Carolina Motorcycle Events - Tech Talk

Basic Rider's Maintenance

By Dennis Thurlow

Section "One": Engine

Oil

1. Draining oil - every 5000 miles

  1. Run engine until normal operating temperature is reached (15-20 miles)
  2. Remove oil tank drain plug and allow oil to drain:
    - XL models use "Corbin" clamp and hose
    - Fashion some sort of funnel to direct draining oil away from motorcycle - a piece of down spout or funnel with a hose.
    - Remove dipstick and oil will drain faster.
  3. Install plug - tighten to 14-30 ft-lbs torque.

2. Oil Filter - every oil change

  1. Completely drain engine oil tank before removing filter.
  2. Remove filter using oil filter wrench HD-41215.
  3. Clean filter gasket contact surface on mounting plate.
  4. Apply thin coat of fresh oil to gasket contact surface on mounting plate and to gasket on new filter.
  5. Replace only with Harley-Davidson oil filter - It's the only one with the correct pressure relief valve.
  6. Install new filter by hand 1/2 to 3/4 turn after gasket contact.
    (Dyna-Glide models require 3/4 to 1 full turn after gasket contact.)

3. Filling with oil

  1. Use Genuine Harley-Davidson 20w50 Motorcycle oil. It's specially formulated for your Harley-Davidson engine. (Refer to your owners manual for proper weight to use.)
  2. Fill with recommended amount of oil. Start bike, let run for a few minutes, check for leaks and check oil level on dipstick. Top off if necessary.
  3. Be sure to dispose of used oil and filter properly.

Air filter - every 5000 miles

1. Remove the cover screws and cover.
2. The filter should be inspected and cleaned if necessary.

  1. Remove filter element and wash with luke warm water and mild detergent.
  2. Allow filter to air dry or blow dry, from the inside, with low pressure air. Do not use an air cleaner oil on Harley-Davidson paper/mesh air filter element.
  3. Wipe inside of air filter housing before installing cleaned filter element.

Fuel strainer - every 5000 miles

1. Fuel strainer is located on top of the fuel valve, inside the fuel tank.
2. See your Harley-Davidson dealer for proper service.

Spark Plugs - Check every 5000 miles, replace every 10,000 miles

1. Removal

  1. Grab wire by boot. Don't pull on wires - this may damage the internal conductor.
  2. Clean dirt from around the plug before removal so grit will not fall into cylinder when plug is removed.
  3. Use proper spark plug wrench to remove.

2. Setting gap

  1. Refer to owner's maintenance guide for correct plug number and gap.
  2. Use a wire gauge.

3. Installing spark plugs.

  1. Tighten plugs on Big-Twins to 18 to 22 ft-lbs. torque, on XL models to 11 to 18 ft-lbs. torque - NO TORQUE WRENCH ? - Tighten finger tight then 1/4 turn with spark plug wrench.
  2. Install spark plug wires.

Section "Two": Transmission/Clutch

Primary Drive Chains

1. Adjusting Chain on Big-Twins - every 5000 miles.
Disconnect the battery before adjusting chain to prevent accidental start-up.

  1. Remove inspection cover.
  2. Rotate sprockets so chain is in its tightest spot. (put transmission in high gear and rotate rear wheel)
  3. Loosen center bolt and move shoe assembly up or down.
  4. Slack in top strand of chain should be:
       5/8 to 7/8 inch up-and-down with cold engine.
       3/8 to 5/8 inch up-and-down with hot engine.
  5. Tighten bolt to 25 ft-lbs. torque.
  6. Replace cover installing new gasket for airtight seal.
  7. Further adjustment or alignment of sprockets should be done by dealer.

2. Adjusting chain on XL models every 5000 miles.

  1. Remove primary chain inspection cover.
  2. Rotate sprockets so chain is in its tightest spot. (put transmission in high gear and rotate rear wheel)
  3. Loosen locknut and turn adjusting screw on bottom of chain case to achieve proper free play in top strand of chain.
  4. Free play midway between sprockets should be:
       3/8 to 1/2 inch up-and-down with cold engine.
       1/4 to 3/8 inch up-and-down with hot engine.
  5. Tighten locknut to 20-25 ft-lbs. torque and replace primary chain inspection cover.
  6. Further adjustment or shoe replacement should be done by dealer.

3. Lubrication

  1. Magnetic drain plug in primary case: Remove and clean every 5000 miles.
  2. Big-Twin oil bath on chain and is not adjustable.
  3. XL models use same oil supply as transmission.

Clutch Cable Lubrication

1. Use Harley-Davidson "SUPER OIL", Part No. 94968-85TV every 5000 miles.
2. Oil top end of cable housing, anchor pin and clutch lever pin.
3. Oil these points more often if bike is washed frequently or ridden in dusty conditions.

Clutch Plate Tension Adjustment

This is best performed by the dealer. If clutch drags or slips, have dealer service it.

Transmission Lubrication

1. Use Harley-Davidson "TRANSMISSION LUBRICANT", Part No. 99892-84, in all Big-Twin transmissions.
2. Use Harley-Davidson "SPORT-TRANS FLUID" in all XL transmissions.
3. Check oil level every month or every 5000 miles. Motorcycle must be upright.
4. Change oil every 5000 miles and clean magnetic drain plugs. (May want to have dealer perform this work.)


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