 00 not add
sulphuric acid to a wet battery. Adding sulphuric acid
NOTE could possible make the electrolyte solution too strong
causing battery life to be shortened.
A new battery is shipped dry and must be activated by
Wllh a hydrometer or syringe, add water 10 each cell to
filling with battery grade sulphuric electrolyle before
maintain level between upper and lower limits shown on
pIecing In service. See the Instruction sheet, furnished
battery.
with the battery, for activation procedure.
1979 XLHIXLS - Fill to triangle or circle at base of filler
hole.
Apply tight coat of petroleum jelly or corrosion retar·
dant material to terminals. 1979 XLCH, 1980 and Later XLHIXLS/XLX - Maintain
level at upper level line on side of battery.
CAUTION
Be careful not to overfill. Overfilling will result in some
See Figure 7-40. On 1982-1985 models, be certain of the electrolyte being forced out through the cap or
positive cable ;s routed away from leading edge of all vent hose, diluting or weakening the solution strength.
tank. This surface could cut the insulation and possibly An overflow of battery solution will cause cables to cor-
cause a short circuit. rode and motorcycle parts near the battery to be damaged.
"115 WARNING
Batteries contain sulfuric acid. Avoid contact with skin,

eyes or clothing.
ANTIDOTE
External - Flush with water.

Internal - Drink large quantities of milk or water fol-
lowed by milk of magnesia, vegetable oil, or beaten
eggs. Call doctor Immediately.
Eyes - Flush with water and get Immediate medical at-
"178 tention.
Route between frame
backbone and oil tank Clean battery and terminals when necessary with a bak-
ing socia-water solution. When solullon stops bubbling,
~~ flush off battery with clean water.
TESTING BATTERY
Use the following tests to determine the condition of a
battery:
Specific Gravity Test

To make specific gravity test on all cells, use a quality
hydrometer with a temperature correction feature.
Figure 7-40. Battery Cable Routing - 1982-1985 1. Specific gravity tests must be made with correct
7-45
electrolyte level in the battery; if electrolyte level is WARNING
too low to test, add water, then fully charge battery
and allow to stand at least 24 hOu rs before testing. Hydrogen gas, formed when charging a battery, is ex·
plosl ve. Avoid open flam e or electrical spark near bat·
2. In maki ng the hydrometer readings, the floa t must tery.
be floating freely and eye must be level with the
liquid level to obtain accurate readings.
3. Correct specific gravity readings can be measured RECOMMENDED CHARGING RATES
only when the electrolyte temperature is80° F. if the
electrolyte temperature is not 80° F., correct the CAPACITY BENCH
reading as follows: (AMP CHARGE
PART NO . VOLT HOUR) (AMP)
a. For each 10" F. above 80· F., add four gravity
points (0.004).
b. For each 10° F. below 80· F., subtract four gravity
65991·82'
66004·65A
12
12
,.
32
1.5
4.0
points (0.004). 66010·82' 12 22 2.0
Example: If the hyd rometer readi ng is 1.225 and 'low mai ntenance
the temperature of the elect rolyte is 90" F., the
corrected read ing wou ld be 1.225 + 0.004, or
1.229.
If battery gets hot, over 110" F., (44" C.), discontinue
BATIERY CHARGE CONDITION charging and let battery cool. If battery gasses ex·
State of Specific cesslvely, lower the charging rate and continue charg·
Charge Gravity (A) ing until required specific gravity reading is obtained.
100% 1.270 . 1.280
BENCH CHARG E at above rate for 16 hours or until
75% 1.240 . 1.250
1.270·1.280 specific gravity is obtained.
50% 1.210 ·1.220
25% 1.180·1.190 Charge rates shown in chart are maximum rates.
4. The battery shOuld be charged until the specific Discontinue charging, or lower AMP rate whenever bat·
gravit}( remains the same for three successive hour· tery heats to over 110· F. (44- C.) or gasses excessively.
Iy readings. If the specific gravity between the
highest and lowest cell varies 50 (0.50) points or Allowing a battery to remain in a discharged condition
more, the battery should be replaced. will shOrten its life. II is important that a battery be kept
well charged during below freezing weather.
5. Make sure exhaust tube is securely clamped to the
battery exhaust nipple. SERVICING
Load Testing 1. Conventional battery: Check battery electrolyte
level, check and clean connections every 500 miles.
Fully charge the battery before tes ting. Load battery to
3 times Ampere·hour rating, using a su itable tester. 2. Low mai ntenance battery: Check battery electrolyte
VOltage reading after 15 seconds should be 9.6 volts or level after first 500 miles. Chec k elect rolyte level,
more. check and clean connect ions every 5,000 miles or
once annuall y.
CHARGING BATTERY
3. If vehicle is in storage or only occasionally used,
Battery should be charged BEFORE installation. A slow remove battery from vehicle and charge until the cor-
" bench" charge is recommended. rect specific gravity is obtained.
WARNING This should be done every other month for vehicles

