Index Harley Davidson Harley Davidson Panhead. Service manual (1948-1957 Rigid)

Harley Davidson Panhead. Service manual (1948-1957 Rigid) - page 1

тhis Service Manual is dedicated to attaining for Harley-Davidson motorcycle owners the highest degree of performance and satisfaction.

Except when a particular model or year model is indicated, the information in this manual applies to O.H.V. Twin Models back to 1948.

This Service Manual is dedicated to attaining for Harley-Davidson motorcycle owners the highest degree of performance and satisfaction.

Except when a particular model or year model is indicated, the information in this manual applies to O.H.V. Twin Models back to 1948.

Product
General Specifications 1948-1954.. 4

General Specifications 1955-1957.. 6

Lubrication Chart ..............................8

Signal Lights ......................................9

Starting Engine ..................................9

Stopping Engine ................................9

Running in New Engine ....................9

High Speed Tips ................................10

Trouble Shooting Charts....................10

engine ..............................................10

generator ........................................11

carburetor ........................................11

transmission ....................................11

brakes ..............................................12

General Lubrication ..........................12

Lubrication Chart ..............................13

Servicing Air Cleaner ........................14

Initial Servicing of New Motorcycle. 14

first 250 miles ............... 14

first 750 miles ............... 14

first 1500 miles ..............................15

Regular Interval Inspection &

Maintenance ................................15

Care & Lubrication of Drive Chain. 16

adjusting drive chain ....................16

adjusting front chain........... 16

adjusting rear chain ........... 16

lubrication front chain....................16

lubrication rear chain ....................17

repairing drive chain......................17

Clutch & gear shifter ........................18

Compensating sprocket (early style). 18

Chassis

Wheels ........................ 20

general ...................... 20

removal ...................... 20

removal (side car) ............. 21

servicing wheel hubs .......... 22

replacing rear wheel sprocket ... 23

spoking wheels ............... 23

truing wheels ................. 24

removing & installing tires...... 25

Shop Data

wheels ....................... 26

Servicing Handlebar Controls ..... 28

early model .................. 28

late model ................... 29

Removing & Installing Forks...... 29

springers ..................... 31

Fork Frame & Handlebar Alignment. 34 rough check for fork alignment... 34

rough check for frame alignment. 34

frame alignment diagram....... 35

springer shock................ 36

Glide Forks..................... 37

general ...................... 37

changing oil .................. 37

glide fork diagram ............ 39

glide fork diagram (adjustable) .. 40 disassembling fork sliders & tubes 41

adjusting steering damper...... 41

adjusting fork trail (adjustable)... 42

disassembling front fork........ 42

steering head bearings......... 43

replacing slider bushings....... 43

inspecting & servicing fork..... 44

straightening fork tubes ........ 44

straightening fork stem & bracket

assembly ................... 45

assembling fork ............... 46

assembling fork (adjustable) .... 47

Brakes......................... 48

disassemble front brake (glide) .. 48 inspection & servicing (glide) ... 48 assembling front brake (glide) ... 48 adjusting front brake cable (glide) 48 adjusting front brake shoes (glide) 48

glide brake diagram ........... 49

springer brake diagram ........ 49

rear brake diagram ............ 50

adjusting rear & springer brakes. 51 servicing rear & springer brakes. 51

Servicing Saddle Spring Post..... 52

Engines

general ...................... 54

engine diagram ............... 55

lubrication ................... 56

winter lubrication .............. 57

changing oil .................. 57

oil pressure signallight......... 57

operating oil pressure.......... 57

oil filter ...................... 57

pressure oil system............ 58

return oil system .............. 59

engine repair procedure........ 59

pressure oil system diagram .... 61

return oil system (early)........ 62

return oil system (late) ......... 63

disassembling cylinder & piston.. 64

refinishing cylinders ........... 65

fitting piston rings ............. 66

connecting rod bushings ....... 67

straightening connecting rods ... 68 assembling cylinder & piston ... 69

Shop Data

cylinder reboring & piston fitting.. 70 pistons & rocker arms.......... 72

removing cylinder head assembly. 73

disassembling cylinder head----73

replacing valve guides......... 73

cylinder head diagram ......... 74

replacing valve seats .......... 75

grinding valve faces & seats .... 75

lapping valve faces & seats..... 76

assembling cylinder head....... 76

adjusting tappets.............. 76

Shop Data

valve guides.................. 77

installing high lift cam ......... 78

intake valve guides ............ 79

valve guide sizes.............. 80

exhaust valve rotating mechanism 81 valve spring testing information.. 82

FLH valve springs ............. 83

hydraulic pushrods ............ 84

adjusting hydraulic pushrods .... 85 servicing hydraulic pushrods .... 86 tappet check valve servicing .... 88 misc. clearances & oil pressure.. 89

