Harley Davidson 250 and 350 Sprint

8/2/2019 Harley Davidson 250 and 350 Sprint

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HARLEY-DAYIDSON250 AND 350 CC SPRINT

M O T O R C Y C L E

Sprint "H " Sprint "SS"Sprint "H " Sprint "SS" & "SX"MODEL Sprint **C" Prio r to 1967 1967-1968 After 1968Dis place me nt-cc 246.2 246.2 248.4 344Boremm 66 66 72 74Strokemm 72 72 61 81IgnitionSpark plugtype H-D 5-6or Autolite AG901Electrode gapmm 0.5-0.6 0.5-0.6 0.5-0.6 0.5-0.6Inch 0.020-0.025 0.020-0.025 0.020-0.025 0.020-0.025Pointg ap mm 0.46 0.46 0.46 Inch 0.018 0.018 0.018 *Valve c learance (cold)Intake mm 0.1 0.08 0.5 0.5Inch 0.004 0.003 0.002 0.002Ex ha ust ^m m 0.1 0 .13 0 .5 0 .8Inch 0.004 0.005 0.002 0.003Electrical system voltage 6 6 6 12#Battery term inal grounded Negative Negative Negative NegativeTire sizefront 3.00-17 3.00-18 3.25-19t 3.25-19**Rear 3.00-17 3.50-18 3.50-18 3.50-18**Tire pressureFr on t^k g/c m2 1.4 1.3 1.3 1.3Psi .. 20 18 18 18Rear-kg/cm= 1.7 1.3 1.6|- 1 .^ *Psi .. 24 18 22t 18^*Rea r chain free playmm 13 13 13 13Inch y^ y^ ^ ^^Nu mb er of speed s 4 4 4 5TT*Po int gap shou ld be 0.46mm (0.018 in.) for models prior to 1973 and 0.4mm (0.016 in.) for models after 1972.tTi re size and pressure for Sprint "H " models 1967-1968 same as Spr int "H " models prior to 1967.#Mo dels prior to 1973 equipped w ith 6 volt systems.**Tire size and pressu re for Sprint "SS" models after 1968 same as Sp rint "SS" models 1967-1968.ft Models prior to 1974 equipped with four speed transm ission.Il lustrat ions courtesy AM F/H arley-Davidson Motor C o.

M A I N T E N A N C ESPARK PLUG. RecommendedAG901.

C A R B U R E T O R D e r O r t o U B t y p eodels are equipped with square4-1 or Fig. HD4-1A). Make cer-

Distance between straig ht edge4-3 for float level

M ain JetM o d e lEarly 1961 "C"1962 "H "Late 1961-1966 "C "1963-1966 "H "1967-1968 "H" & " S "1969-1972 "S S"1971-1972 "SX"SS" & "SX" After 1972

i d l e J e tM o d e l1961-1968 All Modelsi969.Ear ly 1971 "SS"Af te rEar ly 1971"SS"& "SX"

Starter Je tM o d e l1969-1972 "SS" & " SX "

J e tSize1.08mm1.00mm1.05mm1.18mm1.25mm

J e tSize0.5mm0.55mm0.45mml Throttle cable4 . T h iel cu

0.6mm ^

12. Nozzle (atomizer)15. Fiber washers


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SERVICE Harley-Davidson 250 &

18Fig. HD4-1 A-Expioded view of square sildeDel'Orto carburetor used on models after 19S8.

1. Cahle adjuster 12. "O" ring2. Cap 13. Starting jet3. Spring U . Inlet fuel valve4. Jet needle clip 15. Idle jet5. Throttle slide 16. Needle jet6. Jet needle 17. "O" ring7. Starte r plunger 18. Float bowl8. Float pin 19 Gasket9. Float 20. Main jet10. Idle speed screw 21 . Jet holder11 . Idle mixture screw 22. Fuel inlet1 3 / 6 4 " T O 1 5 / W "

STRAIGHT EDGE\

Fig. HD4-2'Float level Is measured as shown. Ifheight Is Incorrect, float lever can be bent.

