1970-1978 HARLEY DAVIDSON XL XLH XLCH XLT SERVICE MANUAL – PDF DOWNLOAD
VIDEO PREVIEW:
IMAGE PREVIEW:
DESCRIPTION:
1970-1978 HARLEY DAVIDSON XL XLH XLCH XLT SERVICE MANUAL – PDF DOWNLOAD
- 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.
TABLE OF CONTENTS:
1970-1978 HARLEY DAVIDSON XL XLH XLCH XLT SERVICE MANUAL – PDF DOWNLOAD
SPECIFICATIONS Drum
Type 2-18 Disassembling and CYLINDER HEAD Dimensions 1
. 1 Assembling 2-18 Removing 3-11
Capacities 1. 1 Disassembling 3-11
Engine 1 . 1 FRAME 2-19 Cleaning and Inspecting 3-11
Transmission 1. 1 FORKS Repair Rocker Arm
Tire Data 1. 1 Front Fork 2-21 and Bushings 3-13
SERVICE Servicing 2-21 Refacing Valves and
Servicing a New Motorcycle 1-3 Disassembling and Repair 2-24 Valve Seats 3-13
Recommended Operations at Assembly 30 Assembling Cylinder Head 3-14
First 500 and 1,000 Miles 1-3 Rear Shock Absorber 2-31 Adjusting Tappets 15
Regular Service Intervals 1-4 Rear Fork 2-32 Removing and Installing
Lubricants 1-5 BRAKES Push Rods Only 3-15
TORQUE REQUIREMENTS Servicing 2-35 CYLINDER AND PISTON
Fastener Tightening 1-13 Adjusting Front Wheel Removing 3-17
Brake 2-35 Cleaning and Inspecting 3-17
LOCATING TROUBLES Adjusting Rear Wheel Refinishing Cylinders 3-17
Engine 1-15 Brake 2-35 Fitting Piston Rings 3-19
Lubrication System 1-16 Replacing Front Wheel Connecting Rod Bushing 3-20
Electrical System 1-16 Brake Cable 2-36 Straightening Connecting
Carburetor 1-16 Disassembling Brakes 2-36 Rods 3-20
Transmission 1-16 Inspecting and Repairing Assembling Cylinder
Clutch 1-16 Brakes 2-36 and Piston 3-21
)” 1-17 Assembling Brakes 37 GEARCASE
ASSIS Cross Shaft 2-37 Oil Pump 3-23
Rear Brake Foot Pedal Check Valve 3-23
DRIVE (1977 & Later) 2-3’8 Cleaning and Inspecting
Front Chain 2-1 Front Disc Brake Oil Pump 3-24
Adjustment 2-1 (1973 & Later) 2-40 Assembling Oil Pump 3-25
Lubrication 2-2 Check List 2-41 Disassembling Oil Pump 3-25
Replacing 2-2 1973 Front Disc Brake 2 -42 Valve Tappets and
Rear Chain 2-2 Disassembling and Guides 3 -28
Adjustment 2-2 Reassembling 2-42 Gearcase Cover and
Rear Chain Oiler 2-2 1974 and Later Front Timing Gears 3-30
Servicing Rear Chain 2-3 Disc Brake 2-43 Disassembling 3-30
WHEELS Front Brake Master Cleaning and Inspecting 3-31 Service Chart 2-5 Cylinder 2 -45 Bearing Replacement 3-31 Removing and Installing Bleeding Hydraulic Assembling 3-32 Wheels 2-5 System 2-46 CRANKCASE
Hubs 2-7 FIBERGLASS BODY CARE General 3-35
Sp[()cket Replacement 2-10 AND REPAIR Disassembling Crankcase 3-35
Spoking Wheels 2-11 General 2-47 Flywheels 3-37
Truing Wheels 2-13 Surface Finishing 2-47 Assembling Crankcase 3-42
Truing Rim 2-13 Molded-in-Color Surface
Removing Tire and Repairs 2-48 FUEL SYSTEM
Tube from Rim 2-14 Patching of Holes, Carburetor (Tillotson) 3-45
Mounting Tire and Pum:.tures and Breaks 2-49 Description 3-45
Tube on Rim 2-T4 TOOLS 2-53 Operation 3-45
Checking Tire Trueness .
