Market Niche:
Targeted at owners and independent mechanics of the 1976 Harley-Davidson SS 250, a significant model in Harley-Davidson's lineup during a period of evolution for the company.
Context:
This manual served as the definitive guide for a motorcycle competing in the 250cc class, requiring specific knowledge of Harley-Davidson's engineering and design philosophies of the era, differentiating it from Japanese competitors.
Value Proposition:
Provides essential, manufacturer-verified information for maintaining and repairing the SS 250, crucial for preserving its performance and value.
Engine:
Complete overhaul, tuning, lubrication, cooling system, ignition system, carburetor (specific model details would be listed if known)
Transmission:
Gearbox disassembly, assembly, clutch service, lubrication
Drivetrain:
Final drive, chain adjustment and maintenance
Brakes:
Front and rear brake system inspection, service, and adjustment (likely drum brakes)
Suspension:
Front forks (telescopic), rear shock absorbers, bushings, and linkage service
Electrical:
Wiring diagrams, lighting system, ignition system, battery service, charging system (generator/alternator, rectifier/regulator)
Fuel System:
Fuel tank, petcock, fuel lines, carburetor overhaul and adjustment
Exhaust System:
Exhaust pipe and muffler inspection and replacement
Bodywork And Frame:
Frame inspection, fenders, seat, fuel tank mounting, control levers
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, air filter cleaning/replacement
Troubleshooting:
Diagnostic charts for common engine, electrical, and mechanical issues
Engine Overhaul:
Piston, ring, cylinder, crankshaft, valve train service and replacement
Transmission Repair:
Gearbox disassembly, inspection, and reassembly, clutch plate replacement
Electrical Diagnostics:
Fault finding using wiring diagrams, component testing
Brake Adjustment:
Lever and pedal free play, cable tension
Carburetor Tuning:
Idle speed, jetting adjustments, float level setting
Wheel And Tire:
Tire pressure, spoke tensioning (if applicable), wheel bearing service
Depth:
Comprehensive: Covers from basic maintenance to full engine and transmission rebuilds, including detailed component specifications and torque values.
Digital Format:
PDF (if converted from original print)
Print Quality Original:
Factory original print quality (typically black and white line drawings, some halftones).
Binding Type Original:
Stapled or perfect bound (typical for factory manuals).
Paper Type Original:
Newsprint or semi-gloss paper stock, intended for workshop use.
Type:
Two-stroke, parallel-twin cylinder
Displacement:
248 cc (approx. 15.1 cubic inches)
Bore X Stroke:
Specifications would be detailed in the manual, typically around 43mm x 43mm for a 250cc twin.
Compression Ratio:
Specifications found within the manual, crucial for performance tuning.
Cooling System:
Air-cooled
Horsepower Output:
Figures typically in the range of 20-25 HP, detailed in manual.
Torque Output:
Torque figures would be specified in the manual, important for low-end grunt.
Carburetor Type:
Likely a single or twin Mikuni or Amacareb carburetor (specific model details are critical and within the manual).
Fuel Delivery:
Gravity feed from fuel tank via petcock.
Type:
Contact breaker points ignition with coil.
System:
Pre-mix fuel and oil (common for two-strokes of this era) or oil injection system (less common for this class then).
Wheelbase:
Specifications would be found in the manual, typically around 54-56 inches.
Seat Height:
Specifications would be found in the manual.
Dry Weight:
Estimated around 260-280 lbs, precise figures in manual.
Fuel Capacity:
Typically 2.5-3.5 gallons, exact tank size in manual.
Crash Test Results:
Not applicable for motorcycles of this era.
Braking System:
Single disc front (optional or standard depending on specific SS 250 sub-model, but likely drum for base), drum brake rear. Manual provides service details.
Lighting:
Headlight, tail light, brake light, turn signals (if equipped).
Frame Construction:
Steel frame, construction details and inspection in manual.
Oil Change Frequency:
Detailed in manual, typically every 1,000-2,000 miles or annually for gearbox oil.
Spark Plug Replacement:
Every 3,000-5,000 miles, specific recommendations in manual.
Chain Lubrication:
Every 500 miles or after riding in wet conditions.
Air Filter Service:
Every 2,000-3,000 miles or as needed based on conditions.
Engine Oil Type Two Stroke:
Two-stroke pre-mix oil meeting specific API TC or JASO FD standards (manual will specify).
Transmission Oil Type:
Gear oil (e.g., SAE 80W/90 GL-4 or GL-5), specific viscosity and capacity detailed in manual.
Fork Oil Type:
Suspension fluid, viscosity specified in manual (e.g., 10W or 20W).
Typical Wear Items:
Clutch plates, piston rings, fork seals, electrical connectors (corrosion), carburetor jets clogging.
Maintenance Challenges:
Finding correct replacement parts, understanding specific two-stroke tuning intricacies.
Manufacturer Origin:
United States
Ss 250 Context:
The SS 250 was part of Harley-Davidson's effort to compete in smaller displacement classes, often utilizing Italian Aermacchi technology due to the company's partial ownership at the time. This model represented a move towards lighter, more agile motorcycles.
Production Period:
Mid-1970s, specifically covering the 1976 model year.
Manufacturing Location:
Likely assembled in the USA, with components potentially sourced or manufactured by Aermacchi in Italy.
