E-Book Content
Harley-Davidson SERVICE MANUAL Sportster Part
No. 99484.68
T h e maintenance and repair information in t h i s manual applies PO t h e and K-KH modeis
1959
to
1969
Harley-Bavidson
Sporis~er
COPYRIGHT 1968 BY HARLEY-DAVIDSON MOTOR CO., INC, ALL RIGHTS RESERVED
Pr~ntedIn U.S.A on Recycled Paper
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 prof itable.
HOW TO USE YOUR SERVICE MANUAL Your Service is arranged for quick, easy reference. This manual is divided into numbered seetions. Sections are then divided into sub-sections. Use this manual as follows:
WARNING
Gasollne is extremely fsammable and highly explosive under certain conditions. Always stop engine, and do smoke or open flame or sparks whew refueling sewicing the system.
.,
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 fo 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. Pools, 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.
SERVICE BULLE"B$NS In addition to the information given in this Service Manual, Service Bulletins are issued 'to Harley-Bavidson 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
Whew replacement parts are required, use only genuine Harley-Devidson parts or parts with equivalent characteristics including type, strength and materiel. Failure to do so may result in product malfunction end possible injuv to the operator andlor passenger. To ensure a satisfactory and lasting repair job, follow the manual instructions carefully and use only genuine Harley-Bavidson replacement parts. Behind the emblem bearing the words GENUINE HARLEY-DAVlDSON 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 instnament may be used in place of the one mentioned.
CONTENTS All photographs and illustrations may not necess