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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
6. Shift lever drain plug 16. Choke knob
17. Clutch hand lever
Figure 1·15. XlS Left Side Vlew- Early 1984 Model

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


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
5. Throttle control grip 10. Rear sprocket & drive chain 15. Steering lock

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
4. Oil filter 9. Clutch access plug 14. Battery
5. Timing inspection hole plug 10. Transmission Be chain case 15. Ignltlonllight switch
6. Shift lever drain plug 16. Choke knob
17. Clutch hand lever
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
5. Throttle control grip 10. Rear sprocket & drive chain 15. Steering lock

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
4. Oil filter 9. Clutch access plug 14. Battery
5. Timing inspection hole plug 10. Transmission & chalncase 15. Ignition-light switch
6. Shift lever drain plug 16. Choke knob
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
4. Oil filter 9. Clutch access plug 14. Battery
5. Timing Inspection hole plug 10. Transmission & chaincase 15. Ignltlon·light switch
6. Shift lever drain plug 16. Choke knob
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
3. Voltage regulator 6. Transmission oil level plug 13. Ignition module
4. Oil filter 9. Clutch access plug 14. Battery
5. Timing inspection hole plug 10. Transmission & chain case 15. Ignltlonllight switch
6. Shift lever drain plug 16. Choke knob
17. Clutch hand lever
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
6. Shift lever drain plug 16. Choke knob
17. Clutch hand lever

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


1·14
".

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


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
5. Throttle control grip 10. Rear sprocket & drive chain 15. Steering lock

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
6. Shift lever drain plug 16. Choke knob
17. Clutch hand lever
Figure 1·26. XLH Left Side View - 1985 Model
1·15
1. Headlamp 6. Carburetor air cleaner 11 . Rear chain adjuster
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
5. Throttle control grip 10. Rear sprocket & drive chain 15. Steering lock

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
3. Voltage regulator 8. Transmission oil level plug 13. Ignition module
4. 011 IIlter 9. Clutch access plug 14. Battery
5. Timing Inspection hole plug 10. Transmission & chain case 15. Ignition flight switch
6. Shift lever drain plug 16. Choke knob
17. Clutch hand lever
Figure 1·28. XLX Left Side View - 1985 Model
1·16
""

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


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
5. Throttle control grip 10. Rear sprocket & drive chain 15. Steering lock

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
cones in the matching cups.
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
cones in the matching cups.
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
Figure 2·37. Front Hydraulic Master Cylinder - 1983

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

Figure 2·38. Front Hydraulic Master Cylinder - 1984

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
problems are being experienced. When disassembling
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-
problems are being experienced. When disassembling
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 ,
'.-©
1 2-~
,-8 I
I _ 11
I

7-0 I

:~ i<OJ-'
-'
I
I
I
II-@ I 11_11
I 0 --'
I
I
~

15 /";s
2
I
I
I
_ I
H
d
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]

;6/ r, I ~
~!l-10
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I ~

® /"I
g----14 I
I
I
I
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

" I3~O
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

Figure 2·84. Front Hydraulic Master Cylinder - 1983


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.
1. Rear exhaust cam gear
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
1. Rear exhaust cam gear
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 pro- be .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
2. Front engine mounting hardware
3. Engine rear mount
4. Rear engine mounting hardware

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
2. Front engine mounting hardware
3. Engine rear mount
4. Rear engine mounting hardware

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
-
1/8 in. wide x 3/8 in. long
Crank Key Small Woodruff key, - Large woodruff key,
1/8 in. wide x 112 in. long
-
1/8 in. wide x 3/8 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

Figure 4-1. Carburetor - 1979

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
30. Accelerating pump housing
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

Figure 4-20. Carburetor - 1983

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
30. Accelerating pump housing
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
Air Fuel Mixture - Purple

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
Air Fuel Mixture - Purple

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
Air Fuel Mixture - Purple

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 t