Description
This 165 page, 1940 1941 1942 1943 1944 1945 1946 1947 Harley Davidson Big Twins Service Manual is a reprint of the original, out of print, service manual. This manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1940-1947 Harley-Davidson Big Twin motorcycles. This Service Manual is dedicated to attaining for Harley-Davidson :motorcycle owners the highest degree of perfor:m ance and satisfaction. Except when a particular :model or year :model is indicated, the infor:mation in this :manual applies to both, O.H.V. and Side Valve Models, 1940 to 1947, and in a general way to Big Twin Models back to 1937.
Table of Contents
Troubleshooting Chart
Initial Servicing of New Motorcycle
Engine Lubrication
Engine Overhaul
Electrical System
Servicing Carburetor
Transmission and Clutch
Wheels, Hubs and Tires
Fork, Frame and Handle·bars
Sidecar
Detailed Index
Air Cleaner Assembly Illustration
Air Cleaner, (Mesh Pack Type)
Air Cleaner, (Oil Bath Type)
Alignment, Fork, Frame and Handlebar
Aligning, Gas Shut-off Valve Fittings
Battery, Care of
Bearings, Engine Main
Bearings, Connecting Rod Lower
Brake, Front Wheel, Assembly Illustration
Brake, Rear Wheel, Assembly Illustration,
Brake, Front and Rear Wheel Assembled,illustration
Brakes, Adjusting
Brakes, Servicing
Breather Valve, Timing (Side Valve Engine)
Bushings, Connecting Rod Upper
Bushings, Cam Gear Shaft
OHV Engine
Side Valve Engine
Carburetor, Adjusting
Carburetor, Servicing
Chains, Adjusting
Chains, Lubricating
Chains, Repairing
Circuit Breaker Assembly Illustrations
Circuit Breaker, Removing
OHV Engine
Side Valve Engine
Circuit Breaker
Circuit Breaker, Servicing
Circuit Breaker, Installation and Timing Ignition
Clutch Assembly
Clutch, Spring Tension, Adjusting
Clutch, Disassembling
Clutch, Reassembling
Clutch Control, Checking and Adjusting
Clutch Hub, Removing
Clutch, Installing
Commutator, Cleaning
Connecting Rods, Aligning
Control Cable, Front Brake, Replacing
Control Wire, Throttle and Spark, Replacing
Crankcases, Assembling
Cylinders, Reboring and Rehoning
Cylinder Head Assembly Illustration
(ohv engine—rear head)
Cylinder Heads, Servicing (OHV Engine) Cylinders, Installing
OHV Engine
Side Valve Engine
Cylinder Heads Installing
OHV Engine
Side Valve Engine
Electrical System
Engine Overhauling
Engine, Disassembling for Top Overhaul Only
OHV Engine
Side Valve Engine
Engine, Removing (Assembled)
Engine, Disassembling for Complete Overhaul
OHV Engine
Side Valve Engine
Engine, Fitting and Reassembling
Engine, Installing
Engine, Starting
Engine, To Stop
Engine, Running in New
Engine Serial Number
Flutter Valve, Servicing (Side Valve Engine) Flywheels, Servicing and Installing Crank Pin
Flywheels, Assembling
Flywheels, Truing
Forks, Removing and Installing
Gear Ratios, Standard
Gear Shifter Control, Checking and Adjusting
Generator Assembly Illustrations
Generator, Removing
Generator, Testing
Generator, Disassembling
Generator, Reassembling
Generator, Installing 6
Generator Charging Rate