in winter storage, at temperatures below SO - F
Charg ing should be done in a well ventilated area . Ex· (16"C), and those vehicles only occasionally used;
plosive hydrogen gas escapes from battery during once a month for vehicles stored in a warm area,
charging. Avoid open flame or electrical spark near bat· above 6O -F (16-C).
tery at all times, especially during charging.
RECLAIMING SULPHATED
To determine the amount or condition of a battery BATTERY
charge, check solution i n each cell with a battery
hydrometer. When hydrometer reading is 1.200 or less, If a battery has been allowed to stand in a disc harged
battery i s considered discharged and should be reo condit ion for a period of time, the lead sulphate in the
moved from motorcycle and charged at 1.5 amperes plates will crystallize and not take a charge at normal
maximum continuous charge rate, using appropriate 12 rates. Such batteries should be charged at half the
volt charger. specified continuous rate for twice the computed time.
A longer charging lime at a slower rate wi ll many limes
Always charge battery with all filler caps in place. See break down the crystalline structu re i nto act ive
chart for recomm ended charging rates. materials and restore the battery.
7·46
LAMPS
HEADLAMP and adjusted . Then, posillon the motorcycle on a level
surface with headlamp approximately 25 feel away from
The head lamp is a sealed-beam type. When replace- the test paltern. Have a rider sit on the motorcycle to
ment Is required , use only the prescribed sealed-beam sImulate actual running conditions. Motorcycle must be
unit. If either filament burns out, or the lens breaks, the vertIcal with Iront wheel In straight ahead alignment
entire unit must be replaced. and tires correctly Inflated . Aim the head lamp direclly
at the screen and turn on the light switch. Set beam
To remove sealed beam unit , remove screw from outer selector switch on the high beam positIon, and check
clamping ring. Pry unit from rubber mounting and pull beam lor height and direction.
connector block from unll prongs.
The top of the main beam of light should register even
Assembly Is the reverse order of disassembly. Be sure with, but no higher than the horizontal line 01 the test
connector block contacts are clean to ensure a good pattern.
electrical contact. After final assembly, readjust head-
lamp as described under ADJUSTING BEAM. To aim beam, loosen the head lamp mounting hardware
and position the lamp to correclly adjust the beam 01
light in relation to the horizontal line. At the same time,
ADJUSTING BEAM turn the head lamp right or left to direct the beam 01 light
straight ahead. Tighten the mounting hardware after the
To gel the greatest efficiency from the headlamp and to lamp Is correctly adjusted .
meet the requirements of the law, correctly adjust
head lamp according to the fOllowing Instructions. BULBS
Draw a horizontal Une on a wall or screen exactly the See the bulb chart in electrical SPECIFICATIONS for
same height as the center of the headlamp to be checked proper bulbs.
7·47
HORN
Horn is shown in Figure 7-41. If the horn fails to blow or
does not blow satisfactorily, check for loose, frayed or
damaged wiring leading to horn terminals, discharged
battery, etc. If these steps do not correct the trouble,
turn in contact point adjusting screw, located back of
~~
horn, until horn best tone is obtained. If horn fails to
operate after moving adjusting screw, entire horn must
be replaced because it is permanently riveted together.
Mounting parts are replaceable.
'\. Br~cket Nut
Horn
Figure 7·41 . Horn
7·49
SPECI FICATIONS
(XR-1000)
IGNITION TIMING Gap ............... . 0 .038.0.043 In.
Tightening torque . . . . . . . . . . . .. 18·28 ft·lbs
Full advance (above 1600 rpm) 30 ° BTDC
Fully retarded . 2 ° AlOe
Idle Advance (600·1600 rpm) ... .16 0 BlOC
GENERAL
Battery '................ 12v.19amp.
SPARK PLUGS Generator - Two brush shunt, external regulator control
............. 13amp.
Type ...................... Harley·Davidson No. SA? Regulator ...... solid slate current and voltage control
(Champion RN7YGj Horn. . . . ... Electric, vibrating type
Size .. 14mm Armature end play. . . .004-.010 In.
BULB CHART
The chart below gives the light bulb locations and requirements.
CANDLE HARLEY·
NUMBER POWER DAVIDSON
LAMP DESCRIPTION OF BULBS OR PART
(ALL LAMPS 12 V.) REQUIRED WAnAGE NUMBER
Headlamp 1
High Beam 50 Walts
Low Beam 35 Watts 67698-81A
Tall and Stop Lamp 1 68165-64
Tail Lamp 3 C.P.
Stop Lamp 32 C.P.
High Beam Indicator Ught 1 2 C.P. 70021-83
Generator Signal Light 1 4 C.P. 68495-83
Oil Pressure Signal light 1 4 C.P. 68489-83
Speedometer, Tachometer Lights 1 2 C.P. 71090-64
Turn Signal Lamps 4 32 C.P. 68572-64A
7·51
IGNITION SYSTEM
(XR·1000)
are located in the gearcase cover on the right side of the

DESCRIPTION motorcycle. The Ignition module is mounted to the
(Figure 7·42) frame under the side cover next to the battery. The
module has two functions. First, It computes the spark
The ignition system is a breaker less inductive advance lor proper ignition firing. Second, It opens and
discharge ignition system. It has two circuits, the closes the low vollage circuits between the battery and
primary circuit and the secondary circuit. The primary ignition coil to produce high voltage discharge to the
circuit consists of the battery, switch, primary call wind· spark plugs.
ing, computerized ignition timer and associated wiring.
The secondary circuit consists of the secondary coi l,
the spark plugs and associated wiring. A single Ignition coil fires both spark plugs at the same
time, but one spark occurs with no effect In the exhaust
The computerized ignition system consists of two stroke of one cylinder, while the other spark fires the
assembl ies, the rotor and sensor plate and the com· combustible gasses in the other cylinder to produce the
puterized ignition mOdule. The rotor and sensor plate power stroke.
'0
~------~ w }---------~ 5
w.r-;=Q..:t+:...::;/ / .
o
y
"'--.
D
1. SensOf plate
2. Computerized Ignition module
3. Ignition switch
4. Battery
5. Ignition coli
6. Sparit plug
= o 7. Main circuit breaker
9. Engine stop switch
10. Rotor
Figure 7·42. Ignition System Components

