Engine:
Full disassembly, assembly, tuning, lubrication, cooling system (air-cooled specific)
Fuel System:
Carburetor (e.g., Linkert, Keihin) service, adjustment, troubleshooting
Ignition System:
Points ignition system, timing, coil, spark plugs
Transmission:
4-speed gearbox, clutch, primary drive servicing
Drivetrain:
Final drive, chain maintenance, sprocket wear
Brakes:
Front and rear brake systems (drum or early disc), hydraulic components, adjustment
Suspension:
Front forks (often leading-link or telescopic), rear shock absorbers, servicing, lubrication
Electrical System:
Wiring diagrams, lighting, battery, charging system (generator/alternator), starter motor
Chassis And Frame:
Frame inspection, bearing services (steering head, swingarm)
Bodywork:
Fenders, tanks, seat mounting, basic trim removal/installation
Lubrication System:
Oil pump, oil filter, oil lines, lubrication passages.
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, spark plug checks, lubrication points
Component Removal Installation:
Step-by-step guides for major components like engine, transmission, wheels, forks
Disassembly Assembly:
Detailed instructions for internal engine, transmission, and component rebuilds
Troubleshooting:
Diagnostic procedures for common starting, running, and electrical issues
Adjustment:
Carburetor tuning, ignition timing, clutch and brake lever adjustments
Special Tools:
Identification and usage of Harley-Davidson specific tools
Engine Rebuild:
Complete step-by-step for cylinder heads, pistons, crankshaft, connecting rods, and oil pump assembly.
Transmission Rebuild:
Detailed process for disassembly, inspection, and reassembly of the 4-speed gearbox, including gear selection mechanisms.
Carburetor Overhaul:
Detailed instructions for cleaning, replacing jets, and adjusting the float level.
Wheel Bearing Service:
Removal, cleaning, greasing, and installation of wheel bearings.
Depth:
Comprehensive (suitable for full rebuilds and advanced diagnostics)
Diagnostic Procedures:
Specific troubleshooting charts for ignition, fueling, and mechanical issues.
Specifications Data:
Torque values for critical fasteners, clearances (e.g., piston-to-cylinder wall, valve lash), and engine timing marks.
Part Identification:
Likely includes exploded views for part identification and order reference.
Engine Type:
Air-cooled, four-stroke, OHV V-twin
Engine Displacement:
1200cc (73.7 cubic inches)
Bore X Stroke:
Typically 3.4375 in x 4.00 in (87.3 mm x 101.6 mm) for this era
Horsepower Est:
Approx. 60-65 hp @ 5000-5500 RPM (actual figures varied slightly)
Torque Est:
Approx. 68-72 ft-lbs @ 3000-3500 RPM
Carburetor Type:
Often a Linkert M-series or early Keihin butterfly carburetor
Fuel Type:
Unleaded gasoline (post-1975 models, though leaded was still common)
Oil Change Interval:
Typically every 2,000-3,000 miles or 6 months, depending on usage.
Transmission Fluid Change:
Annually or as specified in the manual.
Primary Chain Tension:
Check and adjust regularly, often at 1,000-mile intervals.
Engine Oil Type:
Refer to manual for specific viscosity (e.g., SAE 20W50, SAE 50) and Harley-Davidson approved oils.
Transmission Fluid Type:
Refer to manual for specific type (e.g., Harley-Davidson transmission lubricant or equivalent).
Primary Chain Case Oil Type:
Often a blend of engine oil or specific primary lubricant, refer to manual.
Common Wear Items:
Valve guides, oil pump drive gears, primary chain wear, generator brushes, carburetor float bowl seals.
Leaks:
Gaskets (e.g., crankcase, primary cover, rocker boxes) and oil seals can be prone to leaks over time.
Carburetor Issues:
Float height adjustments, jetting, and accelerator pump wear can affect performance.
