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Harley Davidson Softail Service Manual opt. Harley Davidson Parts Manual All cc. Harley-davidson Electra super Service. Harley Davidson Electrical Diagnostics Manual.

Harley Davidson Electrical Diagnostic Manual. Harley Davidsonsportster-electrical-diagnostic-manual. Harley Davidsonsportster-service-manual. Harley Davidson Sportster Service Manual. Harley Davidson Electra super Service. Thread hose from Test Gauge Kit A6 into brass fitting on adaptor. Remove circlip securing manual release valve and unscrew release valve from trim assembly.

Reinstall fill plug. Disengage tilt lock lever. Check valve is preset to operate at a specific pres- sure. Removal and installation of check valve could result in improper operating pressure and possible system damage.

NOTE: Check valve is in port side trim rod only. Install trim rods and caps. Use installation tool A1 or spanner wrench to tighten caps securely.

Remove cross pin. Remove lower swivel pin. Clamp tilt rod in a soft jawed vise. Remove bolt or nut as applicable to disassemble rod assembly. Remove O-ring. Design 1 tilt rod assembly re- places either tilt rod assembly. Remove end cap from tilt rod. Remove allen plug. Insert shaft into cylinder. Place cylinder as shown. Hold down on cylinder and inject air into shaft opening. Remove shaft after Memory Piston Cup has been expelled. Replace allen plug re- moved in Step 5 and tighten securely. Any debris in the system can cause the system to malfunction.

Install components on rod. Tighten securely 6. Clamp cylinder in a soft jawed vise and install tilt rod assembly. Use spanner wrench and tighten end cap securely. Lubricate alignment tool and shaft.

Align tilt ram and housing using alignment tool. Install shaft. Remove frame and armature from end cap. Use care not to drop armature. Replace ar- mature if a short is indicated. If commutator is worn it may be turned on an armature conditioner or a lathe. Carefully inspect power cord for cuts or tears which will allow water to enter motor. Replace cord if cut or torn.

Clean, inspect, and test motor components. To replace brush card, disconnect spade terminal. Cut crimped brush lead. Remove 2 screws securing brush card to end cap. Inspect seal and O-ring for cuts and abrasions. Inspect bushing for wear.

If bushing appears to be excessively worn — grooves, scratches, etc. Any debris in power trim system can cause system to malfunction. The Vise Grip pliers will prevent the armature from being drawn out of the brush card assembly by the frame magnets while installing the frame assembly.

Install pump onto power trim manifold. Insure O-rings are in proper locations. Secure with two 2 screws. Torque screws to 80 lb. Priming Power Trim System 1. Shift Shaft Bushing Tool 2. Gear Housing Cover Nut Tool 3. Slide Hammer Puller A1 5. Bearing Removal and Installation Kit A5. This kit contains the following tools: Pilot ; Puller Plate 9. Mandrel Driver Rod Universal Puller Plate Cross Pin Tool Driveshaft Holding Tool A1or Oil Seal Driver Forward Gear Bearing Tool Backlash Indicator Rod Dial Indicator A1 Bearing Retainer Tool Bearing N.

Washer N. In many cases, disassembly of a sub-assembly may not be necessary until cleaning and inspection reveals that disassembly is required for replacement of one or more compo- nents.

Remove 2 locknuts from bottom middle of anti-cavitation plate. Remove locknut from the front gear housing mounting stud. Loosen the side mounting locknuts. DO NOT attempt to remove one nut before oppo- site side is loosened sufficiently, or driveshaft housing could be damaged. Slide rubber centrifugal slinger up and off driveshaft.

Remove water tube guide and seal from water pump cover. Retain guide for reas- sembly and discard seal. Drive insert out of cover with a punch and hammer. Remove impeller from driveshaft. It may be necessary to use a punch and hammer to drive impeller upward on driveshaft. Place gear housing in a suitable holding fixture with propeller shaft in a horizontal posi- tion. Use propeller thrust hub to maintain outward pressure on puller jaws.