7·53
The rotor is bolted to the camshaft and operates at one· (black) lead is securely fastened to the frame and
half crankshaft speed. The ignition module automatical· that the ground wire from the battery to the frame
Iy advances the spark as the engine speed Increases, is in good condition. If spark is still not evident,
and retards as the speed decreases without the action continue with the following voltmeter checks.
of flyweights, or an advance mechanism. This ensures
correct spark timing to suit starting, low and high speed NOTE
requirements.
Voltmeter should have a resistance of 20,000 ohmNolt
As the rotor turns, slots in its external edge break the or more in order to obtain correct readings .
magnetic field of a Hall·effect device mounted on the
sensor plate. The output of the Hall·effect device is a 5. Connect voltmeter between ignition coil positive
logic·type signal that corresponds to the timing infor· terminal (white wires) and engine ground. With jg.
matlon from the spinning rotor. This technique gives ac· nition and engine stop switches on, the voltmeter
curate timing information down to "0" speed. reading should equal battery voltage within 0.5
volts unless a rotor slot is in line with the sensor.
Basical ly, the system gives a spark near top dead center Crank the engine slightly to change the rotor posi·
(2 " ATDC) for starting, and at rpm's and loads above tion and recheck reading. If battery voltage reading
this gives a spark advance between 16" and 30·. The cannot be obtained, trouble lies In circuil between
whole timing program can be shifted by mechanical battery and Ignition coil. Check the connections at
rotation of the sensor plate. See CHECKING ADVANCE or in circuit breakers and ignition SWitch.
TIMING WITH STROBE TIMING LIGHT and SETTING
RETARDED TIMING . 6. Disconnect blue wire from coil negative terminal.
Connect voltmeter between coli negative terminal
The computerized ignition module contains all of the and ground. With Ignition and engine stop switch·
solid state components used in the ignition system. The es on, the voltmeter reading should equal battery
dwell time for the Ignition coil is also calculated in the voltage. If not, ignition call primary is not function·
module and is dependent upon engine speed. The pro· ing. Replace call. Retest for spark after corrections
grammed dwell is an added feature to keep battery are made.
drain to a minimum and yet gives adequate spark dura·
lion at all speeds. (The ignition module has added pro· 7. (See Figure 7·43). To perform module and sensor
tection against transient voltages, continuous reverse checks, fabricate a jumper cable as shown. The
voltage protection, and damage due to jump starts.) The parts needed are:
system will operate down to 5.7 volts DC. The module is
fully enclosed in a polyurethane material to protect it DESCRIPTION PART NO. QTY.
from vibration, dust, water or oi l. This unit is a non·re·
palrable item. II it falls, It must be replaced. Pin connectors 74539·83 3
Socket connectors 72028·83 3
Socket housing 72051·83
TROUBLESHOOTING Pin housing 74521·83 1
Wire ring terminals 9857 3
When the engine wi ll not start, or when hard starting or 18 gauge insulated wire (4 ttl.
missing indicates a faulty ignition system, proceed as Electrical tape
follows:
8. Disconnect sensor plate from ignitlon module at
1. Disconnect spark plug cables from spark plugs. the connector. Insert fabricated jumper cable be·
Check condition of plugs and cables. Clean or reo tween the connector plug and socket. Connect a
place as necessary. voltmeter from pin #1 (red wire) to pin #2 (black
wire) of the module connector (Figure 7·33). With
2. Insert a 3116 diameter No. 10 screw into spark plug the Ignition and engine stop switches on, the
cable nipple and establish a 3116 in. gap between voltmeter should read 5.0 ± .5 volts. If not, the
screw and cylinder head. Turn on ignition and module is not functioning and must be replaced.
engine stop switches. Crank engine. Check to see
if a spark Is obtained across the gap. If a spark is CAUTION
obtained, the problem is not in the electronic
system or coil. Check carburet lon, choke and When using the Jumper cable, extreme care must be
spark plugs. used to avoid touching exposed wire terminals to each
other or ground which could result In damage to Ignition
module.
battery connection condition. Turn on ignition and
engine stop switches to crank engine with voltmeter
9. Connect the voltmeter from pin 113 to 112 to check
across the battery. Voltage should be 11.5 or above.
sensor output. This output should be 5.0 ± .5 volts
If voltage Is low, battery neeeds charging.
when the slot Is not present at t he sensor and
should be 0 to 1 volt when the slot Is at the sensor.
4. Check to make sure that Ignition module ground
7·54
If these voltages are not present, the sensor plate CHECK ADVANCE TIMING WITH
must be replaced.
STROBE TIMING LIGHT
CAUTION (Figure 7·44)
Coli wires must be connected correctly. Both white Ignition timing should be checked every 2500 miles.
wires must be connected to the same coli primary ter·
mlnal or the module will be permanently damaged. Use an INDUCTIVE TIM ING LIGHT, Part No. HD-33813
(timing gun) to view advanced ti mi ng of flywheel
th rough TIMI NG MA RK VIEW PLU G, Pa rt No.
HD·96295-65, screwed In to tim ing inspection hole. Make
sure view pl ug does not touch flywheels. Timing lighl
r
soci ets Electrical tape ground and battery positive terminal. Start engine and
f'" set engine speed at 2000 rpm. Light will flash each lime
\ PI~'
spark occurs. Loosen sensor plate screws jusl enough
so Ihal plate can be shifted using a screwdriver in nolch
Red ' i - Green as lighl aimed inlo inspecl ion hole SlOPS timing mark in
center of hole. Timing marks are shown in Figure 7·44.
o r-- Black Pin housing Timing will reta rd au tomatically when engine is at idle
Socket housing . _~ speed or is stopped. See the timing advance table.
Wire ring terminals
-Sensor - Module
RANGE
TIMING ADVANCE TABLE
2 0 ATDC - 30 ° BTDC
Eng ine rpm Ig nit ion Timi ng
0-600 2° ATDe
=l 16° BTDC
600·1600
1600 and up 30° BTDC
Slack (2)
~ ............. Red(1 )
'-""'1m-.-
Ignition Module Check
(Figure 7·45)
CAUTION
This procedure will result In approximate timing and

engine can be operated In an emergency lor a short
period 01 time. Advanced timing should·be checked and
a strobe timing light as described In preceding section.
rn
Red 111", Whenever Ignition components have been dlsassem·
........- Black (2) bled, such as during engine disassembly and reassem·
bly, or if a st robe timing light Is not available, approx·
Green (3 ) Y -
imate ti ming can be obtained by usi ng the followi ng pro·
Vol1mele' ced ure:
1. Set sensor plate (8) so th.t sensor plate screws (6)

are centered in the slots. Snug down the screws (6~
Sensor Output Check 2. Engine can now be started.
3. Adj ust the advanced ti ming wit h t imi ng light fol·

Figure 7·43. Fabricating and Using Jumper Cables lowi ng procedure in the preceding section as soon
as possi ble.
7·55
INSPECTION AND
REPLACING PARTS
Inspect lip of seal and replace It If worn or rough. Also
replace the seal If there Is any evidence of oil leakage
Into the timer compartment.
Front cylinder Rear cylinder Front cylinder

