Market Position:
Essential reference for owners and technicians maintaining vintage Harley-Davidson golf carts.
Value Proposition:
Provides authoritative factory data, crucial for preserving and repairing these classic recreational vehicles.
Key Features:
Comprehensive coverage of all gas models from 1963-1980, includes both service and parts information on a single CD.
Engine Mechanical:
Complete disassembly, inspection, and reassembly of engine components (pistons, rings, cylinders, crankshaft, camshaft, valves, etc.).
Fuel System:
Carburetor overhaul, fuel pump inspection and repair, fuel tank maintenance, fuel line routing.
Ignition System:
Ignition coil testing, spark plug selection and gap, distributor maintenance, timing adjustment.
Lubrication System:
Oil pump operation, oil filter replacement, lubrication points, oil type recommendations.
Cooling System:
Air-cooled system design, cooling fin maintenance, heat dissipation principles.
Transmission:
Clutch operation and adjustment, belt inspection and replacement, gearbox maintenance.
Drivetrain:
Drive axle inspection, bearing maintenance, wheel hub assembly.
Braking System:
Drum brake inspection, adjustment, and replacement; brake cable maintenance.
Electrical System:
Basic 12V system troubleshooting, battery maintenance, starter motor operation, lighting circuits.
Steering System:
Steering column adjustment, tie rod inspection, wheel alignment basics.
Suspension System:
Front and rear suspension component inspection, shock absorber details.
Frame And Body:
Frame inspection, body panel removal and installation, seat mounting.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, lubrication points, tire pressure checks.
Troubleshooting:
Diagnostic charts for common starting, running, and braking issues.
Repair Procedures:
Step-by-step instructions for component overhauls and replacements.
Part Identification:
Detailed diagrams and part numbers for a comprehensive range of components.
Specifications And Tolerances:
Torque values, clearances, and critical measurements for engine and chassis components.
Depth Of Coverage:
Comprehensive Factory Service Manual covering all aspects from routine maintenance to major component overhauls and diagnostics.
Engine Type:
Gasoline, typically 2-cylinder, 4-stroke (specific engine configurations vary by year/model within the covered range).
Displacement Range:
Likely in the 250cc to 400cc range, though specific factory data would be detailed in the manual.
Horsepower Range:
Estimated 5-10 HP, focused on torque for low-speed operation.
Torque Characteristics:
Designed for low-end torque delivery for consistent golf course operation.
Carburetion:
Single-barrel carburetor, specific models like Mikuni or Keihin likely used. Manual provides overhaul procedures.
Fuel Type:
Unleaded gasoline.
Fuel Delivery:
Mechanical fuel pump.
Oil Type:
SAE 10W-30 or 10W-40 engine oil recommended, specific viscosity detailed in manual.
Oil Capacity:
Varies by engine, typically around 1-2 quarts. Manual specifies exact capacities.
Transmission Type:
Automatic, Variable Speed Drive (VSD) utilizing a centrifugal clutch and drive belt system.
Optional Transmission:
Not applicable for this era of golf carts.
Clutch Type:
Centrifugal clutch engaging at higher RPMs.
Drive Belt:
V-belt drive for power transmission to the differential. Manual covers inspection and replacement.
Gear Reduction:
Integral gear reduction in the rear axle assembly for torque multiplication.
Engine Oil Change:
Every 50 operating hours or annually. Manual provides precise recommendation.
Air Filter Cleaning:
Inspect and clean as needed, replace annually or if damaged. Specific interval in manual.
Spark Plug Replacement:
Replace every 100 operating hours or as needed based on inspection. Manual specifies type and gap.
Clutch Belt Inspection:
Inspect at least annually for wear and cracks. Replace as needed. Manual provides inspection criteria.
Lubrication Points:
Lubricate suspension, steering, and axle components every 50 operating hours or as specified in manual.
Engine Oil Specification:
SAE 10W-30 or 10W-40 API Service SG or higher. Specific manual recommendations are paramount.
Gear Oil Specification:
Refer to manual for specific gear oil type and viscosity for the rear axle differential.
Carburetor Fouling:
Common with age and infrequent use, leading to poor running conditions. Manual details cleaning and adjustment.
Drive Belt Wear:
Belts can degrade over time, leading to slippage or breakage. Regular inspection is key.
Brake Cable Adjustment:
Cables can stretch or seize, affecting braking performance. Manual provides adjustment procedures.
Electrical Connection Corrosion:
Older vehicles are prone to corrosion in wiring terminals, affecting electrical system reliability.
Brand Heritage:
Harley-Davidson, a legendary American manufacturer with a long history in motorcycling and powersports.
Model Evolution:
Harley-Davidson produced golf carts for a significant period, evolving engine technology and chassis designs throughout the 1960s and 1970s.
Production Period:
Harley-Davidson manufactured golf carts from the late 1960s through the early 1980s.
