Harley-Davidson 250 & 350

HARLEY -DAVIDSON AMF/HARLEY·DAVIDSON MOTOR CO.

Milwaukee, Wisconsin

250 AND 350 CC SPRINT

MODEL Displacemenf.-.cc . . . . . . . . . . . . . . . . • . . . Bore--mm , . . . . . , . . . . . . , . . . . . . • . . . . . Stroke-mm , . . . . . . . . . . . . . . . • • . . • • • Ignition-

Spark pi ug-type ................. . E lectrode gap-rom ............. .

Inch ......................... . Point gap--mm , . . . . . . . . . . . . • . . . . . ,

In� ........................... . Valve clearance (cold)

Intak&-mm ...................... . Inch ........................... .

Exhaust-mm .................... . In� ........................... .

Electrical system voltage . . . . . . . . . . . • . Battery tenninal grounded ........... . Tire s�front ..................... .

Rear . . . . . . . . . . . . . . . . . . . . . . . • • . . . , _ Tire pressure---

Sprint "C" 246.2

66 72

0.5·0.6 0.020·0.025

0.46 0.018

0.1 0.004

0.1 0.004

6 Negative

3.00·17 3.00·17

Sprint uB" Priorto 1967

246.2 66 72

Sprmt"H" Sprint "SSIt

1967·196S 248.4

72 61

H-D 5-6 or A utalite AG901 0.5·0.6 0.5·0.6

0.020-0.025 0.020·0.025 0.46 0.46

0.018 0.018

0.08 0.003 0.13

0.005 6

Negative 3.00·18 3.50-1S

0.5 0.002

0.5 0.002

6 Negative 3.25-191 3.50-18

MOTORCYCLE

Sprint "SS" & nsx"

After 1965 344 74 Sl

0.5·0.6 0.020-0.025

* *

0.5 0.002

0.8 0.003 12#

Negative 3.25-19*-3.50-18**

Front-kg/em' . . . . . . . . . . . . ... . . . . . . 1.4 1.3 1.3 1.3 Psi . . . . . . . . . . . . . . . . . . . .. . . ... . . . 20 18 18 lS

Rear-kg/cm2...................... 1.7 },3 1.6t 1.3** Psi . . . . . . . . . . . . . . . . . . . . . . . . . . • . . 24 18 22t lS--

Rear chain free play-mm . . . . . . . . . . . . 13 13 13 13 Inch . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . I' I' I' I'

N umoor of speeds ..... . . . . . ..... . . . . . 4 4 4 Sit ·Point gap should be O.46mm (0.018 in.) for models prior to 1973 and O.4mm (0.016 in.) for models after 1972. tTire size and pressure for Sprint "H" models 1967·1968 same as Sprint "H" models prior to 1967. #Models prior to 1973 equipped with 6 volt systems. "Tire size and pressure for Sprint "SS" models after 1968 same as Sprint "SS" models 1967·1968. ttModels prior to 1974 equipped with four speed transmission. lliustrations courtesy AMFlHarley·Davulson Motor Co.

MAINTENANCE SPARK PLUG. Recommended

spark plug for normal use is Harley· Davidson No. 5·6 or Autolite AG90l. Spark plug electrode gap should be 0.020-0.025 inch.

Main Jet

Model Early 1961 "C" 1962"H" Late 1961·1966 "C" 1963·1966 "H" 1967·1968 "H" & US" 1969·1972 "SS" 1971·1972 "SX" toSS" & t·SX" After 1972

Idle Jet

Model

Jet Size

l.08mm

l.OOmm l.05mm

l.18mm l.25mm

CARBURETOR. Del'Orlo UB type carburetor is used on pre-1969 models. Later models are equipped with square slide Del'Orto carburetor. Idle speed is a<ljusted by turning stop screw (10-Fig. HD4-1 or Fig. HD4-1AJ. Make cer­tain lock nut (9-Fig. HD4-1) is tight· ened after adjustment is complete. Idle mixture is adjusted at needle (8). Normal setting for idle mixture needle is 'l4·turn open. Clip (6) should nor­mally be positioned in center groove in needle (7). Float level on pre-1969 models can be checked as shown in Fig. HD4-2. Distance between straight edge and float lever should be 13/64·15/64 inch. Refer to Fig. HD4·3 for float level on later models. Refer to the following for correct jet sizes and equivalent drill bit size.

1961·1968 All Models 1969-Early 1971 "SS" After Early 1971 "SS" & "SX"

Jet Size

O.5mm O.55mm O.45mm

Fig. HD4-1-bploded view of D&I'Orto US car· bureror typical of early model •.