NOTE: When bearing carrier is removed from gear housing, the bearing carrier alignment key will come out with it. Clean shift shaft and bushing with solvent and dry with compressed air. If reverse gear bearing remains attached to reverse gear, install Universal Puller Plate and position puller plate, gear and bearing on a press with gear side down. Use a suitable mandrel and press gear out of bearing.

Clean propeller shaft assembly with solvent and dry with compressed air. Inspect bearing carrier oil seal surfaces for grooves.

Run fingernail across seal sur- face to check for groove. Replace shaft if groove is found. Inspect sliding clutch. Check reverse gear and forward gear clutch jaws. Rounded jaws indicate one or more of the following: a. Improper shift cable adjustment. Push cross pin out of sliding clutch and propeller shaft with Cross Pin Tool Pull sliding clutch off propeller shaft. Pull cam follower and clutch actuator rod out of propeller shaft.

DO NOT force cam follower up-or-down or side-to-side when pulling from propeller shaft. Remove gear housing from vise and re-position it as shown. Be sure to use soft jaw vise covers and clamp as close as possible to water pump studs. Place a block of wood on gear housing mating surface. Use a mallet and carefully tap gear housing away from driveshaft. Bearing cannot be reused. Reach into gear housing and lift out forward gear. Clean forward gear and bearings with solvent and dry with compressed air.

Inspect gear teeth for pitting, grooves, scoring, uneven wear and for discoloration from overheating. Pull bearing up into bore until it bottoms on gear housing shoulder. DO NOT use ex- cessive force. Press ball bearing onto gear with a suitable mandrel until firmly seated. Be sure to press only on inner race of bearing and that bearing is firm against gear. Apply a light coat of Quicksilver Super Duty Gear Lubricant onto outside diameter of propeller shaft needle bearing.

Place second seal on short shoulder side of seal driver with lip of seal toward shoulder. Press seal into bearing carrier until seal driver bottoms against bearing carrier. Place forward gear on a press with gear teeth down.

Apply a light coat of Quicksilver Super Duty Gear Lubricant onto the inside diameter of forward gear tapered bearing. Position forward gear tapered bearing over gear. Place shim s retained from disassembly into gear housing. If shim s were lost or a new gear housing is being used, start with approximately 0. Apply a light coat of Quicksilver Super Duty Gear Lubricant to forward gear bearing race bore in gear housing. Thread a used pinion nut onto end of driveshaft.

Install bearing race and bearing retainer. Measure distance a and increase that distance by 1 in. Turn driveshaft clockwise 2 or more turns to seat driveshaft bearings. Secure pipe against carrier with propeller nut and tab washer. Torque propeller nut to 45 lb. Insert clutch actuator rod assembly into end of propeller shaft. Align cross pin slot in actuator rod with cross pin slot in propeller shaft.

Spirally wrap spring into groove on sliding clutch. Place gear housing in a soft jaw vise with the driveshaft in a vertical position. Side force on propeller shaft may break the neck of the clutch actuator rod. Start cover nut a few turns by hand, then using Cover Nut Tool and torque wrench, torque cover nut to Ib. Bend one lock tab of tab washer into cover nut only one will align. Install divider block if removed. Use RTV Sealer to seal seams between divider block and gear housing.

Install a new water pump base gasket and install water pump base. Slide impeller down driveshaft to impeller drive key. Align drive key with keyway in the center hub of impeller, and slide impeller over drive key. If removed, install new water pump insert into pump cover as follows: a. Install new gaskets on Fill and Vent screws. Move gear housing up toward driveshaft housing, while aligning shift shaft splines and water tube with water tube guide in water pump cover.

