LUBRICATION, MAINTENANCE AND TUNE-UP
95
tion. Even though the firing end of the plug is dry,
2. Improperly operating ignition component.
the plug’s insulation decreases when in this condi-
3. Engine lubrication system malfunction.
tion. An electrical path is formed that bypasses the
4. Cooling system malfunction.
electrodes, resulting in a misfire condition. Carbon
5. Engine air leak.
fouling can be caused by one or more of the follow-
6. Improper spark plug installation.
ing:
7. No spark plug gasket.
3
1. Rich fuel mixture.
2. Cold spark plug heat range.
Worn out
3. Clogged air filter.
4. Improperly operating ignition component.
Corrosive gases formed by combustion and high
5. Ignition component failure.
voltage sparks have eroded the electrodes. A spark
6. Low engine compression.
plug in this condition requires more voltage to fire
7. Prolonged idling.
under hard acceleration. Replace with a new spark
plug.
Oil fouled
Preignition
The tip of an oil-fouled plug has a black insulator
tip, a damp oily film over the firing end and a carbon
If the electrodes are melted, preignition is al-
layer over the entire nose. The electrodes are not
most certainly the cause. Check for intake air leaks
worn. Oil-fouled spark plugs may be cleaned in an
at the manifold and carburetor, or throttle body,
emergency, but it is better to replace them. It is im-
and advanced ignition timing. It is also possible
portant to correct the cause of fouling before the en-
that a plug of the wrong heat range (too hot) is be-
gine is returned to service. Common causes for this
ing used. Find the cause of the preignition before
condition are:
returning the engine into service. For additional in-
1. Incorrect air/fuel mixture.
formation, refer to Engine Performance in Chapter
2. Low idle speed or prolonged idling.
Two.
3. Ignition component failure.
4. Cold spark plug heat range.
5. Engine still being broken in.
Ignition Timing
6. Valve guides worn.
7. Piston rings worn or broken.
The engine is equipped with a fully transistor-
ized ignition system and is controlled by the igni-
tion module. This solid state system uses no
Gap bridging
breaker points or other moving parts, and there are
no means of adjusting ignition timing.
Plugs with this condition exhibit gaps shorted out
Harley-Davidson does not provide any ignition
by combustion deposits between the electrodes. If
timing procedures. Because of the solid state de-
this condition is encountered, check for excessive
sign, problems with the transistorized system are
carbon or oil in the combustion chamber. Be sure to
rare and adjusting the ignition timing is not neces-
locate and correct the cause of this condition.
sary or possible. If an ignition-related problem is
suspected, inspect the ignition components as de-
Overheating
scribed in Chapter Eight.
Incorrect ignition timing can cause a drastic loss
Badly worn electrodes and premature gap wear
of engine performance and efficiency. It may also
are signs of overheating, along with a gray or white
cause overheating.
blistered porcelain insulator surface. The most
common cause for this condition is using a spark
plug of the wrong heat range (too hot). If the spark
IDLE SPEED ADJUSTMENT
plug is the correct heat range and is overheated,
consider the following causes:
1. Start the engine and warm it to normal operating
1. Lean air/fuel mixture.
temperature. Shut off the engine.
96
CHAPTER THREE
2. Make sure the starting enrichment (choke) valve
73
(Figure 67) is pushed all the way to the OFF posi-
tion.
3. On models without a tachometer, connect a por-
table tachometer to the engine, following its manu-
facturer’s instructions.
NOTE
Figure 73 is shown with the air filter
assembly removed to better illustrate
the step.
4. Start the engine and, with the engine idling,
compare the tachometer reading to the idle speed
5. Accelerate the engine a couple of times and re-
specification in Table 8. If the tachometer reading is
lease the throttle. The idle speed must return to the
incorrect, adjust the idle speed with the carburetor
speed set in Step 4. If necessary, readjust the idle
throttle stop screw (Figure 73).
speed by turning the throttle stop screw (Figure
73). Shut off the engine.
NOTE
The idle mixture is set and sealed by the
6. If installed, disconnect and remove the portable
manufacturer and is not adjustable.
tachometer.