5 Adjusting 3-48
Alipriing Wheels ., 6 ENGINE Inspecting and Testing 3-49
)DLEBAR THROTTLE,
I’ Disassembling 3-51
GENERAL Cleaning, Inspecting,
NTROL • Specifications 3-1 and Repairing 3-51
Spiral Type 2-17 Description 3-1 Assembling 3-53 Disassembling Lubrication r 2 Troubleshooting Guide 3-53
TABLE OF CONTENTS (cont’d)
Page Page Page
Number Number Number
Carburetor (Bendix) 3-54 1970 Clutch 4-8 SWITCHES
Operation 3-54 Disassembling 4-8 Sutton 5-17
Adjusting 3-55 Inspecting and Repairing 4-8 Solenoid Switch 5-18
Disassembling 3-56 Replacing Clutch Sprocket Stop Lamp Front
Cleaning and Inspection 3-56 Needle Bearing and Brake Switch 5-18
Assembling 3-58 Starter Clutch 4-9
Carburetor (Keihin) 3-58 Assembling Clutch 4 -9 Starter Relay Switch 5-19
Operation 3-58 1971 and Later Clutch 4-11 LAMPS
Adjusting 3-61 Disassembling 4-11 Headlamp 5-21
Disassembling 3-61 lnsμecting and Repairing 4-11 Adjusting Beam 5-21
Cleaning and Inspecting 3-62 Assembling Clutch 4-14 Bulb Chart 5-21
Assembling 3-62 Compensating Sprocket 4-15
GENERATOR
Installing 3-62
Checking, Testing and
Troubleshooting Chart 3-64 KICK STARTER
Air Cleaner 3-66 General 4-17 Repair 5-23
Fuel Tank 3-66 Disassembling 4-17 Brushes 5-23
Fuel Supply Valve 3-66 Inspecting and Repair 4-18 Field Coils 5-23
Assembling 4-18 Armature 5-25
TOOLS 3-69 Commutator 5-26
ELECTRIC STARTER Disassembling 5-27
TRANSMISSION Starter Drive 4-21 Assembling 5-28
Disassembling Solenoid 4 -21
GENERAL Disassembling Starter CIRCUIT BREAKER Specifications 4-1 Drive Shaft and Housing 4-22 Description 5-29 Description 4-1 Assembling Starter and Operation 5-29
CLUTCH Solenoid 4-22 Troubleshooting 5-29
Diagnosis Chart 4-3 TRANSMISSION Adjusting Points 5-29
1970 Clutch Controls 4-3 General 4-23 Ignition Timing 5-30
Adjusting Clutch Release 1975 and 1976 Shifter Disassembling and
‘ Mechanism 4-3 Assembling 5-31 Linkage 4-23
Adjusting Clutch Spring Removing Transmission 4-24 Installing Circuit
Tension 4-3 Inspecting and Replacing Breaker 5-33
Replacing Clutch Control Parts 4-25 Disassembling and As-
Cable and Coil 4 -4 Assembling Transmission 4-28 sembling 1971 & Later
Disassembling Clutch Lubrication 4-30 Models 5-33
Release Mechanism 4 -4
Inspecting Clutch Release TOOLS 4-31
IGNITION COIL
Mechanism 4-5
Troubleshooting 5-37
Assembling Clutch ELECTRICAL Replacing Cables 5-37 Release Mechanism 4-5
1971 and Later Clutch WIRING
SPARK PLUGS
Controls 4-6 Wiring Diagrams
Removing Plugs 5-39 Adjusting Clutch Release 1970-71 XLH 5-3 Cleaning, Inspecting and
Mechanism 4-6 1970-71 XLCH 5-5
Repair 5-39
Adjusting Clutch Spring 1 972 XLH Std. Seat 5-5
Setting Spark Gap 5-40
Tension 4-6 1972 XLCH Std. Seat 5-6
Testing Spark Plugs 5-40
Disassembling Clutch 1 972 XLH Low Seat 5-7
Installing Spark Plugs 5-40
Release Mechanism 1 972 XLCH Low Seat 5-7
and Clutch Cable 4-6 1973-74 XL 5-9 REGULATORInspecting
and Repairing 1973-74 XLCH 5-9 1977 & EARLIER
Clutch Release 1975 & 1976 XL 5-11 Tests 5-41
Mechanism and Clutch 1975 & 1976 XLCH 5-11 Test Specifications 5-41
Cable 4-6 1977 XL 5-13 Testing Method I
Assembling Clutch 1977 XLCH 5-13 (Model XLH) 5-42
Release Mechanism 1978 XL 5-15 Testing Method I
and Clutch Cable 4-8 1978 XLCH 5-15 (Model XLCH) 5-43
TABLE OF CONTENTS (cont’d)
) Page Page
Number Number
Testing Method II Testing 5.53 Starter Motors
(Model XLH) 5-44 Charging 5-54
Testing Method II
(Model XLCH) 5-45 HORN 5-55
TOOLS
Servicing 5-47 MISCELLANEOUS
REGULATOR – 1978 STARTER MOTOR
General 5-49 Troubleshooting 5-57 INSTRUMENTS
Checking Charging System 5-49 Starter Motor and Drive 5-57 Speedometer
Prestolite Starter Motor 5-58 Tachometer
BATTERY Hitachi Starter Motor 5-58
Care 5-53 Prestolite and Hitachi
Page
Number
5-60
5-61
6-1
6-1
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
- So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com