Starter Jet

Model 1969·1972 "SS" & "SX" After 1973 toSS" & "sx"

Jet Size

O.6mm O.7mm

1. Throttlecable 2. Choke JUide 3. Choke rod dip

�: �:!l: :��:g �: ��ve needle 8. Idle mixture needle 9. Locknut

10. IdlellGplJCJ'ew 11. Idlejel

12. Noule (et.omiur) 13. M.injet 14. c.p IS. Fiberwashers 16. Float 17. Floatlevu 18. Inlet needle 19. Snap lin, 20. Pivotlhtifl. 21. Primer 22. Filter acnen

SERVICE

'---10 _11 12 16 14 13 18 �20 1J� 19

1_21 Fig. H04·1A-Exploded view of .quare slide Del'Orto carburetor used on models after 1968. 1. Cable adjuster 2. Cap 3. Sprin, 4. Jet nC!iedle clip 5. Throttle .lIde 6, Jet. needle 7. Starter plunger 8. Floatpin 9. noat

10. Idlespeechcrew 11, Idle mixture atrew

5TRA1GHT EOGE

12. "0" rinS 13. Starlingl" 14. Inletfue valve 15. Idle jet 16. Needlejet 17. "O"ring 18. Flo.atbowl 19. Gasket 20. Mainjet 21. Jelholder 22. Fuel inlet

13/64" TO 15/W'

Fig. HD4-2-Floaf leve' Is measured as ,hown. If height /s Incorrect, float lever can be bent.

IGNITION AND ELECTRICAL. Models prior to 1973 are eqwpped with a 6 volt generator while later models are equipped with a 12 volt alternator. All models are equipped with a battery ignition with the breaker pointa lo­cated under a small cover on the right side cover. Breaker point gap should be 0.46mm (0.018 in.) for models prior to 1973 and O.4mm (0.016 in.) for models after 1972. Ignition timing is acljusted by loosening breaker 'plate retaining screws and rotating breaker plate.

Dynamic timing of ignition on models prior to 1971 is accomplished by removing tachometer drive on left side cover or left side cover and attaching a

Fig. HD4-J-Flollf height (H) on model. after 1968 should I)e J1/32/nch.

Fig. HD4-4-View of Ignition timer (I)reaker points usembly). Factory timing marks are shown at

(1). 2. Cover 3. Cam �taininl acrew 4. Lodcwasher 6. Washer0961

models)

6. Baae p\SUl aa-eWII 7. Timing mar ... 8. Ignition cam

11. Breaker point base plal.e

degree wheel to the end of the crank­shaft. Using a suitable mark, position degree wheel to coincide with piston at TDC on compression. To dynamically time ignition on 1971 and 1972 models, remove tachometer drive cover from left side cover and attach a degree wheel to end of crankshaft. Ignition timing may be checked on 1971 and 1972 models by removing access plug in crankcase and directing timing light into hole. Timing mark on crankshaft and crankcase should be aligned at engine speed of 5000 rpm. If ignition timing is not correct, remove tachom­eter drive cover and attach a degree wheel to crankshaft and follow the pre­vious ignition timing procedure to set ignition timing. Ignition timing on models 1973 and 1974 may be checked with a timing light by removing plug in left side cover and noting alignment of "R" (retard) and "AU (advance) timing marks. Pointer and "AU mark should be aligned at approximately 5000 rpm.

Ignition may be timed statically in retard and advance positions. Ignition is normally retarded and may be checked in advanced position by holding weights outward with a wedge

Harley-Davidson 250 & 350

Fig. HD4-6-Va/lffl clearance Is measured be­tween rocker arm and valve stem with engine cold. Adjusting screws (t) are locked by nuts (2).

or by inserting a washer under the cam retaining screw (a-Fig. HD4-4).

Refer to the following chart for timing specifications in crankshaft degrees and piston position:

Model Retarded Advanced Year BTDC BTDC

1961 21'/0.250 in. 41'/0.406 in. 1962-66 5' 41'/0.406 in. 1967-68 5'/0.015 in. 35'/0.250 in. 1969-72 7'/0.005 in. 28'/0.219 in. 1973-74 12'/0.044 in. 34'/0.338 in.

VALVE SYSTEM. The valves are actuated by a camshaft located in the crankcase via, cam followers, push rods and rocker arms. Clearance between rocker arm and valve stem should be set with engine cold. Clearance for both valves for an Sprint "COO models should be O.lmm (0.004 in.). For Sprint "H" models prior to 1967, exhaust valve clearance should be 0.13mm (0.005 in.) and inlet valve clearance should be 0.08mm (0.003 in.). Clearance for both valves of 1967 and 1968 "H" and "55" models should be 0.5mm (0.002 in.). Valve clearance for "SS" and "SX" models after 1968 is O.amm (0.003 in.) for the exhaust valve and 0.5mm (0.002 in.) for the intake valve. Refer to Fig. HD4-6.