Full advance Full advance TOC
INSTALLING IGNITION
Figure 7·44. Ignition Timing Marits
COMPONENTS (Figure 7·45)
1. Assemble Ignition module to frame. Make sure
that the black ground wire Is secured. Install
sidecover.
REMOVING IGNITION
2. Connect ignilion module wires to Ignition call as
COMPONENTS (Figure 7·45) shown in the wiring diagrams.
WARNING
3. If seal (1 1) was removed, install new seal (11) In
To avoid accidental start·up of vehicle and possible per· gearcase, lip side to flywheel side of gearcase.
, onal injury, disconnect the battery cablas, (negative
cable first) before performing any of the following pro- CAUTION
cedures.
Sea' (11) must be pressed Into gearcase until It Is flush.
1. Using a 318 In. drill bit, drill through outer cover A seal that Is not all the way In may leak .
rivets (1) and remove outer cover (2).
4. Apply Loclile LOCK 'N SEAL to rotor bolt (9). In·
stall rotor (10) with rotor boil (9). Torque bolt (9) to
2. Remove inner cover screws (3) and remove Inner
75-80 In·lbs (6 ft·lbs).
cover (4) and gasket (5).
3. Remove sensor plate screws (6) and washers (7). CAUTION
4. To remove sensor plate (8) from gearcase, dlscon· Use only the grade of locille specified.
nect connector (12) and remove connector from
sensor plate wires. Pull wires through gearcase 5. Install sensor plate (8) with sensor plate screws (6)
hole one at a time. and washers (7).
5. Remove rotor screw (9) and rotor (10). NOTE
6. Seal (11), if damaged, can be pried out from ignition If sensor plate (8) was completely removed It may be
side of gearcase. Use care not to damage camshaft necessary to Install new wire pins, sockets and body
end while prying. receptacle.
7. Disconnect ignition module wires from coil. 6. Set retarded Ignition timing as previously describ-
ed. Check advanced ignition timing under runn ing
8. Remove ignition module side cover located next to conditions as described.
the battery. Remove two mounting screws secur·
Ing Ignition module and the screw securing the 7. Install gasket (5) and Inner cover (4) with screws (3).
black ground wire. Remove Ignition module from
frame. 8. Rivet outer cover (2) to Inner cover (4) with rivets (1).
7·56
To tachometer
To stop switch
1. Outer cover rivet (2) 9. Rotor screw and star washer

2. Outer cover 10. Rotor
3. Inner cover screw (2) 11. Camshaft 011 seal
4. Inner cover 12. Connector
5. Gasket 13. Ignition module
6. Sensor plate screw (2) 14. Ignition coil
7. Washer 15. Spark plug cable (2)
8. Sensor plate 16. Ignition coli terminal
Figure 7·45. Ignition Components
CAUTION 1173
Use only rivets, Part No. 8699 to secure outer cover. (See
Figure 7·46.) Timing cover rivets ere specially designed
so there Is not rivet end to fall off Into timing compart· Incorrect Correct
ment as with regular rivets. Use of regular rivets could
cause damage to ignition components.
Figure 7·46. Special Timing Cover Rivet
7·57
IGNITION - LIGHT SWITCH
(XR·1000)
(Figure 7·47)
The combination Ignition - light switch Is a three posi.
tlon switch. The vertical position Is OFF. For U.S.A.
operation, the next two clockwise positions are ignition Off
and head light. Key will lock Ignition in OFF position I Ignition
only, Switch must be replaced as a unit. : / .nOlighIS
(@
~ Ignition
.nOlighls
Figure 7-47. Ignition - Light Switch
HORN
(XR·1000)
The horn Is on the left side of the bike and is mounted
on the fuel tank mounting bOll. If the horn fails to blOW
or does nol blow satisfactorily, check for loose, frayed
or damaged wiring leading to horn terminal, adequate
ground to frame through mounting hardware, dis-
charged battery, etc. If these steps do not correct the
trouble, the entire horn must be replaced. Mounting
parts are replaceable.
SPARK PLUGS
(XR·1000)
GENERAL INSTALLING SPARK PLUGS
Spark plugs should be replaced every 2500 miles. Use Tighten the spark plugs to 18-28 It-Ibs torque.
on ly the replacement spark plugs listed In SPECIFICA-
TIONS XR·1000.
The GR7 pl ugs have a resistor element to reduce radio

interference originating In the motorcycle ignition
system. Only resistor type plugs should be used In the
XR-1000 ignition system:
7·59
STOP SWITCH
RIGHT DIRECTIONAL SWITCH
STOPLIGHT SWITCH
RIGHT DIRECTIONAL LAMP
BROWN TAG
SPEEDOMETER
OIL LAMP RIGHT REAR

DIRECTIONAL LAMP
TAIL LAMP
HEADLAMP PlUG
TAG
LEFT DIRECTIONAL LAMP
TAG
+t-
HANDLEBAR GROUND WIRE
NO CONNECTION
CONNECTION
@ BLACK o
COLOR CODE:
YELLOW
0---e--0-I1" REAR STOPLIGHT SWITCH
TAG
@BROWN
0 RED
IGNITION SWITCH @BLUE ® ORANGE

POSITION
OFF •
• I L
® GRAY @ PINK
- IGNITION CIRCUIT
RUN ~GREEN 0 VIOLET • CHARGING CIRCUIT
LIGHTS
§TAN @ WHITE
VOLTAGE REGULATOR
1979 XLCH
~
,RIGHT DIRECTIONAL SWITCH
SlOP SWITCH
START SWITCH
rrI+ll+~={;;JSTc;PLIIG'"HTT SWITCH FASTEN TO'

~II UI r - -I ~ER'ND PICKUP
~DIRECTIONAL LAMP
~ l'= ~&' • M -SPARK COIL
III L..4- I ~ ~
~ VJ) 1__ 'BRO'WN TAG
IIII
IIII rrm -
SPEEOOMETER rE:n-[)+---~
~I
DIRECTIONAL
FLASHER
OILUMP " copp ~ s I
..tk;\ ~ I
I le~~ti/J.-'l~ '
~;::c:M ~-VIOLETTAG ml~tl
~ 'fi'!l
~ ~~l =~JI
L===\j])=1J)==L=EFT=DI=RE=CT='O=NA=L=LA=M=P=GIJ::<;-<'oZG=I~i~[111~I--~.u@~L'='I~L sw,I~T.!'H~~~I~~~~~! ... i '= '<: "'" -I
HANDLEBAR GROUND WIRE II GENERATOR ~ ,\:,~IC?~~TAG

