Positioning:
Essential technical documentation for owners and mechanics of the 1982 Harley-Davidson CLE Sidecar. Targets enthusiasts and professionals seeking in-depth repair and maintenance information.
Analogy:
Similar to factory service manuals for other major motorcycle manufacturers of the era, providing authorized procedures and specifications.
Feature 1:
Specific to the 1982 Harley-Davidson CLE Sidecar, ensuring accuracy for this particular model and configuration.
Feature 2:
Includes detailed procedures for the unique aspects of integrating and maintaining the sidecar unit.
Feature 3:
Offers a blend of mechanical and electrical repair information, crucial for vintage motorcycles.
Engine Mechanical:
Top-end, bottom-end, lubrication, cooling (air-cooled)
Fuel System:
Carburetor overhaul (e.g., Keihin), fuel tank, fuel lines, petcock
Ignition System:
Points and condenser, ignition timing, coils, spark plugs, wiring
Transmission And Drivetrain:
Clutch, gearbox overhaul, primary drive, final drive (chain)
Brakes:
Front and rear brake systems (likely drum brakes, possibly early disc for front), hydraulic systems, adjustment
Suspension:
Front fork (e.g., Shovelhead style), rear shock absorbers, swingarm, sidecar suspension
Wheels And Tires:
Spoke wheels, wheel bearing maintenance, tire selection and pressures
Electrical System:
Wiring diagrams, lighting, charging system (generator/alternator), battery, starter motor, horn
Frame And Bodywork:
Frame inspection, fenders, fuel tank, seat, handlebars, controls, sidecar mounting and components
Maintenance:
Routine checks, lubrication, fluid changes, filter replacement, battery maintenance
Troubleshooting:
Diagnostic charts, identification of common problems and their solutions
Disassembly And Assembly:
Step-by-step instructions for component removal and reinstallation
Repair:
Detailed instructions for component repair and rebuilding
Adjustment:
Carburetor tuning, clutch adjustment, brake adjustment, suspension setup
Inspection:
Checks for wear, damage, and proper function of all components
Installation:
Sidecar attachment, accessory installation
Depth:
Comprehensive; covers everything from basic maintenance to complete engine and transmission rebuilds, including specialized sidecar integration
Format:
Printed paper document
Quality:
Typically good quality for factory manuals of this era, designed for workshop use. May include diagrams, illustrations, and photographic steps.
Binding:
Perfect bound or stapled, designed for lay-flat use
Paper Type:
Durable paper stock, suitable for workshop environments
Engine Type:
Air-cooled, 45-degree V-twin OHV
Displacement:
Likely 74 cubic inches (1200cc) or 80 cubic inches (1340cc) for the Shovelhead era
Bore X Stroke:
Dependent on specific engine variant (e.g., 3.4375 in x 4.000 in for 74 CI, 3.500 in x 4.250 in for 80 CI)
Compression Ratio:
Typically around 8.0:1 for stock models of this era
Horsepower:
Estimated 50-60 HP (approximate, varies with engine size and state of tune)
Torque:
Estimated 60-70 ft-lbs (approximate)
Carburetor:
Likely a single Keihin butterfly or CV carburetor (e.g., Keihin CV with 36mm or 40mm venturi)
Fuel Type:
Leaded or Unleaded Gasoline (refer to manual for specific recommendations)
Oil Type:
Viscosity Grade: SAE 20W-50 motorcycle-specific oil is common. Consult manual for specific Harley-Davidson recommendations or equivalents.
Oil Capacity:
Approximately 4 quarts (3.8 liters) for the engine and primary drive system. Verify with manual.
Type:
4-speed constant mesh manual transmission
Optional Gearbox:
None typically offered for this model year and configuration.
Clutch:
Dry multi-plate clutch, cable actuated
Primary Drive:
Chain drive from engine crankshaft to transmission input shaft
Final Drive:
Chain drive from transmission output shaft to rear wheel
Transmission Oil Type:
Gear oil (e.g., Harley-Davidson's own formulation or equivalent GL-4 rated gear oil). Manual will specify viscosity.
Wheelbase:
Varies, but typically around 60-64 inches for the motorcycle, plus sidecar length. Manual will provide specific measurements for sidecar attachment.
Length:
Significantly increased with sidecar. Manual will detail overall dimensions.
Dry Weight:
Motorcycle alone approx. 550-600 lbs. Sidecar adds substantial weight. Manual will list combined approximate weight.
Gross Vehicle Weight Rating:
Manual will specify GVWR, considering the added weight and load capacity of the sidecar.
Oil Change Interval:
Typically every 2,000-3,000 miles or annually. Manual will provide precise recommendations.
Primary Chain Adjustment:
As needed, usually every 5,000-10,000 miles. Manual will detail the procedure and slack specification.
Spark Plug Replacement:
Every 5,000-10,000 miles, depending on plug type and condition.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (if disc brakes are present). Manual will specify.
Grease Type:
Lithium-based grease for various pivot points and bearings. Manual will list specific types and locations.
Issue 1:
Shovelhead engine oil leaks (common for the era, manual provides repair procedures).
Issue 2:
Carburetor adjustment and tuning can be finicky; manual provides detailed steps.
Issue 3:
Wear and tear on drivetrain components (clutch, transmission gears) requires regular inspection and maintenance as detailed in the manual.
Issue 4:
Sidecar mounting points and suspension can experience stress and require periodic checks for tightness and wear.
Heritage:
Harley-Davidson, a storied American motorcycle manufacturer with a long history of producing powerful V-twin motorcycles and various configurations, including sidecar-equipped models.
Evolution:
The CLE sidecar was often an aftermarket or factory-installed option on Harley-Davidson models, enhancing carrying capacity and stability. This manual focuses on a specific year where this configuration was prevalent.
Production Era:
1982 model year, part of the Shovelhead engine era for Harley-Davidson.
