Insufficient Braking Power Worn brake pads or disc, air in the hydraulic system, Stiff or Heavy Fork Operation glazed or contaminated pads, low brake fluid level, or a leaking brake line or hose can cause this problem. The second compression ring must be installed with its dot mark facing up. Measure the rocker arm bushing inside diameter Fig- ure 20 and the lower rocker arm cover bore diameter where the shaft rides Figure 21. Tap the wedge and force Spacer it into the slit in the adapter. Slide the sleeve 2, Figure 162 onto the pilot until the sleeve contacts the inner bearing race.
Check for loose or damaged rivets. Disconnect the voltmeter and turn the ignition switch off. Install the test har- nesses Figure 44 between the ignition module and the module connectors. Replace or flatten a distorted flange. Measure the rocker arm shaft outside diameter Figure 19 where it rides in the rocker arm and in the lower rocker arm cover.
Straddle the motorcycle and apply the front brake lever. Free Harley Davidson Motorcycle Service Manuals for download Lots of people charge for motorcycle service and workshop manuals online which is a bit cheeky I reckon as they are freely available all over the internet. The knob should also stay in its fully closed or fully open position without creeping. Clean all of the parts in solvent, except the access door bearings, and dry with compressed air. .
Note that one spacer will be underneath the pawl and the other spacer will be on outside of the pawl. Frame downtube alternator stator 4. By itself, this tool is used to remove the valve guides. Turn the ignition switch off. Connect the ohmmeter positive lead to the module con- nector black pin and the ohmmeter negative lead to ground. Rear intake cam gear B, Figure 57. The armature can be checked for winding shorts using a growler.
Pack the armature bearings with water-resistant bearing lubricant Lubriplate 110 or equivalent. Remove the primary drive cover C, Figure 2 and gas- drive, clutch assembly and clutch cable. New advanced frame was similar to the frame of the bike 1903 Milwaukee Merkel constructed by Joseph Merkel, the creator of Flying Merke. Use it when reading decimals from one-tenth to one one-thousandth of an inch or millimeter. Make sure the size of the tip conforms to the size and shape of the fastener.
Remove the safety pin, push the wire end of the lead Figure 194 or Figure 195. Remove the screws securing the right handlebar switch housing. Axle nut late 1991-1999 models 3. Turn the handle clockwise until the left and right bearings 7 and 13, Figure 128 and end play shim 8 are drawn together. If self-locking fasteners are removed, replace them with new ones. Check brake fluid level and condition.
Because gasoline is extremely flammable and explosive, perform this procedure away from all open flames, in- cluding appliance pilot lights and sparks. If not available, the manufacturer recommends using oil certified for use in diesel engines. Inspect the filter mounted on top of the fuel valve. Pinion gear 1986-1987 models 3B. Lightly wipe the throttle area on the handlebar with graphite. Clutch cable 1988-1990 models 13A. Bolt 1986-1991 models switch all models except 13B.
Remove the screws securing the cover. Wipe the protective cover with clean engine oil and place a new valve guide seal on the cover. Install the shift forks and shift drum as described in this chapter. Do not remove the spark plugs from the cylinder heads. Remove the two screws A, Figure 79 securing the end cover to the brush holder. Trim the wires on the replacement bulb assembly to the same length as that on the discarded assembly.
On 1991-1993 models, remove the inspection cover Figure 16 and refill with the recommended quantity Ta- ble 4 and type Table 5 transmission oil. On 1991 models, remove the speedometer or tachometer if equipped. Disconnect the negative battery cable Chapter Twelve. Slide the gear over the bearing Figure 76. Remove the bulb from the socket.
Install the upper bearing around the fork stem and seat it into the upper race. Smooth scratches on the sealing surface with emery cloth. Four cam gear bushings installed in the gearcase cover. Inspect the tappet socket Figure 47 for pitting, scor- ing, galling or excessive wear. Insert a second tire iron next to the first iron to hold the bead over the rim. Replace the pump rod if bent or worn. Disassembly Refer to Figure 9.