1959-1969 HARLEY DAVIDSON SPORTSTER SERVICE MANUAL – PDF DOWNLOAD
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1959-1969 HARLEY DAVIDSON SPORTSTER SERVICE MANUAL – PDF DOWNLOAD
- 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 latest field-tested and factory-approved major repair methods.
- We sincerely believe that this manual will make your association with Harley-Davidson products more pleasant and prof itable. HOW TO USE WARNING YOUR SERVICE MANUAL Gasollne is extremely fsammable and highly explosive Your Service is arranged for quick, easy under certain conditions. Always stop engine, and do reference.
- This manual is divided into numbered see- smoke or open flame or sparks whew refueling tions. Sections are then divided into sub-sections. Use ., sewicing the system. this manual as follows: 1. Check the TABLE OF CONTENTS located in the front of each section to find subject desired. 2. Page number is listed across from subject. Page number consists of section number and page number.
- 3, Information is presented in a definite order as follows: Adjustments Disassembly Cleaning, Inspection and Repair Assembly In figure legends, the number following a name of a part indicates the quantity necessary for one complete assembly. NOTE All information for servicing a part should be read before repair work is started fo avoid needless disassembly. PREPARATION FOR SERVICE Proper preparation is very important for efficient service work. A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible, and reduce the incidence of misplaced tools and parts.
- A motorcycle that is excessively dirty should be cleaned before work starts. Cleaning will occasionally uncover trouble sources. Pools, instruments and parts needed for the job should be gathered before work is started, Interrupting a job to locate tools or parts is a needless delay. Special tools required for a job are listed at the end of each section.
TABLE OF CONTENTS:
1959-1969 HARLEY DAVIDSON SPORTSTER SERVICE MANUAL – PDF DOWNLOAD
GENERAL
Specifications 1A-3
Sprocket and Gear Ratios 1A-3
Tire Data 1A-3
SERVICE
Servicing a New Motorcycle 1B-5
Lubrication and Service 1B-6
Lubricants to Use IB-7
GEARCME
Servicing Oil Pump Check
Valve
Disassembling Oil Pump
Assembling Oil Pump
Valves, Tappets and
Guides
Disassembling Timing
Gears
Replacing Gearcase
Bearings
Adjusting Cam Gear
End Play
Timing Breather Valve
Installing Timing Gears
LOCATING TROUBLES
Engine 1C-3
Generator 1C-4
Carburetor IC-4
Transmission 1C-4
Clutch 1C-4
Brakes 1C-4
BRAKES
Adjusting Front Wheel
Brake 2G-5
Adjusting Rear Wheel
Brake 2G-5
Replacing Front Wheel
Brake Cable 2G- 6
Disassembling Rear Wheel
CHASSIS Brake 26- 6
DRWE
Front Chain Adjustment
Front Chain Lubrication
Replacing Front Chain
Rear Chain Adjustment
Rear Chain Oiler
Servicing Rear Chain
Assembling Front Wheel
Brake
Assembling Rear Wheel
Brake
Repairing Cross Shaft
Assembling Cross Shaft
CRAEaKCME
Checking Flywheel
End Play
Disassembling Crankcase
Disassembling Flywheels
Repairing Crankcase
Fitting Rod Bearings
Assembling Flywheels
Lapping Main Bearing
Races
Fitting Pinion Shaft
Bearing
Assembling Crankcase
SEAT
Seat Post
WHEELS
Removing Front Wheel
Removing Rear Wheel
~isasseiblinFr~o nt
Wheel Hub
Disassembling Rear
Wheel Hub
Repairing Wheel Hubs
Assembling Front
Wheel Hub
FBERGLASS
Surface finishing 25-1
Touch-Up and Surface
Repairs 2J-1
Patching Holes, Punctures
and Breaks 25-2
Assembling Rear
Wheel Hub
Replacing Rear Wheel
Sprocket
Spoking Front Wheel
Spoking Rear Wheel
Truing Wheels
Tires
Wheel Alignment
TOOLS
FUEL SYSTEM
Model HD Carburetor
Model M Carburetor
Model DC Carburetor
Model MD Carburetor
Air Cleaner
Fuel Strainer
Fuel Tank
Fuel Supply Valve
GENERAL
Engine Specifications
Engine Description
Lubrication
Oil Pressure Signal Light
Oil Pressure Signal Light
Switch
Servicing Oil Filter
Engine Oiling System
Engine Repair Procedure
Stripping Motorcycle for
Engine Repair
HANDLEBAR
Spark and Throttle Controls
TOOLS
FRAIVIE
Basic Dimensions TRANSMISSION
GENERAL
Specifications
Description
FORK
Changing Fork Oil
Replacing Breather Valve
Replacing Fork Boot Parts
Disassembling Front Fork
Disassembling Front Shock
Absorber
Removing Fork Stem and
Bracket
Straightening Fork Tubes
Straightening Fork Stem
and Bracket
Replacing Front Fork
Slider Bushings
Assembling Front Shock
Absorber
CLUTCH
Diagnosis Chart
Adjusting Clutch
Disassembling Clutch
Release
Assembling Clutch Release
Disassembling Clutch
Repairing Clutch
Assembling Clutch
Removing Compensating
Sprocket
CYLINDER HEAD
Removing Cylinder Head
Repairing Rocker Arm
Refacing Valves and
Valve Seats
Replacing Valve Seat
Inserts
Replacing Valve Guides
Assembling Cylinder Head
Adjusting Tappets
Removing and Installing
Push Rods
Revised:
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]