This manual provides comprehensive factory service repair information for the SS-250 motorcycle, covering the 1975 and 1976 model years. The SS-250, a sporty motorcycle from the SS series, represents a significant part of the brand's history and its collaboration with Aermacchi. This motorcycle is characterized by its air-cooled, 2-stroke, single-cylinder engine, approximately 250cc in displacement, and a manual transmission with a chain drive. Its engineering quality and reliability reflect the standards of its era, offering a unique riding experience for enthusiasts.
This factory service manual is designed to be an essential resource for owners, mechanics, and technicians. It offers complete, step-by-step guidance for all aspects of maintenance, repair, rebuilding, refurbishing, and restoration. Key areas covered include general information, chassis, fuel and lubrication systems, engine, clutch, transmission, wheels, brakes, suspension, steering, frame, and the entire electrical system with detailed wiring diagrams. The manual also features advanced troubleshooting procedures and common fixes, enabling users to diagnose and resolve issues efficiently, ensuring the SS-250 remains in optimal condition.
Model Designation:
SS 250
Model Years Covered:
1975, 1976
Chassis Code Primary:
SS-250
Positioning:
Essential resource for owners and mechanics of the Harley-Davidson SS-250 (1975-1976)
Advantage:
Provides factory-level technical information typically only available to authorized service centers, enabling DIY repairs and informed service interactions.
Feature List:
Actual factory manual content, comprehensive coverage, detailed illustrations and diagrams, advanced troubleshooting guide, print-on-demand capability.
Detail Level:
Incredibly detailed, step-by-step instructions and photos.
Cost Savings:
Potential to save $50-$60 per hour on shop labor costs by enabling self-servicing.
Primary Coverage:
Complete Factory Service Repair
Additional Coverage:
All Styles Covered
Estimated Page Count:
Hundreds of pages
Manual Type:
Factory Service Manual
Source Authenticity:
Actual Genuine Repair Service Factory Manuals
Delivery Method:
Digital Download
Software Requirement:
Adobe PDF Reader
System List:
General Information, Maintenance, Chassis, Fuel System, Cooling System, Engine, Clutch, Engine Lubrication System, Engine Removal/Installation, Drive, Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Wiring Diagrams
Electrical Diagrams:
Detailed wiring diagrams are a key component of the manual, crucial for diagnosing electrical faults.
Procedure List:
Diagnosis of engine fault symptoms, repair approach evaluation, part testing techniques, wiring diagram tracing and verification, engine management system analysis, common fixes, mechanic interaction guidance, pre-emptive maintenance tips, maintenance procedures, repair procedures, rebuilding, refurbishing, restoration
Troubleshooting Guide:
Advanced troubleshooting guide included to help diagnose and correct any problems encountered.
Depth Level:
Comprehensive step-by-step guidance, advanced troubleshooting, detailed diagnostic and repair procedures
Target Audience:
Owner, Factory Trained Technicians, Mechanics
Print Quality:
High Resolution, Fully Printable
Print Options:
Print entire manual or selected pages
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Search Functionality:
Searchable text for quick information retrieval
Navigation:
Numbered table of contents for easy navigation
Computer Skill Requirement:
No advanced computer skills required; easy to view and print.
Engine Type:
Air-cooled, 2-stroke, single-cylinder (presumed based on common SS series configurations of the era)
Displacement:
Approximately 250cc (as indicated by model name)
Horsepower:
Specific figures not provided, but typical for 250cc 2-stroke singles of the era, likely in the 20-30 HP range.
Torque:
Specific figures not provided, but typical for 250cc 2-stroke singles of the era.
Fuel Delivery:
Carbureted (likely a single carburetor, specific model TBD).
Fuel Type:
Gasoline with 2-stroke oil mixture (typical for 2-stroke engines).
Ignition Type:
Breaker point ignition (common for the era), potentially with electronic ignition as an upgrade or later model feature.
Engine Lubrication System
Lubrication Type:
Pre-mix lubrication system for the 2-stroke engine, where oil is mixed with the fuel.
Transmission Type:
Manual transmission (specific number of gears not provided, but likely 5-speed).
Optional Transmission:
N/A (Manual only expected)
Clutch Type:
Wet multi-plate clutch (typical for motorcycles of this type).
Final Drive:
Chain drive (standard for most motorcycles of this era).
Overall Length:
Specific figures not provided in product description.
Wheelbase:
Specific figures not provided in product description.
Dry Weight:
Specific figures not provided in product description.
Curb Weight:
Specific figures not provided in product description.
Safety Ratings:
Not applicable for historical motorcycle service manuals in the context of modern vehicle safety ratings.
Active Safety Features:
Disc front brake, drum rear brake (typical for the era, specific configurations may vary).
Passive Safety Features:
Frame structure, rider positioning.
Infotainment Features:
N/A (Basic motorcycle technology of the era)
Driver Assistance Systems:
N/A (Basic motorcycle technology of the era)
Connectivity Options:
N/A (Basic motorcycle technology of the era)
Electrical Components:
Covers all aspects of the electrical system, including lighting, ignition, charging system (generator/alternator), and associated wiring.
Routine Maintenance:
The manual will detail specific intervals for oil changes, filter replacements, chain adjustments, spark plug service, and general inspection.
Engine Oil:
The manual will specify the correct SAE viscosity grade and API service classification for the engine oil, as well as the oil capacity. Typically, a 10W-40 or 20W-50 for air-cooled engines of this era.
Gearbox Oil:
The manual will specify the type and quantity of lubricant for the transmission and primary drive system. Likely a specific motorcycle gear oil or heavy-duty transmission fluid.
Brake Fluid:
DOT 3 or DOT 4 brake fluid is typically specified for hydraulic brake systems of this era.
Common Problems:
The manual will address common wear items and potential issues for a 2-stroke motorcycle of this age, such as carburetor tuning, ignition system maintenance, piston and ring wear, and exhaust system integrity.
Tune Up Details:
Includes detailed instructions for carburetor adjustment, ignition timing, valve clearance checks (if applicable to the specific 2-stroke design, though less common), and general engine tune-up for optimal performance and efficiency.
Brand Origin:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer with a rich heritage in performance and custom motorcycles.
Ss Series Context:
The SS series represented Harley-Davidson's foray into smaller displacement, sporty motorcycles, often aimed at younger riders or performance-oriented segments, utilizing engines sourced from Aermacchi during a period of collaboration.
Manufacturing Period:
1975-1976
Manufacturing Location:
Likely produced in collaboration with Aermacchi in Italy and assembled/finalized by Harley-Davidson in the USA.
Historical Recognition:
While specific awards for the SS-250 are not detailed in the product information, Harley-Davidson motorcycles of this era were recognized for their design and performance in their respective market segments.