~
+t- NO CONNECTION COLOR CODE: Q--e-01rl' I 1)",1,1,
~~ ~ ~
'\ BROWN TAG
.\ 8
1rl
~ f "-~
tBi0 BLACK fy\ YELLOW lw _0 REAR STOPLIGHT SWITCH
CONNECTION \...:J , " ........-
~ ~~~~~:~~.H ~
IGNITION SWITCH
POSITION B I L
@) BROWN
@ OLUE
tQY\ ORAY
®
G ORANGE
Q PINK
RED
_ IGNITION CIRCUIT
i 11"S.SWW,I1TCH[ t START RELAY
OFF. V
Q V
r.;-., • STARTING CIRCUIT -
"'W'" --r-
~ TO CRANKCASE
RUN e GREEN ~ VIOLET CHARGING CIRCUIT ""='" BOLT UNDERNEATH BATTERY
LIGHTS
@ TAN ® WHITE ~
VOLTAGE REGULATOR
1979 XLH/XLS
\ rr==
\\
,0
~
J RIGHT I I SWITCH
I
, ' . SWITCH FASTEN TO'
BOLT V 'BATTERY
W
ELECTRONIC MODULE
im~&~A~~~
[ " SW·4
I ~, :t ~ ~~E;-
»
STARTER
@RIGHTDIRECTIONALLAMP
I
I
I .~i~ I
Y ~ '~
I ~)
G)
l - BRQWNTAG : ~
\~ '
I
~l
SPEEDOMETER
DIRECTIONAL
FlASHE\'I
C-
~
on,
<@f
I ~....:..J.-'O"GS1UO..,..--
a: ( ~J~
FRONT PLUG
~
REAR PLUG
I RIGHT REAR
.
OIL LAMP 1
( -- DIRECTIONAL LAMP
'~
~ ""'" d ~ ~ r:r~ Z~
~
~~TAILLAMP
-
~ I~' . ~~ ~
HEADLAMP PLUG
fJ/ GEN,
LAMP ~
-=- "'.R".
L-V' I~,- k-
Y
I~~
r
V'Q;;
h
'== 0;== I"'KU ~~"" Y
'" (~J~
(t1t -, -,~~
'", lEFT REAR
I<*,>:" DIRECTIONAL LAMP
TACH
l-vIOLET TAG
jt2jFiJ ~, If~l~L ;::
~
I""'
LIGHT SWITCH
"I' ·'"1·"
-+-~ -~
@ L E F T DIRECTIONAL LAMP
I ,~ m~!
''f ' ""
II )TI '
II I I
I
I
I
"""
II I " ~'VIOlET TAG
Fe~ ~ih
GENERATOR
+
II BROWN TAG
COLOR CODE: C)-e-o-jl"
'tg; ,
'r;~ HORrND~:~';.H [~
NO CONNECTION = REAR STOPLIGHT SWITCH
+-- CONNECTION
@SLACK
@SROWN
0VELLOW
®RED
(
1 =&ARTRELAY
@ORANGE
IGNITION SWITCH @SLUE
:F= I "-
f
• IGNITION CIRCUIT
t
POSITION B I L
@GRAY ®PINK • STARTING CIRCUIT
OFF • • CHARGING CIRCUIT
FASTEN TO FRAME AT
RUN @GREEN (i)Vl0LET OIL FILTER BRACKET
LIGHTS
@)TAN ®WHITE -..,
VOLTAGE REGULATOR
I:::::::::..
1980 XLH/XLS
RIGHT 01 RECTIONAl SWITCH
STOP SW IITCH
START S\NITCH
DIRECTIONAL LAMP
Q--BRC)WN TAG
SPEEDOMETER
FRONT PLUG
R1GtfT REAR
DIRECTIONAL LAMP
TAIL LAMP
9---VI("01 TAG
TACH
DIRECTIONAL lAMP
+ NO CONNECTION COLOR CODE:

~I"
VIOl~TAG
BROWN TAO
+- CONNECTION
@
@
BLACK
BROWN
0 YEllOW
0 REO . tGNITION CIRCUIT

IGNITION SWITCH @BlUE ® ORANGE
• STARTING CIRCUIT
• CHARGING CIRCUIT
POSITION B I l
®GRAY @PINK
OFF.
RUN ~GREEN 0V10lET
LIGHTS
@TAN o WHITE
FASTEN TO FRAME AT
OIL FilTER BRACKET
VO LTAGE REGULATOR
1981 XLH/XLS
FASTEN TO STARTER
rFF!~~~~i~
ROCKER BOX STUD '""""
• J
STOP SWITCH
RIGHT DIRECTIONAL
START SWITCH
lJ=r;===-
.;:;:;1 r- ~~ €J ~
~
i#i1011= ~ ,----t--:j~L
~r
\
CS:v RIGHT DIRECTIONAL LAMP

1" I F=o\o'-=i==O=l:r:;;1T,issrcrlPPLIGHT SWITCH I COIL
~ ~d,tlW
BATTERY
rW
, r-
I
6u
~
.' ~O
- BROWNTAG
SPEEDOMETER :o-+--------; "

l ~ FLASHER
REAR PLUG
I FRONT PLUG ,-~--t-
~1G0
RIGHT REAR
DIRECTIONAL lAMP
~
-=- LiL~9
1 =~H\t:(~::®, ':? ~ TAIL LAMP
OIL LAMP
~ -.;\
I'M ,~
tLv ~"--~W'+1~~-f-tfJt'+'--
( / ,' LEFT REAR
r--j"
I---I<=~( ) DIRECTIONAL LAMP
HEADlAMP PLUG GEN
LAMP
Q
~b,;!'~'~iFl9d l 0 ~ t'1 ,'-----J ~ , . o. 0 Q
I@~'i'~~---®-
rv- 0° ,~
HI-BEAM lAMP ((~rr. ". I V G' BROWN TAG
\~~
' ; ;HO:ETER _ VIOLET
(w
'r '1~rt
1~11 1 J~
~ IGNITION
SWITCH
(-
HORN
"I~-*1tB1u,!! ~ r 101 ~ ~~ - VIOLET TAG
II IrH
~ LEFT DIRECTIONAL LAMP II It-!
+
,,-----=:..,
NO CONNECTION
@
COLOR CODE:
BLACK 8 VELLOW • IGNITION CIRCUIT

+-- CONNECTION STARTING CIRCUIT
@ BROWN ® RED • CHARGING CIRCUIT
IGNITION SWITCH @ BLUE @ ORANGE

POSITION B I L
OFF •
RUN
LIGHTS ~
@
@TAN
GRAY
GREEN
@
®
PINK
V'OLET
WHITE
// 'cr
,
1982 XLH/XLS
<;=::::-
\\\ IGNITION MOnUlE
GAOUNO ~
~~
TO FRAME _~
FASTEN TO STARTER
'I
STOP SWITCH
blSTART SWITC~UNAl
)Ii-- ~O ~ .. j
~ ~~
I SWITCH
HI_·WlAM' @ AIGHT OIA.CTlONAlLAM'