IGNITION AND ELECTRICAL.Models prior to 1973 are equipped w itha 6 volt generator while later modelsare equipped with a 12 volt alternator.All models are equipped with a batteryignition with the breaker points lo-cated under a small cover on the rightside cover. Breake r point gap should be0.46mm (0.018 in.) for models prior to1973 and 0.4mm (0.016 in.) for modelsafter 1972. Ignition timing is adjustedby loosening breaker plate retainingscrews and rotating breaker plate.Dynamic t iming o f i gn i t i on onmodels prior to 1 971 is accomplished byremoving tachometer drive on left side

} ^

Fig. HD4-3-Fioat height (H} on models after t968should be 31132 inch.

Fig. HD4'4'View of ignition timer (breaker pointsassembly). Factory timing marks are shown at(7).

2. Cover3. Cam retaining screw4. Lockwasher5. Washer (1961models)

6. Base plate screws7. Timing marks8. Ignition cam11 . Brea]plate

iker point base

degree wheel to the end of the crank-shaft. Using a suitable mark, positiondegree wheel to coincide with p iston a tTDC on compression. To dynamicallytime ignition on 1971 and 1972 models,remove tachometer drive cover fromleft side cover and attach a degreewheel to end of crankshaft. Ignitiontiming may be checked on 1971 and1972 models by removing access plugin crankcase and directing timing l ightinto hole. Timing mark on crankshaftand crankcase should be aligned atengine speed of 5000 rpm. If ignitiontiming is not correct, remove tachom-eter drive cover and attach a degreewheel to crankshaft and follow th e pre-vious ignition timing procedure to setign i t i on t iming . I gn i t i on t iming onmodels 1973 and 1974 may be checkedwith a timing light by removing plugin left side cover and noting alignmentof '*R** (r et ar d) an d "A " ( ad va nc e)timin g m ark s. P ointer and **A" ma rkshou ld be a l igned a t appr ox imate ly5000 rpm.Ignition may be timed statically inretard and advance positions. Ignitioni s no r mal ly r e t a r ded and may bechecked in advanced posi t ion by

Fig. HD4-6-Vaive clearance Is measuredtween rocker arm and valve stem with ecold. Adiusting screws (i) are iocked by nor by inserting a washer under theretain ing screw (3Fig. HD4 -4).Refer to the following chartt iming spec i fi ca t ions in c r a nksdegrees and piston position:ModelYear19611962-661967-681969-721973-74

RetardedBTDC2170.250 in.5570.015 in.770.005 in.1270.044 in.

AdvanBTD41 70 .4041 70 .403570.252870.213470.33VALVE SYSTEM. The valveactuated by a camshaft located i

crankcase via, cam followers, pushand rocker arms. Clearance betrocker arm and valve stem shoulset with engine cold. Clearance forvalves for all Sprint "C" models shbe 0.1mm (0.004 in.) . For Sprintmodels prior to 1967, exhaust vclearance should be 0.13mm (0.00and inlet valve clearance shoul0.08mm (0.003 in.) . Clearance for valves of 1967 and 1968 "H" and models should be 0.5mm (0.002 Va lve c l ea r ance f or "SS " and "models after 1968 is 0.8mm (0.003for the ex haust va lve and 0.5mm (0in.) for the intake valve. Refer toHD4-6.

L U B R I C A T I O N . The eng inegear box are lubricated by 2 quaroil contained in the crankcase. Recmended oil is Harley-Davidson g105 above 75 degrees F., H-D 75tween 40 degrees and 75 degreesH-D 58 oil below 40 de grees. O il shbe changed and f i l ter (F ig . HDcleaned every 1000 miles. Oil lshould be maintained between mon f i l ler p lug dipst ick . F i l ler should not be screwed in wchecking oil level.The oil pump used on models be


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250 & 350 MOTORCYCLE

1. Drain plug2. Gasket3. Inner screen4. Outer screen5. Filter spring6. Magnetic plug7. Gasket8. Filter screen(1963 and Earlier)

4'7-Oil filter screens shouid be cleanednger filter (8) is used on

modeis before 1964.16) supply pressure for lubricationon shafts3 & 17) return oil to the crankcase.1964 and later models, the scav-is omitted as shown inandis driven by the crankshaftgear. Both types of pump can beandsecuring bo lts (6).

CLUTCH CONTROLS. The clutchbeadjusted to provide theto VB-V^its total movement. Adjustment isat both en ds of cable.SUSPENSION. Each front suspen-

4^A fl. oz. of Harley-rk Oil. Un its can beat plug (7Fig. HD4-11) andat plug (2). NOT E: If front sus-is disassembled and cleanedbe ser-5 fl. oz. of oil. To removeit maybenecessary toor saw fork tube (9) as shown in

14 20 5 4J

1 9 1 7 1 3

view of oii pump used or.and eariier Sprint models. Scavenge gears

on shafts (13 A 17) and pressure gears are at(14S.16).