LUBRICATION. The engine and gear box are lubricated by 2 quarts of oil contained in the crankcase. Recom­mended oil is Harley-Davidson grade 105 above 75 degrees F., H-D 75 be­tween 40 degrees and 75 degrees and H-D 58 oil below 40 degrees. Oil should be changed and filter (Fig. HD4-7) cleaned every ,1000 miles. Oil level should be maintained between marks on filler plug dipstick. Filler plug should not be screwed in when checking oil leveL

The oil pump used on models before 1964 is shown in Fig. HD4-8. Gears (14

Harley-Davidson 250 & 350

1 Drtun plug 2 Gnskel 3 Inner .Kret'n 4 Outf'fl.crt!\(', Ii F . lll!rSprr �: �:�ne�tk 8 FillCrscreen

! 1963 and Earlier}

Fig. HD4-7-011 filter screens should be cleaned every 1000 miles. Scavenger fflter (8) Is used on

models before 1964.

& 16) supply pressure for lubrication and scavenger pump gears on shafts (13 & 17) return oil to the crankcase. On 1964 and later models, the scav­enger section is omitted as shown in Fig. HD4-9. Gear (3-Figs. HD4-8 and HD4-9) is dri ven by the crankshaft timing gear. Both types of pump can be removed after removing drive gear and pump securing bolts (6).

CLUTCH CONTROLS. The clutch cable should be adjusted to provide the hand lever with free play equal to Yo-I> of its total movement. Adjustment is provided at both ends of cable.

SUSPENSION. Each front suspen­sion lmit contains 4% fl. oz. of Harley­Davidson Sprint Fork Oil. Units can be drained at plug (7-Fig. HD4-11) and refilled at plug (2). NOTE: If front sus­pension is disassembled and cleaned with solvent, each un.it should be ser­viced with 5 fl. oz. of oil. To remove snap ring (11), it may be necessary to drill or saw fork tube (9) as shown in Fig. HD4-12.

1812 14 20 5 4

�!' e--l0 Jd¥. - l�9 / 1 \ I!J) 191615 • � 11 7 63 2 1

191713 iii �v Fig. HD4-8-Exploded view of all pump used at, 1963 and earlier Sprint models. Scavenge gears are on shafts /13 & 17} and pressure geaf$ Bre at

1. NUL 2. Lock plate 3. Drive gear 4 <Anne(torfilting 05 Copper wlI.ht� 6. Retainingaaew8 ( 4

used) 7. Lock platetl (4 used) 9 Seavange Line

10 Gasket

(14& 16).

II. Outer(ovt't" 12 Inner c:over 13. Driveahaft 14. Pressure gear 115. Drive key :�

. rJI::'��:!tear

18. 0 ring 19. Dowel pinl 20. Pump bod)'

REPAIR CYLINDER HEAD AND VALVES.

The cylinder head can be removed without removing engine. Valves can be removed from cylinder head without removing rocker arms on pre 1967 models. Rocker arms can be removed after removing covers and set screws (43-Fig. HD4-J5). Note position of rocker arm thrust washers (3l) and spring washers (30Y. Spring washer (30) is between thrust washers (31) on valve side of inlet rocker arm and push rod side of exhaust rocker arm, Make certain oil passage (H) in inlet rocker arm cover (27) is clean. Refer to the fol­lowing specifications and Fig. HD4-15.

Valve Springs Free

Model Length Model "H" 1962-63

Length@ Pressure

Inner spring 1.64 in. 1.3 in. C$ 281bs. Outer spring 1.77 in. 1.42 in. @ 551bs.

All other models prior to 1968 Inner spring 1.64 in. 1.28 in. @ 251bs. Outer spring 1.77 in. 1.42 in.@'50Ibs.

1969-1972 model. Inner spring 1.64 in. 1.36 in. @ l8lbs. Outer spring 1.77 in. 1.5 in. @ 42 Ibs.

1973·1974 model. Innerspring 1.61 in. 1.3 in.@"331bs. Outer spring 1.69 in. 1.35 in. @ 57.4 Ibs.

Valve face and seat angle ........ 450 Valve seat width ............ 1/16-in. Valve stem to guide clearance

Inlet-After 1968 .. ...... 0.001 in. Prior to 1969 . .......... 0.0015 in. E�aust . ......... ....... 0.002 in.

Shafts (33) to bushings (32) clearance ......... 0.0005-0.0015 in.