Handlebar Controls, Servicing
Handlebars, Straightening
Handlebar Grip Assembly Illustration
Headlamp, Adjusting
High Speed Tips
Horn
Ignition Coil
Ignition Timing—by Piston Position
Lamp Bulbs
Legend for ohv engine oiling and breather
system
Lubrication, Commutator End Armature Bearing
Lubricants—Types to Use
Lubrication Chart
Lubrication, Engine
Lubrication, General
Lubrication, Transmission
Maintenance, Regular Interval Inspection Motorcycle—Initial Servicing
Oil Pump, Removing (OHV Engine)
Oil Pump, Servicing (OHV Engine)
Oil Pump, Installing (OHV Engine)
Oil Feed Pump, Removing (Side Valve Engine) Oil Feed Pump, Servicing (Side Valve Engine) Oil Feed Pump, Installing (Side Valve Engine) Oil Scavenger Pump, Removing (side valveengine)
Oil Scavenger Pump, Servicing (side valve engine)
Oil Scavenger Pump, Installing (side valve engine)
Oil Feed Pump, Adjusting
Oil Pump Assembly Illustration (OHV Engine)
Oil Feed Pump and Scavenger Pump Assembly illustration (side valve engine)
Piston Rings
Pistons, Fitting Oversize
Pistons, Removing and Installing
Piston and Ring Service
Push Rod Cover Assembly Illustration
Push Rod Cover Cork Washers, Installing
Regulator, Current and Voltage
Relay, Cut-Out
Ride Control Assembly Illustration
Saddle Spring Post Assembly Illustration
Saddle Spring Post, Servicing
Shock Absorber Assembly Illustration
Sidecar
Signal Lights, Instrument Panel
Spark Plugs
Spark Plug Cables, Replacing
Specifications, Carburetor
Specifications, General
Specifications, Engine
Specifications, Transmission
Speedometer- Head and Drive Core, Removing and Installing
Steering Damper
Switch, Ignition-Light, Servicing
Switch, Ignition-Light, Assembly Illustration
Tank Capacities, Gasoline and Oil
Timing Gears, Installing
OHV Engine
Side Valve Engine
Timing Mark, Flywheel
OHV Engine
Side Valve Engine
Tire Inflation Pressures
Tires and Tubes, Removing and Installing
Transmission and- Clutch, Overhauling
Transmission Assembly Illustrations
Transmission, Removing
Transmission, Disassembling
Transmission, Assembling
Transmission, Installing
Trouble Chart
Valve Guides
OHV Engine
Side Valve Engine
Valves
Valve Seats
Valve and Valve Seats, Grinding and Testing
Valves, Installing
Valve Springs
Valve Tappets, Adjusting
OHV Engine
Side Valve Engine
Valve Tappets and Valve Tappet Guides
Wheel Hub Assembly Illustrations
Wheels, Removing and Installing
Wheel, Spoking
Wheel, Truing
Wheels, Hubs and Tires
Wheel and Tire Care
Wiring Diagram: Without current and voltage regulator—1946 and earlier models
Wiring Diagram: With current and voltage regulator—1946 and earlier models
Wiring Diagram: Generator-battery; ignition; horn; generator and oiling system signal lights and stop lamp—1947 models
Wiring Diagram: Lighting system and horn— 1947 models
Wiring Diagram: Lighting system accessory lamps (except police pursuit lamps—1947 models
Wiring Diagram: Generator—current and voltage regulator—battery; speedometer hand lock; police pursuit lamps and radio type coil—1947 models