1. Nut2. Lockplate3. Drive gear4. Connector fitting5. Copper washers6. Retaining screws (4used)7. Lock plates (4used)

U. Outer cover12. Inner cover13. Drive shaft14. Pressure gear15. Drive key16. Pressure gear17. Idler shaft18. OrinB

REPAIRCYLINDER HE AD AND VALVES.The cy l inder head can be r emovedwithout removing engine. Valves canbe removed from cylinder head withoutr emoving r ocker a r ms on pre 1967models. Rocker arms can be removedafter removing covers and set screws

( 4 3 _ F i g . H D 4 - 15 ) . N o t e posi t ion ofrocker arm thrust washers (31) andsp r ing wa sher s ( 30 ). Sp r ing washe r(30) is between thrust washers (31) onvalve side of inlet rocker arm and pushrod side of exhaust rocker arm. Makecertain oilpassage (H) in inlet rockerarm cover (27) is clean. Refer to the fol-lowing speciflcations and Fig. HD4-15.Valve Springs Free Length @Model Length PressureModel "H" 1962-63

Inne r spring 1.64 in. 1.3 in . (ct 28 lbs.Outer spring 1.77 in . 1.42 in . @ 55 lbs.All other m odels prior to 1968Inner spring 1.64 in. 1.28 in . @ 25 lbs.Outer spring 1.77 in . 1.42 in . @ 50 lbs.1969-1972 m odelsInner spring 1.64 in. 1.36 in . @ 18 lbs.Outer spring 1.77 in . 1.5 in . @ 42 lbs.1973-1974 modelsInner spring 1.61 in . 1.3 in . @ 33 lbs.Outer spring 1.69 in. 1.35 in. @ 57.4 lbs.Valve face an d seat angle 45Valve seat width 1/16-in.Valve stem to guide clearanceInle^ -Afte r 1968 0.001 in.Prio rto 1969 0.0015in.Exhaust 0.002 in.Shafts (33) to bush ings (32)clearance 0.0005-0.0015 in.

Valve guides (12 & 26Fig. HD4-15)and bushings (32) can be pressed outafter cylinder head isheated to 250*" F.Bushing (32) for left end of inlet rockerarm shaft must have 0.118 inch diam-eter oil hole drilled. All bushings mustbe line reamed after installation forcor r ec t c l ea r ance to sha f t s . Va lveguides with 0.001, 0.002, 0.003, 0.004,0.006 and 0.008 inch oversize outsided i a m e t e r are a v a i l a b l e for se r v ice .Valve seats (11 &25) areNOT inter-c h a n g e a b l e . Va lve sea t s can be re-moved and installed with cylinder headheated to 540 F.When reassembling, make certainthat spring washer (30) ison valve side

Fig. HD4-11-Exploded view of typical Sprint frontsuspension assembiy. Later modeis are

equipped with bail bearings on steering stem.2, Plug, washer & seal4. Spring5. Screw6. Washer7. Drain screw6, Seal9, Main tube10. Buffer spring11. Snap ring12. Damper valve body13. Washer14. Damper valve15. Snap ring16. Damper piston17. Damper tube19, Snap ring20, Seal21, Seal22, Slider

23. Steering dam pierknob24 . Lock25. Stem nut27. Upper bracket30. Stem34 . Cotter pin35. Nut36 . Spring washer plate37 . Spring washer40, Anchor plate41 , Friction disc43 . Bearing cone44. Bearing balls (25used)45. Bearing balls (25used)46 . Bearing cone47 . Bearing cups

of inlet rocker arm and on push rod sideof exhaust rocker arm. Spring washer(30) should bebetween thrust washers(31) and at least one thrust washershould be at other end of rocker arm.Additional thrust washer can be in-

Notch with hacksaw.Must remove al i burrson inside and outsideof tube.

Dri ll 3 / 32 " holeabove snap ring.DO NOT DRILL THRUT U B E . Removesnap ring.Remove al l burrs.

