Install the middle rocker cover A, Figure 13 onto the lower rocker cover. Inspect the spring plate C, Figure 24 for cracks or damage. Check the continuity between harness between the coil and ignition Terminal A in the ignition coil connector module. Coat the battery connections with dielectric grease or petroleum jelly. Replace the spark plug cable if the resistance is not within the specification in Table 2. Remove the left handlebar switch assembly as described in this section. Rear exhuast cam gear bushing 13.
Disconnect the field wire B, Figure 15 from the sole- noid before performing the following tests. The engine sprocket, primary chain and clutch are in- stalled as an assembly. Filter and screen assembly 9. Clean and lubricate the primary chain as described in this section. Pivot the hook on the ramp to the rear of the cable end coupling. With a Harley Sportster manual or one of the other professional repair guides, nothing is beyond your reach. Remove the cover and diaphragm.
Make sure all loose debris or small parts that could fall into the spark plug holes in the cylinder head are removed. Install the float bowl onto the carburetor. Make sure the shift forks engage the shifter cam after in- stalling the shift fork shaft. The bearing races are pressed into the hub and should not be removed unless they require replacement. Connect a jumper cable from the negative battery terminal to ground Figure 13. Top front engine bracket 10. Install pawls on the pawl carrier, using spacers so that the spring hook holes align.
Hold the bearing race remover tools in place. Do not remove the spark plugs from the cylinder heads. Now quickly remove the load and turn the tester off. The 1977 Confederate Edition Such as the Liberty and Anniversary Editions that instantly preceded and observed all of them, the Confederate versions are stock Harleys with unique paint and decals. In- stall the bolts Figure 7 and washers and tighten to 156-204 in.
Clutch cable 1988-1990 models 13A. Remove the outer timing cover, inner timing cover and Control gasket as described in Chapter Twelve Ohmmeter module 2. Make sure to have the following tools available before starting this procedure: a. Dispose of brake fluid properly. Then wash procedures will be required. Further testing requires the Scanalyzer. Inspect the brake pads for damage.
Later this legendary barn was placed in the center of the factory already present on Juneau Avenue, where it stood for many decades as a memory of the humble origins of the cult of the motorcycle. Chapters typically cover everything from troubleshooting and tune-ups to engines, electrical systems, wiring and suspension. Inspect the fuse for the suspected circuit, and replace it if blown. Discard the upper and lower O-rings Figure 83. Connect the battery positive cable and the starter relay wire to the starter Chapter Twelve. Remove the spring A, Figure 30 and diaphragm B.
Discard the check valve O-ring. Slide a new hose clamp onto the oil feed, return and vent hoses and connect the hoses to the oil tank. Main drive gear shaft 4. The test jumper should be long enough to reach from the ignition coil to a good engine ground. This is a common problem with connectors or joints that have loose or poor connections. Drain the engine oil tank Chapter Three. Loosen the throttle friction screw on the bottom of the throttle control housing.
Un- less instructed to do so, never loosen a tightened fastener to align the holes. The test jumper must be 0. Main drive bearing fifth gear Refer to Figure 101. On the secondary lock side of the connector, push the Metal insert wire and terminal into the correct location until it snaps into place. However, when installing a bearing over a shaft and into the housing at the same time, a tight fit will be required for both outer and inner bearing races. Remove the spring and lockplate B, Figure 14.
Measure and record the valve tappet outer diameter Figure 48. Further testing requires the use of a Scanalyzer. If the hydraulic system, not including the reservoir cover, has been opened, bleed the system to remove air from the system. Clymer and Haynes Harley-Davidson manuals are written by carefully chosen teams of mechanics, copywriters and photographers to ensure the information you receive is not only accurate but also easy to understand and follow. Install a new Deutsch socket terminal to the head of the replacement bulb assembly.