Applicable Years:
1940, 1941, 1942, 1943, 1944, 1945, 1946, 1947, 1948, 1949, 1950, 1951, 1952
Model Variants Covered:
WLA (Military), WL (Civilian), G (Servicar/Tricycle)
Estimated Page Count:
Highly comprehensive, likely exceeding 500 pages based on typical workshop manuals of this era covering multiple model years and variants.
Type:
Complete Workshop Service and Repair Manual
Format:
Downloadable (PDF compatible)
Engine:
Complete overhaul, tuning, carburetor service, lubrication systems, cooling systems (air-cooled).
Transmission:
Disassembly, assembly, repair, maintenance, clutch service, gearbox operation.
Electrical System:
Ignition system, lighting, battery maintenance, wiring diagrams, charging system, starter motor.
Chassis And Suspension:
Front fork service, rear suspension, wheel bearings, steering head maintenance, frame inspection.
Braking System:
Brake shoe adjustment, brake drum service, linkage maintenance.
Fuel System:
Fuel tank maintenance, fuel lines, fuel filters, carburetor rebuilding and adjustment (e.g., Linkert carburetors).
Bodywork And Trim:
Fender adjustments, saddlebag mounting (where applicable), control lever adjustments, general appearance items.
Clutch:
Assembly, disassembly, adjustment, replacement of clutch plates and springs.
Carburetor Details:
Detailed rebuild procedures for Linkert carburetors, including jetting, float level adjustment, and idle speed control.
Ignition System Details:
Magneto ignition system service, breaker point adjustment, condenser testing, spark plug specifications and gap settings.
Wheel And Tire Service:
Wheel bearing maintenance, spoke tensioning, tire pressure recommendations, rim strip inspection.
Frame And Fork Service:
Fork oil replacement and inspection, steering head bearing adjustment and lubrication, frame inspection for cracks or damage.
G Model Specifics:
Unique procedures and specifications for the Servicar (G model), including its differential and cargo box attachment.
Maintenance:
Scheduled maintenance tasks, lubrication, cleaning, periodic inspections.
Troubleshooting:
Diagnosis of common problems, step-by-step troubleshooting guides for performance issues.
Repair:
Detailed instructions for disassembly, component replacement, reassembly, and adjustment of all major systems.
Technical Specifications:
Torque specifications, clearances, tolerances, fluid capacities, and critical measurements.
Cylinder Head Service:
Removal, inspection, decarbonizing, valve seat grinding, valve guide replacement.
Piston And Connecting Rod Service:
Piston ring replacement, piston inspection, connecting rod bearing checks, and end play.
Crankshaft Service:
Main bearing inspection and replacement, crankshaft end play adjustment.
Generator And Regulator:
Generator testing, brush replacement, regulator adjustment (if applicable).
Paint And Finish Guidelines:
May include guidance on original finishes and paint codes, especially for WLA models.
Depth:
Comprehensive workshop level, suitable for experienced mechanics and dedicated enthusiasts. Covers detailed component breakdown, rebuild procedures, and diagnostic techniques.
Diagnostic Charts:
Likely includes diagnostic charts for common performance issues, helping to pinpoint problems quickly.
Rebuild Instructions:
Provides comprehensive, part-by-part instructions for complete engine, transmission, and other major component rebuilds.
Type:
Air-cooled, four-stroke, side-valve V-twin
Displacement:
Approximately 74 cubic inches (1213 cc)
Bore X Stroke:
Typically 3.3125 in x 3.5 in (84.14 mm x 88.9 mm)
Compression Ratio:
Varies, but typically around 5.5:1 to 6.0:1
Horsepower:
Estimated 20-25 HP at the crankshaft, depending on specific configuration and tuning.
Torque:
Not readily published in modern terms; emphasizes low-end grunt for military applications.
Carburetor:
Primarily Linkert M-series (e.g., M-51, M-74), with specific adjustments and jetting for WLA variants.
Fuel Type:
Gasoline (lead content would have been common during original production)
Valve Timing:
Detailed specifications for valve opening and closing points relative to piston position.
Oil Pump Specifications:
Information on the oil pump's operation and any necessary adjustments or checks.
Oil Change:
Frequent oil changes recommended, typically every 1000-2000 miles or seasonally, depending on usage and lubrication system (e.g., total loss or recirculating).
Tune Up:
Regular checks of ignition timing, spark plugs, and carburetor adjustments are crucial for optimal performance.
Engine Oil:
Specific weight oils recommended by Harley-Davidson for the era (e.g., SAE 50 or 60), often in a 'total loss' lubrication system or a recirculating system with a separate oil tank. Manual will detail exact type and capacity.
Transmission Oil:
Specific gear oil type required for the gearbox. Manual will list exact specification.
Carburetion:
Linkert carburetors can be finicky; require precise adjustment. Gumming and clogging are common if fuel is left in the system.
Electrical System:
Original wiring can degrade over time. Proper grounding and insulation are critical. Generator charging output needs regular verification.
Clutch And Transmission:
Wear in the clutch plates and engagement mechanisms, as well as potential wear in the transmission gears and bearings, require periodic inspection and adjustment.
Lubrication:
Ensuring proper oil flow, especially in older engines with total-loss systems, is paramount to prevent premature wear.