Fig. HD4-9-Expioded view of oil pump used onFig. HD4-12~Snap ring (11) must be removedbefore damper valve body (12) can be withdrawnfrom tube (9). Make certain all burrs are re-


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SERVICE Harley-Davidson 250 &

28

35 32\ 31 3 0 3 1

40Fig. H D 4 - 1 S-Expioded view of earty modei cyttnder head assembty. Cam fotiower bushings (S ) andcamshaft bushing (37A) used on 1963 and eariier modeis must be reamed after tnstattatton. On 1964and iater modeis, needie bearing (37B) is used.

Camshaft gearWoodruff ke yCamshaftExhaust cam followerBushingsExhaust push rodAdjusting screwLock nutExhaust rocker armExhaust valveExhaust valve seatValve guide

1 3. Spring seat14 . Inner springs15 . Outer springs16 . Valve caps17 . Keepers18 . Exhaust valve cover1 9 . O rings2 0 . Oil return pipe2 1 . Inlet cam follower2 2 . Inlet push rod2 3 . Inlet rocker arm

2 4 .2 5 .2 6 .2 7 .2 8 .2 9 .3 0.3 1 .3 2 .3 3 .

Inlet valveInlet valve seatInlet valve guideInlet valve coverRocker arm oil tubeAdjusting screwcoverSpring washersThrust washersShaft bushingsRocker arm shafts

3 4 .3 5 .3 6 .37A.3 7 B .3 8 .3 9 .4 0 .42 .4 3 .

stalled at either end to center rockerarm over valve s tem and p a r t i a l l ycompress spring washer (30). The in-side camfollower (21) is for the inletvalve. Make certain that rocker armscrews (43) are tightened into holes inrocker arm shafts. Cylinder head re-taining nuts should be torqued to 25Ft.-lbs. Refer to previous paragrap h inMAI NTENANCE sec t ion f o r se t t i ngvalve clearance.P I S T O N , R I N G S AND CYL-INDER. The cylinder can be removed

Flange (2 used)Oiler flange (2 used)Carburetor flangeBushingNeedle bearing andouter raceThrust washerBall bearingCrankshaft DushingCamshaft supportRocker arm setscrews

as ou t l ined in p r e v i o u s p a r a g r a p h .Refer to the following sp ecifications forpiston, rings, cylinder and piston pin.Standard cylinder bore diameterEa rly 250cc 2.5984 in. (66mm)La te 250cc 2.835 in. (72mm)350cc 2.913 in. (74mm)All piston ringsEnd gap 0.010-0.016 in.Side clearan ce in groove 0.001-0.002in .Piston pin to bushing (in connectingrod)Clearance 0.006-0,0012 in.

I N T A K E A N D E X H A U S TL 6 0 0 M I N IM U M .1 . 6 5 0 M A X I M U M

S E A T W I D T HA P P R O X . 1 /1 6

M O D E L C M OIN . 1 . 2 5 9 in . 1 .

E X . l . Q 2 3 i n . 1 .IN . 1 . 5 4 5 i n . 1 .

E X . 1 . 3 4 8 in . 1 .Fig. HD4'16-When distance from end ostem to valve guide shoulder exceeds f .6wtth new vatve Installed, valve seat mus

newed.

Fig. HD4-17~Condltlon of the connectingtower end (crankpin) bearing can be checmeasuring connecting rod shake as shostde play at connecting rod smait (ptstonend exceeds 1 1 1 6 Inch, crankpin, connectand bearing shouid be renewed.

Piston pin to pistonClearance . . , light press fit@ 7Piston to cylinder clearance1969 models 0.00All other models . . . ! 0.00C o n n e c t i n g rod side play ( shshould be measured as shown in HD4-17. If total side play at pistonend exceeds 1/16-inch, crankpin,necting rod and bearings shouldrenewed. Oversize pistons and rare available.C A M S H A F T AND TIMIGEARS. To remove timing gear c(right side cover), drain crankcaseor lay motorcycle on left side so oilnot drain out when cover is remoThe clutch on models after 1968 mbe removed before the cover caremoved. Ignition breaker pointretaining screw (3Fig. HD4-3) be unscrewed on allmodels. Clutch