,
I
I
I
;
I
I
I
[ I ~
t--,J
BATTERY 'V
I
"f:Lt~
- 8RQWNTAG r::~
~
r(lct:)
r------€r--+_ :\
tJ: l] ~ FLASHER \.. \ 'I: ))
RlalfT . . . .
DIRECTIONAL lAM..
J
:..-
#/7
rb
~
r- TAJL LAMP
~
-II Oil LAMP
'" 5i' ,==
--
:r I
h V- I II
LEfT AlAR
DIRECTIONAL LAMP
+ NO CONNECTION
COLOR CODE:
+-- CONNECTION
@lIlACK
SI"OWN
8VElLOW
0 "EO
jl
IGNmoH SWITCH @ILUE 0 0AANGE
.
POSITION • I l
@ORAY @PINK
"'"
RUN SOREEN o VIOLET
• STARTING CIRCUIT
lIGHTS
@TAN ®WHITE
1983·1984 XR·1000 WIRING DIAGRAM

= VACUUM SWITCH
ELEC1 RONIC MODULE i'"""J.~ P

~ T.o"~~::.~~ -- ~ T FASTEN TO REAR STARTER
I~!~~Q~~~§
~".~~
HANDLEBAR
GROUND WIRE
STOP SWITCH I
~
RIGHT OIRECTlONAL
~ START SWITCH l.[f--
UPPER
FORK BRACKET Irrfll#1 FI=1===
D~STro.IOPlI.HTSW>TCH eu~ .----t--,I~~COIL
III II BATTERY
"I I LL
- BROWN TAG
~ .....
Il'-tel+HQ.,
r6:R1
~~ FLASHER FRONT PLUG
"liJI DIRECTIONAL
~:r---t-t--h!J--j<~:UO.O "GHT ••••
LAMP
REAR PLUG
~
=- LL.~().
I~
~ T.IlLAMP
f(~j " L.--: ~-c~ R " ~ ~r~ ~:

~V ~ ~=:L
LEFT REAR
O
v -w DIRECTIONAL LAMP
H.:!!.!.. ~
I--+I-I+h I~"""~"I''.~r-~-~;a ltMIf~~:1
() - "
",'--<
. >:;;-1
:
~ll!t!Fw.tJ yl----+--~--,I
I )
"
\49-
~~'I"";:: ' ~~l~g~d~~i!~~~~-r.'

L.MP
u' ,I-C>-t-t--o-JJ"•. J ljQ

.,. - r '"S~:~'CO: , ~., ~ I /'
.... f.<;;:;. UPPER
FORK BRACKET =: I
O _ NDU ..
I ~ JJj
lll ~' I V- B.OWNTA.
VIOLET TAG
(JS
()I'CHO~ETE' - "OLET".. I': 1111; HO.N ;':::;k:: ~IHli- tt ;-:T
t1rH
! ~J .i -
_ _ _ _ _"=1!./
\ 'J}-:) LEFT DIRECTIONAL LAMP
-==c...,
iii :i :
II 1 I 1 I
fod CI IJ In ' L -
is?
r
+t- COLOR CODE: I I ) \ 0 REAR STOPLIGHT
1 ~1~IIII~I~I _~"~~~~
NO CONNECTION
CONNECTION
@ SLACK 0 VElLOW = HO.N SW>TCH I( , SWITCH ~
START RELAY
STARTING CIRCUIT
h ~~~~~R:.;~g~AL "L______....'::!:~r-l
==t~~~
~.'.
@ BROWN (RJ REO • CHARGING CIRCUIT
::::::: SWITCH T
VOLTAGE REGULATOR Oil SWITCH
IGNfTlON SWITCH @ BLUE 0 0RANGE
II
~[J>(IJE-HD~M ~~'C'
POSITION B I L
@ GRAY @ PINK
OFF.
.UN @ GREEN o VIOLET
G
LIGHTS
@ TAN ® WHITE ~J) u
GENERATOR
..
F~-
1983· EARLY 1984 XLH

~ FASTEN TO REAR STARTER
~~UNT€cl j
~COIL 'Z~- ~ ~
[J I
HANDLEBAR
HI-BEAM LAMP
-~ - ( oi+-
GROUND WIRE

\
~
BATTERY
,--- ~
[l \P I ~,
®I '~
- BR OWN TAG
w~ FLASHER FRONT PLUG

r--e---Lt--jc(r\'l'
" ~
RIGHT REAR
OIRECTIONAL LAMP
o,"
REAR PLUG
\
-1 1
II
~~
1=
(
J .1
II
1==_ LEFT REAR
DIRECTIONAL LAMP
I M II~
'=--' / ( ; )
GEN.
HEADlAMP PLUG LAMP
+ NO CONNECTION
COLOR CODE:
+-- 0 VEllOW START RELAY

@ BlACK _ IGNITION CIRCUIT
CONNECTION ~ • STARTING CIRCUIT
@ 8ROWN
0 RED . CHARGING CIRCUIT
jl
IGNITION SWITCH @ BLUE 0 0RANGE
RUN
POSITION 8 I l
@ GRAY @ PINII.
OFF.
@ GREEN o VIOLET
LIGHTS
@ TAN o WHITE
1983· EARLY 19B4 XLS

ELECTRONIC MOOULE r .... t-E....!;"1=I-'-L,·~'W~H
GROUND (".--/1 S
TO F:::$Ih~=t;t:el-""
~ FASTEN TO REAR ST"'RTE~
r ~tI~~~~!~ ~~-~j
HANDLEBAR
GROUND WIRE
~
RIGHT DIRECTIONAL
• ?i START
STOP' SWITCH
SWITCH
UPPER
Di TLOOHT SWOTCH ~
,llit--1,--hl
~ ~~COOL
~'
. @) ~
\
@
FORK BRACKET
~ '- ~
IIII
IIII
IIII !:.---,
"OHT D'RECTIONAL 'AMP IIII
~3'dJ
BATTERY
III1 ; I
II I I
\----B.....-+o-I.
- BROWN TAG
,
- ,. - ~
~ FLASHER
~
RIGHT REAR
""G '--'
J\ ,. FRONT PLUG
~
PEEDOMETER
DIRECTIONAL LAMP
"
~
').1 REAR PLUG
..... //// UPPER
~ FOR~ ET
- Q II
'"
~tfl,~I'".~.~~rAE"':Elli~.1J
HI·BEAM
"
~ ~
r
--
-- =
::;1='"",r. 1:::=
IS ~J _.~
O'.' : 'MP
_ 0 II~/
·"t"-"I:-TTl"
'" Y
0
0
l7 ~ill
t-
'" -
'-..J..I-.• rN
LEFT REAR
DIRECTIONAL LAMP
1; "'--0-+ --I!.f+h ~"sl

