1948-1957 HARLEY DAVIDSON PANHEAD SERVICE MANUAL – PDF DOWNLOAD
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1948-1957 HARLEY DAVIDSON PANHEAD SERVICE MANUAL – PDF DOWNLOAD
- All Models: When switch is turned “ON” preparatory to starting engine, both lights should go “ON.” (Exception: When switch is turned “ON” immediately after engine has been primed by cranking. oil pressure signal may not light, but will light after a few seconds.
- This is due to oil pressure built up by cranking and is most likely to be noticed in cold weather.) With engine started and running at a fair idling speed, both lights should go “OFF.” At slow idling speed or under about 20 miles per hour road speed in high gear, generator signal will normally flash “ON” and “OFF” because at that speed generator output is very low and unsteady
- Should generator signal fail to go “OFF” at speeds above approximately 20 miles per hour. generator is either not charging at all or its output is not up to normal and it should be inspected at once.
- Should oil circulation signal fail to go “OFF”, at speeds above idling, it is most likely due to: empty oil tank; oil supply badly diluted, or using very light grade of oil and pump not building up normal pressure; if freezing weather, oil feed pipe may be clogged with ice or sludge. However, it may be: grounded oil signal switch wire, faulty signal switch; or oil pump in bad order.
- Give due attention to oil supply and, if signal still does not operate normally, check to see if oil returns to tank. To do this, remove oil tank cap and, with engine running, look for pulsating return of oil.
- A small flashlight is an aid in making this check. If o il is returning, motorcycle can be driven slowly, but no further than absolutely necessary before checking and servicing oiling system. If oil is not returning, do not drive further before having the fault corrected, as engine is likely to be damaged.
TABLE OF CONTENTS:
1948-1957 HARLEY DAVIDSON PANHEAD SERVICE MANUAL – PDF DOWNLOAD
General Specifications 1948-1954. . 4
General Specifications 1955-1957. . 6
Lubrication Chart . . . . . . . . . . . . . . . 8
Signal Lights . . . . . . . . . . . . . . . . . . . 9
Starting Engine . . . . . . . . 9
Stopping Engine . . . . . . . . . . . . 9
Running in New Engine . . . . . . . . . . 9
High Speed Tips . . . . . . . . . . . . . . . . 10
Trouble Shooting Charts . . . . . . . . . . 10
engine ………………….. 10
generator . . . . . . . . . . . . . . 11
carburetor . . . . . . . . . . . . . . . . . . . . 11
transmission . . . . . . . . . . . . . . . . . . 11
brakes ……… …………. 12
General Lubrication . . . . . . . . . 12
Lubrication Chart . . . . . . . . . . . . . . 13
Servicing Air Cleaner ………… 14
Initial Servicing of New Motorcycle. 14
first 250 miles . . . ……….. 14
first 750 miles . . . . . 14
first 1500 miles . . . . . . . . . . . . . . 15
Regular Interval Inspection &
Maintenance ……………. 15
Care & Lubrication of Drive Chain. 16
adjusting drive chain . . . . . . . . . . 16
adjusting front chain . . . . . . . . . . . 16
adjusting rear chain ……….. 16
lubrication front chain . . . . . . . . . . 16
lubrication rear chain . . . . . . . . . . 17
repairing drive chain . . . . . . . . . . . 17
Clutch & gear shifter . . . . . . . . . . . . 18
Compensating sprocket (early style). 18
Chassis
Wheels …………………… 20
general …………………. 20
removal …………………. 20
removal (side car) . . . . . . . . . . . . . 21
servicing wheel hubs . . . . . . . . . . 22
replacing rear wheel sprocket . . . 23
spoking wheels …………… 23
truing wheels . . . . . . . . . . . 24
removing & installing tires 25
Shop Data
2
wheels ……. …………… 26
Servicing Handlebar Controls . . . . . 28
early model . . . . . . . . . . . . . . . . . . 28
late model . . . . . . . . . . . . . . . . . . . 29
Removing & lnstalllng Forks . . . . . . 29
springers .. , . . . . . . . . . . . . . . . . . . 31
Fork Frame & Handlebar Alignment. 34
rough check for fork alignment … 34
rough check for frame alignment. 34
frame alignment diagram . . . . . . . 35
springer shock . . . . . . . . . . . . . . . . 36
Glide Forks . . . . . . . . . . . . . . . . . . . . . 37
general . . . . . . . . . . . . . . . 37