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MOTORCYCLEBe careful no t to dam agesurfaces of cover or cran kcase .With piston at top dead center on

remove the crank-

shers (38Fig. HD4-15).When reassembling, observe the fol-section, and inside of gear (8 or

the take-up gear (6) should be ro-

Make certain that woodruff key (4)ins t a l l e d in p r ev ious ly ma r ked

A) with crank shaft at TDC. In anycamshaf t d r ive gea r on c r ank

1 0 4

1Fig. HD4-19-View of crankshaft gears. Take upgear (6), thrust washer (5), spring (7) and nar-rower gear (8) are used on early 1961 modelsonly. Late 1961 and all other models use onlygear (8A).4. Woodruff key9. Snap ring10. Crankshaft right end

1. Nut2. Lockplate3. Crankshaft timinggear

CRANK SH AFT AND CO N-NECTING ROD. The condition of theconnecting rod lower end (crankpin)bearing can be checked as shown inFig. HD4-17 after cylinder head, cyl-inder and pis ton are removed. Thecr ankshaf t and connec t ing r od as -sembly can be removed as follows afterthe complete engine assembly is re-moved from the frame. Remove the cyl-inder head, cylinder, and piston. Re-move the cran kcase left side cover, th ecomplete generator assembly, starterratchet assembly (9, 10, 11, 12, 13, 14& 15 Fig. HD4-22) and drive sprocketfrom left side of crankcase. Remove theright side cover, camshaft, oil pumpand crankshaft gears. NOTE: Observethe precautions outlined in previousparagraph before removing crankshaftgea r s . Remove c lu t ch assembly onearly models, and gear shifter pawl.

1 5 1 4

Fig, HD4-22'Exploded view of kickstarter as-sembly, Kickstarter ratchet assem bly (9 thru 15)Is located on left end of transmission malnshaft(19-Fig.HD4-28).3. Kickstarter pedal4. Acorn nut andwasher5. Stop bumper6. Stop stud7. Gear8.'Return spring9. Snap ring

10. Spring seat11. Ratchet spring12. Ratchet13. Ratchet gear14. Snap ring15. Ratchet gear bushing21 . Pedal shaft bushing22. SDrine dowel pinRemove snap ring (9Fig. HD4-19)from right end. Remove the seven capscrews and three socket head screwswhich a t t ach c r ankcase ha lves to -g e t h e r a n d s e p a r a t e h a l v e s . N O T E :One socket head screw is located u nde rbreather on left side as shown in Fig.H D 4 - 2 3 . Do no t dam age c r ank casesea l ing su r f aces when separ a t inghalves. The remainder of removal pro-cedure is self-evident.Refer to Fig. HD4-24 for explodedview of cranksh aft assembly. A press ofapproximately 10 ton capacity is re-quired to press crankpin (5 or 5A) outof flywheels. Oil hole in crankp in mu stbe aligned with hole in flywheel (1).Connecting rod side clearance betweenflywheels sho uld be 0.0005-0.00 10inch. The crankshaft should be disas-sembled ONLY i f tools required tocheck and align reassembled crank-shaft are available. Crankshaft eccen-tricity should not exceed 0.001 inchwhen measured at main bearing jour-nals as close as possible to flywheelswith crankshaft supported at ends inlathe centers.

Fig. HD4-2thiew of properposition for cam gear wood-run key for 1964 thru 1968models (A) and ali othermodels (B). Cranknhaft is atTDC on both versions.


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SERVICEOrifice plug (12should be installed onmodels and Sprint "C1962. Orifice plug andcrankpin must be openbricate connecting rodeter of orifice opening(Drill size 53).

Harley-Davidson 250 & Fig. HD4-24)all Sprint "H"" models afteroil passage toto properly lu-bearing. Diam-is 0.0595 inch

CL UT CH . The clutch assembly usedin 1968 and earlier models (Fig. HD4-26) can be removed after crankcaseright side cover is removed. Use appro-priate tool to compress clutch spring(12) and remove snap ring (1). Clutchdiscs and plates assembly (4) can beremoved. Clutch spr ing (12) shouldhave a free length of 1 29/32 inch andshould be renewed if less than 1 13/16i nch . On 1963 and ea r l i e r mode l s ,spring (12) should exert 223 lbs. whencompressed to 1.12 inch. On 1964 andlater m odels, spring pre ssure should be265 lbs. when compressed to1.12 inch.Clutch assembly used in 1969 andlater models is shown in Fig. HD4-27.Prim ary g ear (20) can be removed afterd i s a s s e m b l i n g and r emoving c lu t chassembly and right side cover. Clutchis dry type an d seal in side cover shouldbe inspected for damage. Inspect fric-tion discs for uneven wear or fractures.Springs (2) should be renewed if lessthan iy2 inches long.When reassembling, observe the fol-lowing. On early models equipped withtake-up gear (6Fig. HD4-19), gear (6)shou ld be r o t a t ed coun te r - c lockwisethree teeth to pre-load spring (7) whenmeshing clutch drum gear with crank-shaft gear. Vary the thickness of shims(15BFig. HD4-26) so t ha t c lu t chdrum (16) has just sl ight end play onshaft. Install hub (15) with small holehub facing out. On late model clutch.

