Harley Davidson Sportster (1959 to 1969). Service manual - page 1
1959 to 1969 SPORTSTER SERVICE MANUAL
PRODUCT
CHASSIS
ENGINE
TRANSMISSION
---------- ---------------------------,
ELECTRICAL
MISCELLANEOUS
The maintenance and repair information in this manual applies to the
7959 to 1969 Harley-Davidson Sportster and K-KH models
FOREWORD
This service and repair manual has been prepared with two purposes in
mind. First, it will acquaint the reader with the construction of the
Harley-Davidson product and assist him in performing basic maintenance
and repair. Secondly, it will Introduce to the professional
Harley-Davidson mechanic the latest field-tested and factory-approved
major repair methods. We sincerely believe that this manual will make
your association with Harley-Davidson products more pleasant and
profitable.
HOW TO USE YOUR SERVICE MANUAL
Your Service Manual is arranged for quick, easy reference. This manual
is divided into numbered sections. Sections are then divided into
sub-sections. Use this manual as follows:
1. Check the TABLE OF CONTENTS located in the front of each section to
find subject desired.
2. Page number is listed across from subject. Page number consists of
section number and page number.
3. Information is presented in a definite order as follows:
Adjustments
Disassembly
Cleaning, Inspection and Repair Assembly
In figure legends, the number following a name of a part indicates the
quantity necessary for one complete assembly.
NOTE
All information for servicing a part should be read before repair work
is started to avoid needless disassembly.
PREPARATION FOR SERVICE
Proper preparation is very important for efficient service work. A clean
work area at the start of each job will allow you to perform the repair
as easily and quickly as possible, and reduce the incidence of misplaced
tools and parts. A motorcycle that is excessively dirty should be
cleaned before work starts. Cleaning will occasionally uncover trouble
sources. Tools, instruments and parts needed for the job should be
gathered before work is started. Interrupting a job to locate tools or
parts is a needless delay. Special tools required for a job are listed
at the end of each section.
WARNING
Gasoline is extremely flammable and highly explosive under certain
conditions. Always stop engine, and do not smoke or allow open flame or
sparks when refueling or servicing the fuel system.
SERVICE BULLETINS
In addition to the information given in this Service Manual, Service
Bulletins are issued to Harley-Davidson Dealers from time to time, which
cover interim engineering changes and supplementary information. Service
Bulletins should be consulted for complete information on the models
covered by this manual.
USE GENUINE REPLACEMENT PARTS
WARNING
When replacement parts are required, use only genuine Harley-Davidson
parts or parts with equivalent characteristics including type, strength
and material. Failure to do so may result in product malfunction and
possible injury to the operator and/or passenger.
To ensure a satisfactory and lasting repair job, follow the manual
instructions carefully and use only genuine Harley-Davidson replacement
parts. Behind the emblem bearing the words GENUINE HARLEY-DAVIDSON is
more than half a century of designing, research, manufacturing, testing
and inspecting experience.
This is your insurance that the parts you are using will fit right,
operate properly and last longer. When you use genuine Harley-Davidson
parts, you use the best.
PRODUCT REFERENCES
When reference is made in this manual to a specific brand name product,
tool or instrument, an equivalent product, tool or instrument may be
used in place of the one mentioned.