Index Harley Davidson Harley Davidson 45" engine overhaul manual / solo 45" model WLA (1929-1952)

Harley Davidson 45" engine overhaul manual / solo 45" model WLA (1929-1952) - page 1

45
ENGINE OVERHAUL

MANUAL
SOLO 45" MODEL

WLA 1929-1952

SERVICE MANUAL
APPLYING TO THE FOLLOWING 45 MODELS
1941-1952

Side Valve Engine Models 45 cu. in. (750 c.c.)

Basic Drive Train 1941 and Later Servi-Car

Generally to 1929-40 45 models

CONTENTS

CHAPTER l. Introduction..............................1-2

CHAPTER 2. Overhaul of Engine in

Vehicle ... .......................3-18

Section I Description and engine data ... 3

II Removal of cylinders and piston

assemblies . . ..........................4-6

III Disassembly, cleaning, inspection,

repair and assembly................7-14

IV Installation....................................15

V Adjustment and tests..................16-17

VI Fits and tolerances......................18

CHAPTER 3. Engine ..........................................19-39

Section I Engine disassembly into sub-

assemblies .............................19-20

II Disassembly, cleaning, inspection

and repair and assembly of cylinders and pistons, and connecting rod alinement ............21

III Disassembly, cleaning and inspec-tion, fitting crank pin and mainshaft roller bearings, and assembling flywheel assembly 22-27

IV Cleaning, inspection, and repair

of crankcase assemblies and

gear case cover........................28-35

V Fitting and assembly of flywheel

and crankcase assembly .... 36-37

VI Engine assembly ......................38

VII Fits and tolerances......................39

CHAPTER 4. Fuel, Intake, and Exhaust

Systems ............................40-53

Section I Description of systems..........40-41

II Carburetor............... 42-47

III Fuel strainer and fuel supply

valve ..........................48-49

IV Intake pipe, air cleaner, and fit-

tings ......................................50-51

V Exhaust system ..........................52-53

CHAPTER 5. Ignition System ....................54-60

CHAPTER 6. Generating System..................61-68

CHAPTER 7. Horn and Lighting System .. 69-78

Section I Switches and instrument panel 69-73

II Horn and lights............. 74-78

CHAPTER 8. Clutch..........................79-86

Section I Description and data....................79-80

II Removal, disassembly, cleaning,

inspection, and repair ............81-83

III Assembly, installation, and

adjustment 84-85

IV Fits and tolerances........................86

CHAPTER 9. Transmission................................87-92

Section I Description and data ................87

II Disassembly, cleaning, inspection, and repair..........................88-90

III Assembly ......................................91

IV Fits and tolerances......................92

Paragraphs
CHAPTER 10. Brakes . . 93-102

Section I Rear wheel brake 93-97

II Front wheel brake ..........98-102

CHAPTER 11. Chains, Sprockets, Wheels,

and Hubs 103-117

Section I Wheel rims and spokes . .. 103-107

II Wheel hubs 108-114

III Chains and sprockets 115-117

CHAPTER 12. Steering System ............118-125

Section I Fork . ............................118-122

II Handlebars and controls 123-125

CHAPTER 13. Chassis Parts and Equipment 126-144

Section I Frame and tanks..................126-128

II Mudguards, chain guards,

stands, and skid plate 129-132

III Battery box, too! box, and foot-

boards ........................133-135

IV Saddle and saddle post............136-137

V Equipment................................138-144

CHAPTER 14. Road Test of Engine, Transmission, and Clutch 145-156

Section I Engine . 145-151

II Transmission and clutch 152-156

CHAPTER 15. Special Tools 157

References ...........

Index ...........................................

CHAPTER 1

INTRODUCTION

1. SCOPE.

a. The instructions contained in this manual are for the information and guidance of personnel charged with the maintenance und repair of Harley-Davidson motorcycle, model WLA. These instructions are supplementary to field and technical manuals prepared for the using arm. This manual does not contain information which is intended primarily for the using arm, since such information is available to ordnance maintenance personnel in 100-series TM’s or FM’s.

b. This manual contains a description of, and procedure for, disassembly, inspection and repair of engine, fuel system, ignition system, generating system, transmission and clutch, and chassis.

c. TM 9-879 contains the replacement instructions of many components of this vehicle. This information is not repeated in this manual.

2. MWO AND MAJOR UNIT ASSEMBLY REPLACEMENT RECORD.

a. Description. Every vehicle is supplied with a copy of A.G.O. Form No. 478, which provides a means of keeping a record of each MWO completed or major unit assembly replaced. This form includes spaces for the vehicle named and U.S.A. Registration No., instructions for use, and information pertinent to the work accomplished. It is very important that the form be used as directed and that it remain with the vehicle until the vehicle is removed from service.

b. Instructions for Use. Personnel performing modifications or major unit assembly replacements must record clearly on the form a description of the work completed and must initial the form in the columns provided. When each modification is completed, record the date, hours and/or mileage, and MWO number. When major unit assemblies, such as engines, transmissions, transfer cases, are replaced, record the date, hours and/or mileage and nomenclature of the unit assembly. Minor repairs and minor parts and accessory replacements need not be recorded.

c. Early Modifications. Upon receipt by a third or fourth echelon repair facility of a vehicle for modification or repair, maintenance personnel will record the MWO numbers of modifications applied prior to the date of A.G.O. Form No. 478.

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