Place forward thrust hub over propeller shaft with shoulder side toward propeller. Place propeller on propeller shaft and slide it up against thrust hub. Place continuity washer if equipped onto shoulder of rear thrust hub. Shift Shaft Bushing Tool T 2. Driveshaft Holding Tool A1 or Pinion Locating Gear Tool A2 or Dial Indicator Holder Clean bearings with solvent and dry with compressed air. Air should be directed at the bearing so that it passes thru the bearing. DO NOT spin bearing with compressed air, as this may cause bearing to score from lack of lubrication.

Bend tabs of propeller tab washer away from thrust hub rear , then remove propeller locknut, tab washer, thrust hub rear , propeller and thrust hub forward from propel- ler shaft. Clean all water pump parts with solvent and dry with compressed air. Inspect water pump cover and base for cracks and distortion from overheating.

Drive water pump insert out of water pump cover with a punch and hammer. Place gear housing in a suitable holding fixture or vise with propeller shaft in a horizon- tal position. Remove and discard shift shaft bushing oil seal by prying it out or driving it out with a punch and hammer. Use bearing removal and replacement tool A5 or equivalent to press bear- ings out of bearing carrier. Mount a dial indicator at front edge of propeller splines. Rotate propeller shaft. Dial indicator movement of more than 0.

Improper shift habits of operator s shift from neutral to reverse gear or forward gear too slowly. Clean clutch actuator rod in solvent and dry with compressed air.

Inspect actuator components for wear or damage. Replace components as required. Remove forward gear from bearing adapter. Remove thrust washer and O-ring. The thrust washer acts as a bearing surface for the thrust bearing and it should be inspected for pits, rust, scoring or discoloration due to lack of lubricant. O-ring should be inspected for cuts or abrasions and replaced if necessary.

Remove bearing retainer using Bearing Retainer Tool Place Driveshaft Holding Tool A1 over driveshaft splines. Use a socket and flex handle to hold pinion nut. Pad area of gear housing, where flex handle will make contact, to prevent damage to gear housing. After driveshaft is removed from gear case, remove and retain shim s that were lo- cated under upper tapered driveshaft bearing.

If inspection determines that replacement of driveshaft tapered bearing is required, remove bearing from driveshaft as follows: a. Clean driveshaft, tapered bearing and race, and pinion gear with solvent. Dry with compressed air. DO NOT allow driveshaft bearing to spin while drying. Remove thrust bearing and thrust washer from reverse gear bearing cup.

Remove reverse gear bearing adaptor. Check clutch jaws on reverse gear for damage. Replace reverse gear if damage is found. Inspect to ensure that all of the needles are present and in position. Needles that have been dislodged may be snapped back into place as long as no damage has occurred to the bearing cage.

Loose fitting needle bearing will move out of position and cause repeated failures. Using suitable mandrel, press forward gear bearing into bearing adaptor until bearing is flush with lip of adaptor. With seal lip facing towards bearing, press inner seal using long end of mandrel into bearing carrier until mandrel shoulder bottoms out on bearing carrier.

With seal lip facing towards mandrel, press outer seal using short end of mandrel into bearing carrier until mandrel shoulder bottoms out on bearing carrier. NOTE: If gear housing has been replaced or inspection determines that reverse gear bearing adapter must be replaced, assemble and install as follows: 2. If the reverse gear, reverse gear adaptor, large thrust bearing, bearing race, or gear housing were replaced, install 0. Welcome, Guest. Please login or register.

Home Help Login Register Donate. Einyodeler Expert Posts: 1, Midnight bugs taste best!!! As long as these get downloaded they will stay active but if a link lays dormant for more than 30 days it will disappear, so just reply here and let me know if a certain link is not working and I will fix it. I've downloaded the K0-K7 manual a few times now, tried to open it with a couple of apps but the file seems to be damaged Anyone else having this problem?

The K8 manual works fine. New bike! I had a problem too. I've lost it now but something about Acrobat couldn't open it because it is not a supported file. Shadowjack Guest. Page said it was 17MB, but the download counter said it was only 9MB.

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