I
I
I
I
~I-~-O++-<u>.~"-j FORK BRACKET

tl
~
~~1T11
10
"A ~ ~1, _ ~
~;!;JJ ~:!:-;:j:±:jjqJ.J,
I"
,~
• "L:>_BR::~E:':AO
I';1111; ~i~:p.~r· ILHII:itI++-! r ~""6-l--Ill~l:e
r-,-----=-,
@} TACHOMETER
~
_ _
LEFT DIRECTIONAL LAMP
_ V'OLEmAO
I1III11
II II I I I
II I I I I I
,....
("--'''"- ,,.,,,
HORN
-
IrH
ILL..!
IT!
-r
!
-'
+t- ['l'~IIIII"I~:~'i~I~' i~~"~~

~~ f~ REARS~:~;~IGHT
COLOR CODE:
NO CONNECTION
@ BLACK 0 YELLOW ~ELAY • IGNITION CIRCUIT
HORN SWITCH I r l, "
CONNECTION LEFT DIRECTIONAL SWITCH • STARTING CIRCUIT
~ BROWN 0 RED DIMMER SWITCH • CHARGING CIRCUIT
IGNITION SWITCH
,, @ SLUE 0 0RANGE
11 ~ VOLTAGE REGULATOR
... n OIL SWITCH
~
POSITION B
@ GRAY @ P1NK ~
t-j
OFF •
RUN 8 GREEN 0 VIOLET
6 --..:::-~!-.--.
. ~-
"
'"4l sJ I
LIGHTS
@ TAN ® WHITE LJ
GENERATOR
1983 - EARLY 1984 XLH

VOLTAGE REGULATOR
ALTERNATOR
HANDLEBAR
GROUND WIRE
Q-4-o--. UPPER
FORK BRACKET
@ -RIGHTOIRECTIONALLAMP
~_0-__I--!li<IT'\I
f--",:':"I.,tEDD'METER ~,\~---<,>-+--o,..,.<B.R:p:::AG , --e---=I-= RIGHT REAR
~ ~ FRONT PLUG 'Q . ,,-~O) DIRECTIONAL LAMP
REAR PLU~
~"r-IlS~
~ ( FORK BRACKET
LEFTRUR
I~
DIRECTIONAL. LAMP
,--f i
-----t==tHU---J--1 ~I ~ ti
~ ~,- ,;~\- -(o;"'O,"-I- I- <>-jlh" cI------~-=-.J ~~iL" ~~~dllli!11
1
L I '-----J, - i ---€>-
~ ~ 'k
I ill I~W:TCH k~ ...- BROWNTAG
J..<;;r- UPPER TAG
IT ~~
~,W;Y.~:"I : il : I ~I I I ~
FORK BRACKET
II I_'
@{j)
I - VIOLETTAG
~ ,l'11(J1.J.1.J.1J.,"'1 HORN ONf ....... E ! --..........r-
LEFT O'RECTIONAL LAMP : I II I I : 13 ~ t:\J~
+
,,--------==_,
NO CONNECTION
COLOR CODE:
: I I ~ "lr1
~
, ....
U REARSTO~HT
SWITCH
~ELAY
~~~~~~~~~
+-- CONNECTION
@
@
SlACK
SROWN
0
G
VELlOW
REO
HORN DIRECTIONAL
LEFT SWITCH
DIMMER SWITCH
SWITCH • STARTING CIRCUIT
IONITION SWITCH @ SLUE 0 0RANGE ~ Oil SWITCH
POSITION B I L
@ GRAY @ PINK
OFF •
RUN @ GREEN 0 V'OlET
UQHTS
=
@ TAN @ WHITE
LATE 1984· 1985 XLH

= REGULATOR
C\\ ELECTRONIC MODULE
GROUHD
TO F:;ME
~~
~~
-=
,~
n~
FASTEN TO REAR STARTER
~
n f.t~~~~§3
...r
RIGHT
STOP SWITCH
DIRECTIONAL
START SWITCH
.........
~~~UNT~.~ )
HI-BEAM LAMP
~
&
( .,
HANDLEBAR
GROUN\D WIRE
RIGHT DIRECTIOHALLAMP [/1
-
/",
SPARK COIL
,,, '-.../
~ II:-:r
n r;, ~,
BATTERY
Ol~ GB=I"
- BROWN TAG
"
, 1"
~ FLASHER
= ... r~
REAR PLUC
FRONT PLUG
;-~&-_+-
(7.-ta::
-A~-
'-..J ~~
~
.'OKT .EAR
DIRECTIDNALLAM'"
~~/ ~
IL =i1~IJ[~ ~~ == ~
(
~00:~4-~ ' 9
'if / "''--<'T-II_--f-ih
ILlII
LJ/ ~ ,... h1+~8ttf==---=='-----'T't--'

ILttt
:;y II ..j,== ~ /B fU':\
"--\ (J)
LEFT REA.
DIRECTIONAL LAMP
I ~~~~~~~~~~~~~~d-~-+~~~~~~~~~
, ~
i
-~- L~ID'- ~,t:'
~J'1 ' ;'>~~~td:~frffl~'in~'
IL-_-+*h !
a~~~p
~ )j
~i"
~,ft
~r~~'GHITIOH II"
SWITCH ( :~hlJ, ~ ~
,I ",v
,BROWNTA.
I-VIOLET TAG
LEFT DIRECnONALL
~ 11
0/)-q)~Il~~~~j,,~~§
,-J.LlJ..llI~.r, HORH '------.#. ~~i.fr Ii :i ~ i '-----, Ii~_J-~J
~
~~:e:
LAMP ~ II I I I J I
I ~
/5!l
1111111 r-1
"='i- II II I I I U ~: ,LJ.J
r -,------==_, ;I J I I I
+ I
:
"«7
REAR STOPLIGHT
II '"
COLOR CODE:
~-
NO CONNECTION
START RELAV
+-- l~~~~~~~~~
@BLACK 0YELLOW . IGNITION CIRCUIT
CONNECTION LEFT
HORN DIRECTIONAL
SWITCH SWITCH .0--.1 • STARTING CIRCUIT
@BROWN
0 REO OIMMER SWITCH • CHARGING CIRCUIT
IGNITION SWITCH @BLUE @)ORANGE ~ OIL SWITCH
POSITION B I L
@GRAY @PINK
OFf.
RUN
LIGHTS f+
§GREEN o VIOLET
=
@)TAN @WHITE
LATE 1984 . 1985 XLS

