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This Harley Davidson HD motorcycle service manual describes the service procedures for the complete bike. Follow the Maintenance Schedule recommendations to ensure that the chopper is in peak operating condition. Performing the scheduled maintenance is very important. It compensates for the initial wear that occurs during the life of the Harley Davidson HD motorcycle.
All chapters in this service manual applies to the whole motorcycle and illustrates procedures for removal & installation of components that are in detailed step-by-step fashion.
Chapters start with an assembly or system illustration, diagrams, exploded parts view, quality pictures, service information and troubleshooting for the section. The subsequent pages give detailed procedures. If you don’t know the source of the trouble, go to the troubleshooting page for a list of causes and effects to determine the problem.

CLEANING AND INSPECTION
1WARNING
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
1. See Figure 7-5. Clean all parts except bearings (2) with
solvent. Blow parts dry with low pressure compressed
air.
2. Inspect bearings (2) and shifter cam ends. If ends of
shifter cam are pitted or grooved, replace the shifter cam
and bearings. Install new bearings in support blocks by
pressing on the side of the bearing with letters stamped
on it. Stamped side of bearing should face outward when
support block is installed on cam.
3. Inspect shifter cam (4) for cracks or wear and replace if
necessary.
4. Inspect neutral indicator switch in top cover. Depress
plunger. It should spring back without binding. The switch
is a non-repairable item and must be replaced if damaged.
1. Assemble shifter cam components if necessary.
a. See Figure 7-5. Place a bearing (2) inside left support
block (5) by pressing on the side of the bearing
with letters stamped on it. This side should face out.
NOTE
See Figure 7-6. When installing new retaining ring verify the
tab is on the right side and opening is towards bottom when
you are looking at the end of the shifter drum.
b. See Figure 7-5. Secure bearing by installing a new
retaining ring (1) with the beveled side facing out.
Place assembly on shifter cam and install a new
small retaining ring (6).
c. Place a bearing (2) inside right support block by
pressing on the side of the bearing with letters
stamped on it. This side should face out. Secure
bearing by installing a new retaining ring (1) with the
beveled side facing out. Slip right support block (3)
over shifter cam (4).
d. See Figure 7-7. Slide spring sleeve (1) inside the
spring (2). Place follower (4) under sleeve and use
pivot screw (3) to attach assembly to right support
block. Tighten to 84-108 in-lbs (9.5-12.2 Nm).

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