Wiring Diagram: 1940 to early 1947 model sidecar
Wiring Diagram: Later 1947 Model Sidecar
O.H.V. Engine Models
61 Cu. In. (1000 c.c.)
74 Cu. In. (1200 c.c.)
Side Valve Engine Models
74 Cu. In. (1200 c.c.)
1940-1947 OHV 61 Cubic Inch (1000cc), 74 Cubic Inch (1200cc) engines, Side Valve 74 Cubic Inch (1200cc) engines and 80 Cubic Inch (1300cc) engines found in 1940 Harley-Davidson Model ULH 80 SV (1312cc), 1940 Harley-Davidson Model UL 74 SV (1214cc), 1940 Harley-Davidson Model UH 80 SV (1312cc), 1940 Harley-Davidson Model UA US Army 74 SV (1214cc), 1940 Harley-Davidson Model U 74 SV (1214cc), 1940 Harley-Davidson ES Knucklehead Sidecar 61ci 1000cc, 1940 Harley-Davidson EL Knucklehead Special Sport Solo 61ci 1000cc, 1941 Harley-Davidson Model ULH 80 SV (1312cc), 1941 Harley-Davidson Model UL 74 SV (1214cc), 1941 Harley-Davidson Model UH 80 SV (1312cc), 1941 Harley-Davidson Model U 74 SV (1214cc), 1941 Harley-Davidson FS Knucklehead Sidecar 74ci 1214cc, 1941 Harley-Davidson FL Knucklehead Special Sport Solo 74ci 1214cc, 1941 Harley-Davidson ES Knucklehead Sidecar 61ci 1000cc, 1941 Harley-Davidson EL Knucklehead Special Sport Solo 61ci 1000cc, 1942 Harley-Davidson Model UL 74 SV (1214cc), 1942 Harley-Davidson Model U 74 SV (1214cc), 1942 Harley-Davidson FL Knucklehead Special Sport Solo 74ci 1214cc, 1942 Harley-Davidson F Knucklehead Solo 74ci 1214cc, 1942 Harley-Davidson EL Knucklehead Special Sport Solo 61ci 1000cc, 1942 Harley-Davidson E Knucklehead Solo 61ci 1000cc, 1943 Harley-Davidson Model UL 74 SV (1214cc), 1943 Harley-Davidson Model U 74 SV (1214cc), 1943 Harley-Davidson FL Knucklehead Special Sport Solo 74ci 1214cc, 1943 Harley-Davidson F Knucklehead Solo 74ci 1214cc, 1943 Harley-Davidson EL Knucklehead Special Sport Solo 61ci 1000cc, 1943 Harley-Davidson E Knucklehead Solo 61ci 1000cc, 1944 Harley-Davidson Model UL 74 SV (1214cc), 1944 Harley-Davidson Model U 74 SV (1214cc), 1944 Harley-Davidson FL Knucklehead Special Sport Solo 74ci 1214cc, 1944 Harley-Davidson F Knucklehead Solo 74ci 1214cc, 1944 Harley-Davidson EL Knucklehead Special Sport Solo 61ci 1000cc, 1944 Harley-Davidson E Knucklehead Solo 61ci 1000cc, 1945 Harley-Davidson Model UL 74 SV (1214cc), 1945 Harley-Davidson Model U 74 SV (1214cc), 1945 Harley-Davidson FS Knucklehead Sidecar 74ci 1214cc, 1945 Harley-Davidson FL Knucklehead Special Sport Solo 74ci 1214cc, 1945 Harley-Davidson F Knucklehead Solo 74ci 1214cc, 1945 Harley-Davidson ES Knucklehead Sidecar 61ci 1000cc, 1945 Harley-Davidson EL Knucklehead Special Sport Solo 61ci 1000cc, 1945 Harley-Davidson E Knucklehead Solo 61ci 1000cc, 1946 Harley-Davidson Model UL 74 SV (1214cc), 1946 Harley-Davidson Model U 74 SV (1214cc), 1946 Harley-Davidson FS Knucklehead Sidecar 74ci 1214cc, 1946 Harley-Davidson FL Knucklehead Special Sport Solo 74ci 1214cc, 1946 Harley-Davidson F Knucklehead Solo 74ci 1214cc, 1946 Harley-Davidson ES Knucklehead Sidecar 61ci 1000cc, 1946 Harley-Davidson EL Knucklehead Special Sport Solo 61ci 1000cc, 1946 Harley-Davidson E Knucklehead Solo 61ci 1000cc, 1947 Harley-Davidson Model UL 74 SV (1214cc), 1947 Harley-Davidson Model U 74 SV (1214cc), 1947 Harley-Davidson FS Knucklehead Sidecar 74ci 1214cc, 1947 Harley-Davidson FL Knucklehead Special Sport Solo 74ci 1214cc, 1947 Harley-Davidson F Knucklehead Solo 74ci 1214cc , 1947 Harley-Davidson ES Knucklehead Sidecar 61ci 1000cc, 1947 Harley-Davidson EL Knucklehead Special Sport Solo 61ci 1000cc and 1947 Harley-Davidson E Knucklehead Solo 61ci 1000cc.