Valve guides (12 & 26-Fig. HD4-15) and bushings (32) can be pressed out after cylinder head is heated to 2500 F. Bushing (32) for left end of inlet rocker arm shaft must have 0.118 inch diam­eter oil hole drilled. All bushings must be line reamed alter installation for correct clearance to shafts. Valve guides with 0.001, 0.002, 0.003, 0.004, 0.006 and 0.008 inch oversize outside diameter are available for service. Valve seats (11 & 25) are NOT inter­changeable. Valve seats can be re· moved and installed with cylinder head heated to 5400 F.

When reassembling, make certain that spring washer (30) is on valve side

12 _ I 17\

�. � • • • " , ;;;;;;;:..,

13/ Fig. HD4-9-Exploded view of 011 pump used on 1964 and lat.r Sprint models. No scavenger

pump Is used. Refer to Fig. HD4·8 for legend.

MOTORCYCLE

23 24� 25----e , ' . 21 · � I Q

2 43

r I i i

4

47 ___ 45 46-./.E�-3D

36 35 34

8 7,-.. ".�1_ -

9

I 22 . 17

<::> I rr-16

1'1=:: _13 . --14 \ 11--.12 �II ._J �:

Fig. HD4-U-Exploded view of typlca' Sprint front suspension assembly. Later models are

equipped wilh ball bearIngs on .teering stem.

2. PIli,. wllher& seal 4. Spnng 5. Screw 6. Washer 7. Drain serew 8. Stal 9. Main tube

10. ButTerlpring II. Snap ring 12. Damper vtllve body 13. Washer 14. Dampervalvl! 15. Snap ring 16. Damper pilnGn 17. Damper tube ��: �:rring 21. Selll 22. Slider

23 Steering damper koob

24. Lock 25. Stem nut 27. Upptrbrackct 30. Stem 34. Cotter pin 35. Nut 36. Spring washer plate 37. Spring wuher 40. An(horplall 41. Friction d isc 43 Bu-rina cone 44. Bearing balls (25 UlltCi) 45. Bearing balll (26

used) 46. Btarlngtone 47. BearingropA

of inlet rocker arm and on push rod side of exhaust rocker arm. Spring washer (30) should be between thrust washers (31) and at least one thrust washer should be at other end of rocke,' arm. Additional thrust washer can be in-

9 12 11

Notch with hadesaw. Must remove aU burrs on inside .,d outside of lube.

Drill 3/32" hole ooove snap ,ing . 00 NOT DRill THRU TUBE. Remove snap ring. Remove all burrs.

Fig. HD4-12-Snap ring (11) must be removed before damper lIallle body (12) can be withdrawn from tube (9). Make certain all burrs are re-

moved.

SERVICE

H� lJ���" 28 15� �

14'-Jt!jW : Il- @ @ 13�

35 32 � 26"1

fJ :b I ,-Wi3

Pod

24'" 12 13 43 31 32 .{ � 14 � � ?L. 15,,"�

��;(?4 5 /\ 18

37A ,A2 38 19 3 :&�41 � 20 1: It;;;Wai . !l� ............

39./"""'& ,,-, 19 40.-0 � 42

Fig. HD4·'5�xp'oded Iflew of early model cylinder hoad assembly. Cam follower bushings (5) and camshalf bushing (3lA) used on 1963 and earlier models must be reamed after InslellsHan. On 1964

and later models, needle bearing (378) Is used.

I. CanllIhlll1.gl!Df' 2. Wooch-utTkey 3. Camahaft 4. Exhawt cam roll ower 5. Bushing. 6. Exhawt pUlih rod 7. AdjulI'ting.crew 8. Lock nut 9. ExhsWit rocker arm

13. Spring leat 14. Inner .pring .. 15. Outulpring. 16. Vlllvceapa 17. Keepera 18. EzhaUllt valve cover 19. Oringa ��. ?r:l:ee:�: toiro�er

10. ExhaWit valve 11. Exhaust valve lIeat 22. Inlet pUlh rod 23. Inlet rocker arm 12. Valve-guide

stalled at either end to center rocker arm over valve stem and partially compress spring washer (30). The in­side cam follower (21) is for the inlet valve. Make certain that rocker arm screws (43) are tightened into holes in rocker arm shafts. Cylinder head re­taining nuts should be torqued to 25 Ft.-lbs. Refer to previous paragraph in MAINTENANCE section for setting valve clearance.