Fig. HD4'24-Expioded viewof crankshaft assembly.Crankpin bearing (4A, 4B &54 ; Is type used on late

modets.1. Right side flywheel2. Thrust washers (2used)3. Connecting rod4. Roller bearing (early models)4A. Retainer4B. Rollers (24 used)5. Crankpin (early models*5A. Crankpin6. Left side ny wheel7. Piston pin bushing8. Oil seal9. Ballbearing10. Snap ring11. Ball bearing12. Orifice plug (late models)

Fig. HD4'26-Exploded viewof dutch assembty used in1961 thru 1968 modets.Spacer (19) is used on 1961models onty and keys (ISA)are used on 1962 thru 1968

modeis.

1. Snap ring2. Release bearing cap3. Ball release bearing5. Nuts (4used)6. Lock plates (4used)7. Release disc8. Outer disc9. Friction discs (4 used)10. Drive plates (4used)11. Pressure plate12. Clutch spring13. Nut14. Lock p late15. Hub15A. H ub keys (1962 and later)

4 B 4A 5A

1819 19 261 12 25

15B 1

15B. Shims16. Clutch drum17. Drum bearing (2used)18. Snap rings (2used)19. Spacer (1961 only)20. Nut21. Lock w asher

22. Release cam23. Snap ring24. Oil seal25. Release lever26. Spacer (Use only on emodels with narrow gdrum 16)

install fiber backed steel plate (7Fig.HD4-27) first with steel side againstbottom of drum (18). Ins tall sufficientshims (22) behind primary gear (20) toobtain 0 .004-0.008 inch c lutch as-sembly end p l a y . R e m a i n d e r of as-sembly procedure is self-evident. Ad-j u s t c lu t ch cab le as o u t l i n e d inp a r a g r a p h in M A I N T E N A N C E sec-tion.

TRANSMISSION. Models prior to1973 are equipped with a four speedt r a n s m i s s i o n w h i l e all models af ter1972 are equipped with a five speedtransmission.

Fiy .^.j-One socket head screw attachingcrankcase halves together is iocated on ieft side

Transmission gears and shaftsaccessible after separating crankhalves as outlined in previous pg r a p h C R A N K S H A F T AND CNECTING ROD. Gears (16 or 16A22 , and 23-~Fig. HD4-28 or 18HD4-29) must be pressed from r espec t ive sha f t s . NOTE: Gear stight press fit on shafts and shoulpressed from shafts one at a t ime.Bushings (18A, 20A and 24AHD4-28 and 28Fig. HD4-29) mu sreamed after installation in gearprovide 0.001-0.002 inch clearancs h a f ts . W h e n a s s e m b l i n g t r a n s msions prior to 1973, second gear (2Fig. HD4-28) must be installed

Fig. HD4-27-Exploded of dutch assembty use

later models.1. Spring nut2. Spring3. Spring holder4. Pressure plate5. Friction disc6. Steel plate7. Fiber & steel plate8. Lock nut9. Clutch adjuster10. Ball11. Push rod12. Nut13. Tab washer14. Hub15. "O"ring16. Nut17. Tab washer18. Clutch drum19. Washer20. Primary driven gear21. Roller bearings


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Hariey-els. Late (350 cc )e equipped with

bushings (2eA).

1.2.3.4.6.H.9.10.I I .12.l.H.14 .15.16.

17 .

19.20 .

21 .22 .23.24

25 .