ELECTRONIC MODULE
~
-
"ROUND
TOF::ME ~
~ .....
I STOP SWITCH
HANDLEBAR
SWITCH ).h-
GROUND WIRE SWITCH I-- .---~"""Jr-..SPARK COIL
1
H'·..... L... P ();:;;., ~I~ III! ~ :""I
f) \:jj!AlGHT D'RECTIONAL LA.P 1111
,,
~
~>---+-~-lo:
1./:;.,~
lllP
1- 8ROWNTAG
a~~rr;;.~~~
\W-<>-i l l' UPPER
FLASHER
FRONT PLUG "ITJ .'OHT ....
DIRECTIONAL LAMP
001--' -
:==
Il~
"rrn
~? )
"'-
L.FT ....
DIRECTIONAL LAMP
1<$1 ~
U!FT D'•• ~;W- @-
f J-I---€>-......J IIi II iii
Idllill 05Q
!!
+ ,..--------. " , j'
IIIIII AEARSTO~HT
~ll~T~1~~~i~~
COLOR CODE: SWITCH
NO CONNECTION
t- CONNECTION
®BLACK
@BROWN
0
0
VELLOW
R£0
HORN SWITCH
LEFT DIRECTIONAl
DIMMER SWITCH
SWITCH • STARTING CIRCUIT
. CHARGING CIRCUIT
IGNITION SWITCH @BLUE o ORANGE

~
OIL SWITCH
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15466566-HDSMSMR11XXX-Harley Davidson Sportster Models Service Manual Repair 1979-1985 XLCH XLH

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15466566-HDSMSMR11XXX-Harley Davidson Sportster Models Service Manual Repair 1979-1985 XLCH XLH

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l!!!!;;;~~ Harley-Davidson. Inc.

HOW TO USE SERVICE BULLETINS

2. Page number Is listed across I rom subject. Page USE GENUINE ·

WARNING Loctite Products

CONTENTS Proper service and repair is important for the safe,

SECTION 1 . PRODUCT Page No. Page No.

Service ........... 1·'

SECTION 2 . CHASSIS Rear Shock Absorber . · .2·55

Wheels .... 2·5 Fenders .. . ...... 2·65

Handlebar Controls Engine (XR·l000) ....... . .. . .. . .. . .... . ... 3·57

Cylinder Head (XR·l000) .. .. . .. . .... . .. .3·63

Cylinder Head . ........... . . . .. 3·15 Cylinder and Pistons (XR·l000) . . . 369

Electric Starter System (XR-l 000) ... .5.17

SECTION 5 - ELECTRIC STARTER Transmission (1979 - Early 1984) ........ 6-17

General . . ..... 6·17 Ignition System 1979 . . . .. . . 7·3

Chains (Late 1984 and 1985) ..... 6·33

Checking Charging System. .. 7·35 Ignition Timing (X A·l000) . . .......... . .. 7·51

Ignition·Ught Switch (XR·l000) ........ . '·59

Specifications (XR·l000) ... . .. . . . 7·51 Wiring Diagrams

1. Service ............. 1-1

MILEAGE INTER VALS

Clean condition of spark plugs and replace ,/ necessary

1. Tail/stop lamp 5. Headlamp 9. Drive chain

Figure 1·1. Right Side View, 1979 Model XLH-1000

1. Tail/stop lamp 5. Ignilion coil 9. Drive chain

Figure 1·2. Right Side View, 1979 Model XLCH·1000

1. Gas cap 6. Regulator 10. Transmission olileni plug

Figure 1·3. left Side View, 1979 Model XLS·l000

1. Tailfstop lamp 5. Gasoline supply valve 9. Orlve chain

Figure 1·4. Right Side View, 1980 Model XlH·l000

1. Gas cap 6. Regulator 10. Transmission 0111&1181 plug

1. Tall/stop lamp 5. Gasoline supply valve 9. Drive chain

Figure 1·6. Right Side View, 1981 Model XlH ·1000

1. Gas cap 7. Rear shock absorber 12. Generator

Figure 1·7. left Side View, 1981 Model XlS·1000

1. Tall/stop 'amp 5. Rear brake pedal 9. Rear shock absorber

Figure 1·8. Right Side View, 1982 Model XlH

1. Gas cap 7. Jiffy stand 12. Steering lock

Figure 1·9. left Side View, 1982 Model XlS

1. Tall/stop light 5. Rear brake pedal 9. Rear shock absorber

Figura 1·10. Right Side View, 1983 Model XLH

1. Gas cap 7. Transmission and primary chain 12. Highway footrest

1. Tall/stop light 6. Electric starter motor 10. Turn signal light

1. Headlamp 6. Carburetor air cleaner 11 . Rear chain adjuster

Figure 1·14. XLH Right Side Vlew- Early 1984 Model

1. Hom 7. Primary chain Inspection & 11 . Jiffy stand

1. Headlamp 6. Carburetor air cleaner 11 . Rear chain adjuster

Figure 1·16. XLS Right Side Vlew- Early 1984 Model

1. Headlamp 6. Carburetor air cleaner 11. Rear chain adjuster

Figure 1·18. XLX Right Side View, 1984 Model XLX

1. Gas Cap 5. Transmission and primary 9. Headlamp

Figure 1-19. XR·1000 Left Side View

1. Gasoline supply valve 5. Rear brake pedal 9. Rear shock absorber

Figure 1·20. XR·1000 Right Side View

1. Ignition coli 7. Primary chain inspection & 11. Jiffy stand

1. Ignition coli 7. Primary chain inspection & 11. Jiffy stand

Figure 1·22. Left Side View, Late 1984 Model - XLH

1. Ignition coil 7. Primary chain Inspection & 11. Jiffy stand

1. Ignition coli 7. Primary chain Inspection & 11 . Jiffy stand

Figure 1·24. XLS Left Side View - 1985 Model

1. Headlamp 6. Carburetor air cleaner 11. Rear chain adjuster

Figure 1·25. XlS Right Side View - 1985 Model

1. Ignition coli 7. Primary chain Inspection & 11. Jiffy stand