PISTON, RINGS AND CYL­INDER. The cylinder can be removed after first removing the cylinder head

24. Inlet valve lUi, Inl.tv.lv ..... t 26. Inlet VlllVil guide 27 Inlet valve c:over 28. Rocker lirm oil tube 29. Adju�ill.K lCrew

oo_u

�?: ��::�:� ��: ��I!����rana

3<1, Flange (2 uledl 35. Oll .. r nan •• ('l undl 36. Carburetor nange

37 A. Bushing 370. Net:dle bearing and

outer race 88. Thrust w8.llher 39. Ball beann'\, 40, Crailihlln u.ahlng 42. CntruhnnluPporl. 43. Rocker IlTm llet

screws

as outlined in previous paragraph. Refer to the following specifications for piston, rings, cylinder and piston pin. Standard cylinder bore diameter-

Early 250cc ...... 2.5984 in. (66mm) Late 250cc .... . ... 2.835 in. (72mm) 350cc .. . . . .. . .... 2.913 in. (74mm)

AlI piston rings-End gap .... .. . ... .. 0.010-0.016 in. Side clearance in groove 0.001-0.002

in. Piston pin to bushing (in connecting rod)-

Clearance ......... 0.006-0.0012 in. wear limit . ............ 0.002 in.

Harley-Davidson 250 & 350

IN •

.IIlDEl H � 1.DZ3IH. 1.6251H. 1.348 IN.

Fig. HD4-f6-When distance from end of valve stem to valve guide shoulder Itxceeds 1.650 Inch w ith new vslve Installed, valve aeat must be re-

newed.

Fig. H04·n-CondlUon of the connecting rod and lower end (crankpln) bearing can be checked by

measuring connecting rod shake 8S shown. If side play at connecting rod small (piston pin) end e.ceeds1/16 Inch, crankp/n, connecting rod

and bearing should be renewed.

Piston pin to piston-Clearance . .. light press fit@ 70· F.

Piston to cylinder clearance--1969 models ............. 0.004 in. All other models ... : ..... 0.002 in. Connecting rod side play (shake)

should be measured as shown in Fig. HD4-17. If total side play at piston pin end exceeds 1I16·inch, crankpin. con· necting rod and bearings should be renewed. Oversize pistons and rings are available.

CAMSHAFT AND TIMING GEARS. To remove timing gear cover (right side cover), drain crankcase oil or lay motorcycle on left side so oil will not drain out when cover is removed. The clutch on models after 1968 must be removed before the cover can be removed. Ignition breaker point cam retaining screw (3-Fig. HD4-3) must be unscrewed on all models. Clutch re­lease lever on models prior to 1969

Harley-Davidson 250 & 350 must be rotated forward when re­moving cover. Be careful not to damage sealing surfaces of cover or crankcase.

With piston at top dead center on compression stroke, camshaft support (found on 1968 and earlier models only) and camshaft can be removed. Before the crankshaft timing gear is removed, the position of the woodruff key (4-Fig. HD4-19) in crankshaft (10), and crankshaft gear (8 or 8A) should be marked. NOTE: There are three key­ways in crankshaft and gear. If key is improperly installed, camshaft timing may be incorrect. To remove the crank· shaft primary drive gear, it is neces· sary to remove the oil pump gear, cam· shaft, crankshaft timing gear and pull the drive gear from the crankshaft taper. Camshaft end play should be 0.001-0.004 inch on models prior to 1973 and 0.004-0.008 on models after 1972 and i s adjusted by varying washers (3S-Fig. HD4-15).

When reassembling, observe the fol· lowing. Thoroughly clean all oil and dirt from end of crankshaft, especially tapered section, and inside of gear (8 or 8A-Fig. HD4-19). On early 1961 mod­els, the take-up gear (6) should be ro­tated 3 t.eeth counter-clockwise before meshing teeth with clutch gear. This will properly preload gear (6) by spring (7). Make certain that woodruff key (4) is: installed in previously marked keyway and install gear with correct keyway in gear on woodruff key. NOTE: If marks were not previously affixed to crankshaft and gear, crank­shaft must be set at Top Dead Center and woodruff key installed in crank­shaft keyslot pointing toward camshaft mount (B-Fig. HD4-20) on all models except 1964 thru 1968. These models should have key installed in lower key slot (A) with crankshaft at TDC. In any case, camshaft drive gear on crank should be installed with timing mark a1igned as in Fig. HD4-18 with crank­shaft at TDC. Nut (I-Fig. HD4-19) should be tightened to 35 Ft.-Ibs. of torque.

Fig. HD4-18-Vlew with right side cover removed and timing marks aligned.

Fig. HD4-19-Vlew 0' crankshaft gears. Take up gear (6), thrust washer (5), spring (7) and nar­rower gear (8) are used on early 1951 models only. L8te 1961 end all other models use only

1. Nut 2. Lnck plate S. Crankaha n timing

gear

gear(SA).