changing oil . . . . . . . . . . . . . . . . . . 37
glide fork diagram . . . . . . . . . . . . 39
glide fork diagram (adjustable) .. 40
disassembling fork sliders & tubes 41
adjusting steering damper …… 41
adjusting fork trail (adjustable) … 42
disassembling front fork . . . . . . . . 42
steering head bearings . . . . . . . . . 43
replacing slider bushings . . . . . . . 43
inspecting & servicing fork . . . . . 44
straightening fork tubes . . . . . . . . 44
straightening fork stem & bracket
assembly . . . . . . . . . . . . . . . . . . . 45
assembling fork …………… 46
assembling fork (adjustable) …. 47
Brakes ……………………. 48
disassemble front brake (glide) .. 48
inspection & servicing (glide) … 48
assembling front brake (glide) … 48
adjusting front brake cable (glide) 48
adjusting front brake shoes (glide) 48
glide brake diagram ……….. 49
springer brake diagram . . . . . . . . 49
rear brake diagram . . . . . . . . . . . . 50
adjusting rear & springer brakes. 51
servicing rear & springer brakes. 51
Servicing Saddle Spring Post 52
Engines
general …………………. 54
engine diagram . . . . . . . . . . . . . . . 55
lubrication . . . . . . . . . . . . . . . . . . . 56
winter lubrication . ·. . . . . . . . . . . . . 57
changing oil . . . . . . . . . . . . . . . . . . 57
oil pressure signallight ……… 57
operating oil pressure ………. 57
oil filter . . . . . . . . . . . . . . . . . . . . . . 57
pressure oil system . . . . . . . . . . . . 58
return oil system . . . . . . . . . . . . . . 59
engine repair procedure …….. 59
pressure oil system diagram . . . . 61
return oil system (early) …….. 62
return oil system (late) ……… 63
disassembling cylinder & piston. . 64
refinishing cylinders ……….. 65
fitting piston rings …………. 66
connecting rod bushings . . . . . . . 67
straightening connecting rods 68
assembling cylinder & piston … 69
Shop Data
cylinder reboring & piston fitting .. 70
pistons & rocker arms ………. 72
removing cylinder head assembly. 73
disassembling cylinder head . . . . 73
replacing valve guides . . . . . . . . . 73
cylinder head diagram . . . . . . . . . 74
replacing valve seats . . . . . . . . . . 75
grinding valve faces & seats . . . . 75
lapping valve faces & seats . . . . . 76
assembling cylinder head . . . . . . . 76
adjusting tappets . . . . . . . . . . . . . . 76
Shop Data
valve guides . . . • . . . . . . . . . . . . . . 77
installing high lift cam . . . . . . . . . 78
intake valve guides . . . . . . . . . . . . 79
valve guide sizes . . . . . . . . . . . . . . 80
exhaust valve rotating mechanism 81
valve spring testing information. . 82
FLH valve springs . . . • . . . . . . . . . 83
hydraulic pushrods . . . . . . . . . . . . 84
adjusting hydraulic pushrods . . . . 85
servicing hydraulic pushrods …. 86
tappet che-::k valve servicing . . . . 88
misc. clearances & oil pressure. . 89
Oil Pump ………………….. 90
servicing oil pump . . . . . . . . . . . . . 90
installing oil pump …………. 91
Shop Data
oil control . . . . . . . . . . . . . . . . . . . . 92
oil pump charges ………….. 94
late oil pump . . . . . . . . . . . . . . 96
oil pump flow diagram . . . . . . . . . 97
1948-1954 Lower End Diagram ….. 98
Disassembling Lower End . . . . . . . . 99
installing timing gears . . . . . . . . 100
installing timing gear case cover. 100
1948-1954 gear & crankcase data
procedures …………….. 100
truing & sizing main bearing
races …………………. 101
fitting main bearings ……….. 102
servicing flywheels & installing
crankpan ………………. 102
truing & sizing connecting rod
lower races ……………. 102
determining correct lower
bearing fit ……………… 103
assembling connecting rods &
flywheels ………………. 103
truing flywheels …………… 104
assembling crankcases ……… 105
installing generator ………… 106
Shop Data
removing & replacing pinion
shaft gear ……………… 1 p7
crankcase drilling procedures … 109
connecting rod roller & retainer
size chart ……………… 111
engine fitting specifications ….. 112
servicing pinion shaft rollers …. 113
pinion shaft assembly diagram … 114
1955-1957 oil pump diagram …. 115
1953-1957 Valve Tappets & Guides .. 116
1954-1957 Gear Case Diagram …. 118
1954-1957 Gear Case Timing Cases. 119
1955-1957 Crankcase ………… 122
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
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