Shifter cam spacer (small)Countershaft thrust washerCotter pin (2 used)Shifter fork pin (2 used*Shifter fork (2 used)PlugWasherSpringCam stop plungerSnap ringShifttT cam spacer (largeIShifter camShifter clutchMuinshafl first gear (17 teeth)Mainsha a first gear (late1962)Snap ring (late I962iShim (Late 1962)Mainshadt second g ear (23teeth IMainshafl third gear (27teeth)BushingMain.shaftCountershaft first gear (33teeth)BushingShifter clutchCountershaft fourth gear (16teeth I(Countershaft third g ear (23teeth ICfiuntershaft second gear (27teeth IBushingCounter.HhaftSpriickct gi'ar(24 teeth iBu.shin^,'(2used)

32

27. Spacer28. Sprocket spacer29. Oil seal30 . Bearing30A. Snap ringf Late 1963)31 . Bearing

31A. R ight mainshaft bearingretainer (Late 1962)32 . Bearing33 . Bearing34 . Shifter cam bushing35 . Shifter cam bushing

Fig. ,HD4'29-Exploded viewof five speed transmissionused on models after i 972.1.2.3 .4.5.6.7.8.9.10 .11 .12 .13 .

14 .15 .16 .17 .18 .19 .2 0.2 1.2 2.23.2 4 .2 5.2 6.2 7.2 8.2 9.3 0.3 1.3 2 .3 3 .3 4 .3 5.3 6.3 7.3 8.3 9.4 0.4 1.42 .

SpacerOil sealBall bearingShimSprocket gearWire ringBushingSpacer^(eedle bearingMainshaft fourth gearLock ringMainshaft third gearMainshaftShimBearing retainerBall bearingShimCountershaft fifth gearLock ringCountershaft fourth gearCountershaftCountershaft third gearLock rin gCountershaft second gearWasherSlider clutchCountershaft first gearBushingShimBushingShimP i nSecond & fourth shift forkThird &fifthshift forkFirst shift forkSnap ringShimBushingShift camPlugWasherSpring

MOTORCYCLErecess on gear away f rom spl ines.Teeth on third gear (23) should be to-ward second gear (24). Teeth on fourthgear (22) should be away from thirdgear (23). Install first gear (20) withrecess away from shift clutch (21) andthird gear (18) with recess away frommain shaf t sp l ines . Tee th on secondgear (17) should be toward third gear(18). First gear (16 or 16A) must be in-stalled with bearing side out. Installsufficient shims (16C) on late 1962-1972 models to obtain zero mainshaftend play.

When assembling transmission onmodels after 1972, install third gear(12Fig. HD4-29) with lugs out andinstall fourth gear (10) with shift forkgroove towards lugs on third gear. In-stall fourth gear (20) with lugs to in -side and fifth gear (18) with flat sideout. Third gear (22) must be installedwith shift fork groove towards fourthgear (20). Install shift clutch (26) withflat side nex t to second gear (24).

C o u n t e r s h a f t end p lay should be0.004-0.008 inch. To measure end play,install countershaft assembly in crank-cases with original washer (29Fig.HD4-29 or a 1.0mm washer placed onthe end of the cou ntershaft. Do not in-stall a washe r on models prior to 1971.Gas ke t mus t be in s t a l l ed be tweencrankcase halves. Measure end playand install necessary shims (2Fig.HD4-28 or 17Fig. HD4-29) to obtaindesired end play.Free length of cam plunger spring(10Fig. HD4-28 or 42Fig. HD4-29)should be 1.535 inch. Shift cam bush-ings must be reamed to provide clear-ance of 0 .0005 -0.0015 inch betw eenbushings and shi f t cam. Shif t forkclearance on shift cam should be 0.001-0.0015 inch. Install necessary shims(13 _Fi g. H D4-28 or 37Fig. HD4-29)to obtain equal clearance with trans-mission in neutral between lugs of shiftclutch (21Fig. HD4-28) and gears (20and 24) on models prior to 1973, or toobtain equal clearance between lugs ofthird gear (22) and gears (20 and 24) onmodels after 1972.

Shift cam end play should be 0.004-0.008 and is adjusted by varyingnumber and/or size of shims (1Fig.HD4-28 or 3 1Fig. HD4-29).Spr ocke t gea r bush ing ( 26AFig .HD4-28) on models prior to 1969 mustbe reamed after installation in gear toprovide 0.0005-0.0015 inch clearanceon mainshaf t (19), Ins t a l l su f f i c i en tshims (27Fig. HD4-28 or 4Fig.HD4-29) to obtain sprocket gear endplay of 0.008-0.010 inch.End play of a l l shaf ts should bechecked after transmission has been


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Harley Davidson 250 and 350 Sprint