4. WoodrufTkey 9. Sn[lpnng 10. Crankehaflrightend

CRANKSHAFT AND CON­NECTING ROD. The condition of the connecting rod lower end (crankpin) bearing can be checked as shown in Fig. HD4-17 after cylinder head, cyl­inder and piston are removed. The crankshaft and connecting rod as­sembly can be removed as follows after the complete engine assembly is re­moved from the frame. Remove the cyl­inder head, cylinder, and piston. Re­move the crankcase left side cover. the complete generator assembly, starter ratchet assembly (9, 10, II, 12, 13, 14 & 15-Fig. HD4-22) and drive sprocket from left Elide of crankcase. Remove the right side cover, camshaft, oil pump and crankshaft gears. NOTE: Observe the precautions outlined in previous paragraph before removing crankshaft gears. Remove clutch assembly on

early models, and gear shifter pawl.

Fig. HD4-ZO-V/ew of proper pos/Hon 'or cam gear wood­ruff hy for 1954 rhru 1968 models tA) and ,," other models (B). Crankshaft Is at

TOC on both versIons.

3

MOTORCYCLE

r 1Ji;;;;;;;;;;l9'�� 1 9 I 0 \I 12 13 15 14

Ij '��JJ� ed-d �;.� ��� � i , 6 5

Fig. HD4-22-Exploded view of klcht.rter 85-sembly. Klc/(starter ratchet assembly (9 thru 15) Is located on left end of transmission ma/nshal'

(19-Flg. HD4-2S,.

3 Kickstarur pedlll 10. Spring leat 4. Acorn nut lind 11. Ratchet.pring

washer 12. Ratchet. 5. Stop bumper 13. Rat.chetgC'ar 6. Stopstud 14. Snaprin, '

7. Ge8r 15. Ratchel gear bushi ng 8. 'Return spring 21. Pedal_hafl buehin, 9. Snap ring 22. SDr i nlc40wei bin

Remove snap ring (9-Fig. HD4-19) from right end. Remove the seven cap screws and three socket head screws which attach crankcase halves to­gether and separate halves. NOTE: One socket head screw is located under breather on left side as shown in Fig. HD4-23. Do not damage crankcase sealing surfaces when separating halves. The remainder of removal pro­cedure is self-evjdent.

Refer to Fig. HD4-24 for exploded view of crankshaft assembly. A press of approximately 10 ton capacity is re­qulred to press crankpin (5 or 5A) out of flywheels. Oil hole in crankpin must be aligned with hole in flywheel (1). Conn.ecting rod side clearance between flywheels should be 0.0005-0.0010 inch. The crankshaft should be disas­sembled ONLY if tools required to check and align reassembled crank­shaft are available. Crankshaft eccen­tricity should not exceed 0.001 inch when measured at main bearing jour­nals as close as possible to flywheels with crankshaft supported at ends in lathe centers.

SERVICE Orifice plug (12-Fig. HD4-24)

should be installed on all Sprint "H" models and Sprint "e" models after 1962. Orifice plug and oil passage to crankpin must be open to properly lu­bricate connecting rod bearing. Diam­eter of orifice opening is 0.0595 inch (Drill size 53).

CLUTCH. The cl utch assembly used in 1965 and earlier models (Fig. HD4-26) can be removed after crankcase right side cover is removed. Use appro­priate tool to compress clutch spring (12) and remove snap ring (1). Clutch discs and plates assembly (4) can be removed. Clutch spring (12) should have a free length of 1 29/32 inch and should be renewed if less than 1 13116 inch. On 1963 and earlier models, spring (12) should exert 223 lbs. when compressed to 1.12 inch. On 1964 and later models, spring pressure should be 2651bs. when compressed to 1.12 inch.

Clutch assembly used in 1969 and later models is shown in Fig. HD4-27. Primary gear (20) can be removed after disassembling and removing clutch assembly and right side cover. Clutch is dry type and seal in side cover should be inspected for damage. Inspect fric­tion discs for uneven wear or fractures. Springs (2) should be renewed if less than 1 Ii! inches long.

When reassembling, observe the fol­lowing. On early models equipped with take-up gear (6-Fig. HD4-19), gear (6) should be rotated counter-clockwise three teeth to pre-load spring (7) when meshing clutch drum gear with crank­shaft gear. Vary the th;ckness of sh;ms U5B-Fig. HD4-26) so that clutch drum (16) has just slight end play on shaft. Install hub (15) with small hole hub facing out. On late model clutch,

Fig. HD4-23-One sockel head screw attaching crankcase halves togelher /5 located on lelf side

.s shown.

Fig. HD4·24-Exploder1 view 01 crankshaft assembly. Crankpin bearing (4A. 48 & SA) Is type used on I.te

models.

