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Harley Davidson Electra Glide. Service manual (1959 to 1969) - page 1

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 entitled "Chassis," "Engine" and 'Transmission." Sections are then divided into sub-sections. The Engine Section, for example, is comprised of "Cylinder" and "Crankcase" 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.

3. Each section is printed with section number for quick general location of subject. Page number consists of section number and sub-section letter and sub-section page number.

4. Information is presented in a definite order as follows:

Minor adjustments Minor maintenance or repair Complete disassembly

Cleaning

Major maintenance or repair Assembly

In figure legends the number following a name of a part indicates the quantity necessary for one complete assembly.

All information or servicing a part should be read before repair work is started to avoid needless disassembly.

USE GENUINE REPLACEMENT PARTS

To insure a satisfactory and lasting repair job, follow the manual instructions carefully and use only genuine Harley-Davidson replacement parts.

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.

TABLE OF CONTENTS

PRODUCT
GENERAL

Specifications 1A-1

Sprocket and Gear Ratios 1A-1

Tire Data 1A-1

SERVICE

Servicing a New Motorcycle Lubrication and Service Lubricants, Engine and Transmission

LOCATING TROUBLES
Engine 1C-1

Generator 1C-2

Carburetor 1C-2

Transmission 1C-2

Clutch 1C-2

Brakes 1C-2
CHASSIS
DRIVE

Chain Adjustment 2B-1

Chain Lubrication 2B-2

Removing and Installing Rear Chain 2B-2A

Removing and Installing Front Chain 2B-2A

WHEELS

Removing Wheels 2C-1

Wheel Hub 2C-3

Replacing Rear Wheel Sprocket 2C-5

Spoking Wheels 2C-5

Truing Wheels 2C-6

Tires 2C-6A

Wheel Alignment 2C-6B
HANDLEBAR

Spark and Throttle Controls 2D-1

FRAME

Basic Dimensions 2E-2

FORKS

Changing Front Fork Oil 2F-1

Disassembling Fork Slider 2F-5

Adjusting Steering Damper 2F-5

Adjusting Front Fork Trail 2F-6

Disassembling Front Fork 2F-6

Steering Head Bearings 2F-7

Replacing Front Fork Slider Bushings 2F-7

Straightening Front Fork 2F-8

Rear Shock Absorbers 2F-1I

Rear Fork 2F-14
BRAKES

Adjusting Front Brake 2G-1

Disassembling Brakes 2G-1

Adjusting Rear Brakes 2G-3

Rear Brake Master Cylinder 2G-3

SEAT

Seat Post 2H-X
Revised: 5-68

FIBERGLASS

Surface Finishing Touch-up and Surface Repairs Patching Holes, Punctures and Breaks

TOOLS

Tools

ENGINE

GENERAL

Engine Specifications Engine Description Lubrication Servicing Oil Filter Engine Oiling and Breather System Engine Repair Procedure Stripping*Motorcycle for Engine Repair

CYLINDER HEAD

Removing Cylinder Head Replacing Valve Guides Replacing Valve Seats Grinding Valves Lapping Valves Assembling Cylinder Head Adjusting Tappets

CYLINDER

Disassembling Cylinder and Piston Refinishing Cylinder Fitting Piston Rings Connecting Rod Bushing Straightening Connecting Rods

Assembling Cylinder and Piston

GEARCASE Oil Pump

Valve Tappets and Guides Disassembling Timing ^ Gears

Replacing Cover Bushings

CRANKCASE

Disassembling Crankcase Disassembling Flywheels Lapping Connecting Rods Fitting Rod Bearing Races Assembling Flywheels Lapping Engine Main Bearing Fitting Pinion Shaft Bearings Fitting Sprocket Bearing Assembling Crankcase

FUEL SYSTEM

Model HD Carburetor Model M Carburetor Model DC Carburetor Model MD Carburetor Fuel Strainer Air Cleaner Fuel Tank Fuel Supply Valve
 

STARTER MOTOR
Locating Troubles Removing Starter Motor and Drive Delco-Remy Starter Motor Service Presto Lite Starter Motor Service

TOOLS

Tools

MISCELLANEOUS

INSTRUMENTS

Servicing Tachometer

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