Oil Pump....................... 90

servicing oil pump............. 90

installing oil pump............. 91

Shop Data

oil control .................... 92

oil pump charges.............. 94

late oil pump ................. 96

oil pump flow diagram......... 97

1948-1954 Lower End Diagram..... 98

Disassembling Lower End ........ 99

installing timing gears .........100

installing timing gear case cover. 100 1948-1954 gear & crankcase data

procedures .................100

truing & sizing main bearing

races ......................101

fitting main bearings...........102

servicing flywheels & installing

crankpan ...................102

truing & sizing connecting rod

lower races ................102

determining correct lower

bearing fit..................103

assembling connecting rods &

flywheels ...................103

truing flywheels ...............104

assembling crankcases.........105

installing generator ............106

Shop Data

removing & replacing pinion

shaft gear ..................1P7

crankcase drilling procedures ...109

connecting rod roller & retainer

size chart ..................111

engine fitting specifications.....112

servicing pinion shaft rollers ... .113

pinion shaft assembly diagram.. .114

1955-1957 oil pump diagram ....115

1953-1957 Valve Tappets & Guides.. 116

1954-1957 Gear Case Diagram ____118

1954-1957 Gear Case Timing Cases. 119

1955-1957 Crankcase ............122

1955-1957 Complete Lower End
Shop Data
engine fitting data ’55 & later____131

roller bearing roller guides......132

identification of roller retainers. .134
Adjusting Carburetor ............136

disassembling carburetor.......136

carburetor diagram ............137

cleaning & repairing carburetor.. 138

assembling carburetor .........139

air cleaner ...................139

fuel strainer ..................140

fuel tanks ....................140
Shop
servicing notes for carburetor.. .141 specification chart for carburetor. 142

float bowl ....................143

adjusting carburetor on engine ..144

carburetor conversions.........145

manifold .....................146

carburetor specifications........147

general ......................148

clutch general ................151

adjusting foot clutch control----151

adjusting hand clutch control ...151

adjusting clutch ...............152

disassembling clutch ..........152

cleaning & inspecting clutch ....153

assembling clutch .............154

disassembling starter ..........155

cleaning & inspecting starter ... .155

assembling starter.............155

disassembling starter clutch .... .155 cleaning & inspecting starter

clutch .....................155

assembling starter clutch ...... .156

starter diagram ...............156

adjusting shifting linkage .......157

adjusting foot shifter cover.....157

replacing main drive gear oil

seal .......................157

removing shifter cover .........158

disassembling shifter cover.....159

cleaning & inspection shifter

cover ......................159

assembling shifter cover........159

shifter cover diagram

(footshift) ..................160

replacing shifter cover..........162

removing shifter forks..........162

disassembling shifter forks......162

cleaning & inspection shifter

forks ....*..................162

assembling shifter forks........163

disassembling gear box........163

counter shaft assembly diagram. .164

disassembling mainshaft .......165

disassembling main drive gear... 166

assembling main drive gear.....167

assembling main shaft .........167

assembling counter shaft.......167

transmission vent screw........168

Electrical

wiring diagram for 1948 model . .170

wiring diagram for 1949-54 .....171

wiring diagram for 1955-57

(standard) .................172

wiring diagram for 1955-57

(radio special)..............173

Ignition Light Switch.............176

Button Switch ..................177

Headlamp Dimmer & Horn Switch.. 177
Data

Headlamps .....................178

3 Brush 32E Generator Diagram.. .179 radio 2 brush generator diagram. 181 trouble shooting & repairing

generator ..................183

removing generator............184

testing field colls & brush holders

assembled..................184

disassembling generator........186

testing armature ..............188

turning down commutator......189

undercutting commutator.......189

reassembling generator ........189

assembling generator to engine.. 190

generator charging rate........190

replacing generator brushes____190

cleaning commutator ..........190

lubricating commutator end

armature bearing ............191

cut out relay .................191

generator brush diagram.......192

current & voltage regulator.....193

fan cooled generator ..........194

fan cooled generator diagram .. .195

Shop Data

fan cooled generator ..........198

model 32E 2R radio generator

diagram ....................199

model 48 3 brush fan cooled

generator diagram ..........200

model 48 2 brush fan cooled

generator diagram ..........201

model 51 *52 & later 2 brush fan

cooled generator diagram____202

model 32E standard 3 brush

generator diagram ..........203

model 52 standard 3 brush generator diagram ..........204

Circuit Breaker Description .......205

single contact point manual

advance ...................205

double contact point manual

advance ...................205

adjusting circuit breaker points..206 checking & adjusting ignition

timing .....................206

circuit breaker diagram ........208

removing circuit breaker .......210

inspection & replacement of

parts circuit breaker.........210

Ignition Coil ....................212

Spark Plugs ....................213

Shop Data

regulator service information____215

Battery.........................217

Horn ...........................218

Miscellaneous

removing side car from

motorcycle .................222

attaching side car to

motorcycle .................222

side car wiring digram.........222
Servicing Speedometer ..........223

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