I. RightllidenywheeJ 2. Thrwt wuhera (2 used) 3. Connecting rod 4. Roller bearing (early models)

.tA. Retainer 48. Rollers (24 uled)

5. Cnmkpin (early models) 5�: ���N!n wheel

7. PiSlonr

intu8hinl: 8. Oil5e8 9. Ball beanng 10. Snaprinl( 11. Ball beann,

12. Orifice plug (Iale models)

Fig. HD4-26-Exploded view of clutch assembly used in 1961 thru 196B models. Spacer (19)'s used on 1961 models only and keys (ISA) are used on 1962 thru 1968

models.

I. Snap ring 2. Relene belU'ing cap 3. Ball releue bearing 5. Nuts (4 ued) 6. Lock pillet 14 Uledi 1. Releas!! disc 8. Oul.erd� 9. Friclion diSQI (4 uliedl

10. Drive plnlea(4 used) 15S. Shims

Harley-Davidson 250 & 350

�

�, 48 4A 5A

24 23 22 21::::;

1 20 22. Release eam

11. Preuure plate 16. Clutch drum 23. Snap ring 24.. Oilles! 12. Cluu:hspnng

13. Nut 17. Drum bearing (2 Wled)

25. RIlleasBlever 14. Lockplate Hi Hub

15A. Hub keya(I962 and IDter)

18. Snap rinp(2uHd) ��: �CU{l961 only) 2L Lock washer

26. Spacer CUse only on early models with narrow gear on drum 16)

install fiber backed steel plate (7-Fig. HD4-27) first with steel side against bottom of drum (IS). Install sufficient shlms (22) behind primary gear (20) to obtain 0.004-0.00S inch clutch as­sembly end play. Remainder of as­sembly procedure is self-evident. Ad­just clutch cable as outlined i n paragraph i n MAINTENANCE sec­tion.

TRANSMISSION. Models prior to 1973 aTe equipped with a four speed transmission while all models after 1972 are equipped with a five speed transmission.

Transmission gears and shafts are accessible after separating crankcase halves as outlined in previous para­graph CRANKSHAFT AND CON­NECTING ROD. Gears (16 or 16A, 17, 22, and 23-Fig. HD4-2S or IS-Fig. HD4-29) must be pressed from their respective shafts. NOTE: Gears are tight press fit on shafts and should be pressed from shafts one at a time.

Bushings (lSA, 20A and 24A-Fig. HD4-2S and 2S-Fig. HD4-29) must be reamed after installation in gears to provide 0.001-0.002 inch clearance on shafts. When assembling transmis­sions prior to 1973. second gear (24-Fig. HD4-2S) must be' installed with

Fig. H04-27-Exploded view ot crutch assembly used In

�moo� 1 2 3 [ __________ ____ _______ .J

later models. I. Spring nul 2. Spring 3. Spnng holder :. �I�� I��

te 6. Steel plate 7. Fiber &..wel plClte 8. Lock nul 9. Cluteh IItlJuster

rU-�-�-�-I--J

n�f)vr\ 12 13 14 15 16 17 18 19 20 21 22 23

10. Sill I It. Push rod 12. Nut 13. Tab was:her 14. Hub 15. "O"rmg 16. Nut 17. Tab washer 18. ClUlCh drum 19. Washer 20 Primary drinn gear 21 RolJerbearings 22. Shims 23. Wll.Iher

Harley-uavloson :.!5U III �50

Fig. H04-28�xploded view of four speed transmission assembly used on Harley­Calf/dsan 250 cc Sprint models. L.ate (350 ee) model' are equipped with needle bearings Instead of

bushings (26A).

1 Sh.l'tercamapacer(limall) Z. (;QUntcrahafl thruat ..... ll5her 3. Cotler pm 12 wsecil :: ��:�:� ���; r2���U:MJ 8. Plug 9, WRlihcr

10 Sprmg II Cnm IItop plunger 12 Snap rillt! 13. Sh.fler cam "pacer tlorgcl 14 Shlfterrnm 15. Shifter dul�h 16. Mamshaft finl 81.'IIrl17 l�th)

16A. Mninahnl'l. (in! gear (late 19(2)

168. Snap ring Ollte 1962) 16C.ShimrLatel9621

17. Mainahllfi.erondgear\23 tl!ethl

18. Mainsha/\ third gtar 127 teelhl 18A. BU!hing

19. Mainahan 20 Count('rahaft lirat gellr 133

teeth) 20A Bushing

21 Shirtercluteh 22. CountenhaA. fourth gellr (16

teeth) 23. Countu,haIt thIrd gf!tlr\23 teeth) 24. CoullleMihllft sec ond gear 127

teeth) 24A. Bu.hmg

25. Counlershal"t 26. Sprocket genr (24 teeth)

26A. Buahlllg(2usedl

5

3t 31 �J.

33

f� 34 35 31 •• Siiz;"L 36 I lill£ / 31

- rfj 38 d<i 39

40 41 42 4� 'c,'@.L.�

21---A 29--V� 30� 30A""'---'

21

32� 222�ilII!I 23----

� 241 � 24 \..

�15 18A 18

_ ,11 �j6 25/'l\

21�..8 20j: .... � 2OI/t

33

leA ��31 .16e fJP' � .if'311 ·V __ 16B r

27. Spacer 28. Sprocket .p8�r 29. OIlseal 30. Bearing

:lOA Snap rillg (1..ate 19631 31. Bearing

31A. Right mallllihan bearing rctaine-(l.IIle 1962)

32. Bcaring 33. Bearing 34 Shiftu cambu,hing 35 Shiner cam bushinK

Fig. HD4-29�:tploded view of five speed transmission

used on models after 1972.

1. Spacer 2. OUleal 3. Ball beanng 4 Shim 5. Sprocket gear 6. Wu-e ring 1. Bushing 8. Spacer 9 N.edle bnrin8

10. Mainahaft fourth gear 11. Lock rin&, 12. Mainahaft third gear 13 Mainahafl 14. Shim It;. Bcarlngretamer 16. Ball benrlng 11. Shim 18. Counterahaft flRh gear 19. Lock ring 20. Countl!r ahaR rourth gear 21. Countenhan 22. CountCIt$hllf\ third gear 2J Lock ring 24 Countuahaf\ .econd gear 25. W .. h.r 26. Slide- dutch 27. Count ..... h.nfirltpar 28. Bushill( 29. Shim 30. BUlhing 31. Shim 32 Pin 33. Second & fourth ,hin fork 34. Third at fifth Ihift fork 3S. Fil'lt .hlft fork 36. Snap ring 31. Shim 38. BUlhing 39. Shll"team 40. Plug 41. Wuhl'r 42. Sp ring 43. Shiftcam lklp plunger

MOTORCYCLE recess on gear away from splines. Teeth on third gear (23) should be to­ward second gear (24)_ Teeth on fourth gear (22) should be away from thlrd gear (23)_ Install first gear (20) with recess away from shift clutch (21) and third gear (18) wiih recess away from rnainshaft splines. Teeth on second gear (17) should be toward third gear (I8). First gear (16 or 16M must be in­stalled with bearing side out. Install sufficient shims (16C) on late 1962-1972 models to obtain zero mainshaft end play.

When assembling transmission on models after 1972, install third gear (12-Fig. HD4-29) with lugs out and install fourth gear (10) with shift fork groove towards lugs on third gear. In­stall fourth gear (20) with lugs to in­side and fifth gear (18) with nat side out. Third gear (22) must be installed with shift fork groove towards fourth gear (20). Install shift clutch (26) with nat side next to second gear (24).

Countershaft end play should be 0.004-0.008 inch. To measure end play, install countershaft assembly in crank­cases with original washer (29-Fig. HD4-29 or a 1.0mm washer placed on the end of the countershaft. Do not in­stall a washer on models prior to 1971. Gasket must be installed between crankcase halves. Measure end play and install necessary shims (2-Fig. HD4-28 or 17-Fig. HD4-29) to obtain desired end play.

Free length of cam plunger spring (lO-Fig. HD4-28 or 42-Fig. HD4-29) should be 1.535 inch. Shift cam bush­ings must be reamed to provide clear­ance of 0.0005-0.0015 inch between bushings and shift cam. Shift fork clearance on shift cam should be 0.001-0.0015 inch. Install necessary shims (l3-Fig. HD4-28 or 37-Fig. HD4-29) to obtain equal clearance with trans­mission in neutral between lugs of shift clutch (21-Fig. HD4-28) and gears (20 and 24) on models prior to 1973, or to obtain equal clearance between lugs of third gear (22) and gears (20 and 24) on models after 1972.

Shift cam end play should be 0.004-0.008 and is adjusted by varying number andlor size of shims (I-Fig. HD4-28 or 31-Fig. HD4-29).

Sprocket gear bushing (26A-Fig. HD4-28) on models prior to 1969 must be reamed after inst.allation in gear to provide 0.0005-0.0015 inch clearance on mainshaft (19). Install sufficient shims (27-Fig. HD4-28 or 4-Fig. HD4-29) to obtain sprocket gear end play of 0.008-0.010 inch.

End play of all shafts should be checked after transmission has been completely assembled.