Table 1 MAINTENANCE AND LUBRICATION SCHEDULE1
Pre-ride check
Check tire condition and inflation pressure
Check wheel rim condition
Check engine oil level; add oil if necessary
Check brake fluid level and condition; add fluid if necessary
Check brake lever operation and travel
Check throttle and choke (enrichener) cable operation
Check fuel level in fuel tank; top off if necessary
Check drive belt tension
Initial 500 miles (800 km)
Change engine oil and filter
Check battery condition; clean cable connections if necessary
Check brake fluid level and condition; add fluid if necessary
Check front and rear brake pads and discs for wear
Check tire for correct inflation pressure and for excessive wear or damage
Check primary chain deflection; adjust if necessary
Check drive belt tension; adjust if necessary
Change primary chain case lubricant
Change transmission lubricant
Check clutch lever operation; adjust if necessary
Check drive belt and sprockets condition
Inspect spark plugs
Inspect air filter element for dirt and damage
Lubricate front brake and clutch lever pivot pin
(continued)
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LUBRICATION, MAINTENANCE AND TUNE-UP
97
Table 1 MAINTENANCE AND LUBRICATION SCHEDULE (continued)
Initial 500 miles (800 km) (continued)
Lubricate clutch cable if necessary
Check operation of throttle and choke (enrichener)
Check engine idle speed; adjust if necessary
Check fuel valve, fuel lines and all fittings for leaks or damage
Check electrical switches and equipment for proper operation
3
Check oil and brake lines for leakage
Check all fasteners for tightness2
Road test the motorcycle
Every 2500 miles (4000 km)
Check transmission lubricant level; add lubricant if necessary
Check drive belt tension; adjust if necessary
Inspect air filter element for dirt and damage; clean or replace as necessary
Check operation of throttle and choke (enrichener)
Check fuel valve, fuel lines and all fittings for leaks or damage
Check oil and brake lines for leakage
Check electrical switches and equipment for proper operation
Road test the motorcycle
Every 5000 miles (8000 km)
Change engine oil and filter
Check battery condition; clean cable connections if necessary
Check brake fluid level and condition; add fluid if necessary
Check front and rear brake pads and discs for wear
Check tire for correct inflation pressure and for excessive wear or damage
Check wire wheel spoke nipple tightness; adjust if necessary (models so equipped)
Check primary chain deflection; adjust if necessary
Check drive belt tension; adjust if necessary
Change primary chain case lubricant
Change transmission lubricant
Check clutch lever operation; adjust if necessary
Check drive belt and sprockets condition
Check steering head bearing adjustment; adjust if necessary
Inspect spark plugs
Inspect air filter element for dirt and damage; clean or replace as necessary
Lubricate front brake and clutch lever pivot pin
Lubricate clutch cable if necessary
Check operation of throttle and choke (enrichener)
Check engine idle speed; adjust if necessary
Check fuel valve, fuel lines and all fittings for leaks or damage
Check electrical switches and equipment for proper operation
Check oil and brake lines for leakage
Check all fasteners for tightness2
Road test the motorcycle
Every 10,000 miles (16,000 km)
Replace spark plugs
Lubricate steering head bearings
Repack rear swing arm bearings
Repack wheel bearings (1999 models)
Inspect engine mounts for wear or damage; replace if necessary
Every 20,000 miles (32,000 km)
Change front fork oil
Inspect fuel supply valve filter screen
1. Consider this maintenance schedule a guide to general maintenance and lubrication intervals. Harder than
normal use and exposure to mud, water, high humidity indicates the need for more frequent servicing to most
of the maintenance items.
2. Except cylinder head bolts. Cylinder head bolts must be tightened following the procedure listed in Chapter
Four. Improper tightening of cylinder head bolts may cause cylinder gasket damage and/or cylinder head leakage.
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98
CHAPTER THREE
Table 2 TIRE INFLATION PRESSURE (COLD)*
Model
kPa
psi
Front wheels
Rider only
207
30
Rider and one passenger
207
30
Rear wheels
Rider only
248
36
Rider and one passenger
276
40
*Tire pressure for original equipment tires. Aftermarket tires may require different inflation pressure.
Table 3 ENGINE OIL SPECIFICATIONS
Ambient operating
Type
HD rating
Viscosity
temperature
HD Multi-grade
HD360
SAE 10W/40
Below 40° F
HD Multi-grade
HD360
SAE 20W/50
Above 40° F
HD Regular heavy
HD360
SAE 50
Above 60° F
HD Extra heavy
HD360
SAE 60
Above 80° F
Table 4 ENGINE AND PRIMARY DRIVE/TRANSMISSION OIL CAPACITIES
Oil tank refill capacity
With oil filter change
2.5 U.S. qts. (2.4 L)
After engine rebuild
2.9 U.S. qts. (2.7 L)
Primary chaincase
26 U.S. oz. (768 mL)
Transmission
Oil change
20-24 U.S. oz. (591-709 mL)
Rebuild (dry)
24 U.S. oz. (709 mL)
Table 5 RECOMMENDED LUBRICANTS AND FLUIDS
Brake fluid
DOT 5 silicone
Front fork oil
HD Type E or an equivalent
Fuel
91 pump octane or higher leaded or unleaded
Transmission
HD Transmission Lubricant or an equivalent
Primary chaincase
HD Primary Chaincase Lubricant or an equivalent
Table 6 MAINTENANCE AND TUNE-UP TORQUE SPECIFICATIONS
Item
ft.-lb.
in.-lb.
N·m
Air filter
Backplate screws
-
20-40
2-5
Cover screw
-
36-60
4-7
Clutch adjusting
screw locknut
-
72-120
8-14
Clutch inspection
cover screws
-
84-108
9-12
(continued)
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LUBRICATION, MAINTENANCE AND TUNE-UP
99
Table 6 MAINTENANCE AND TUNE-UP TORQUE SPECIFICATIONS (continued)
Item
ft.-lb.
in.-lb.
N·m
Crankcase oil plug
-
120-144
14-16
Engine oil drain plug
14-21
-
19-28
Front fork cap bolt
11-22
-
15-30
Primary drive chain
Inspection cover screws
-
84-108
10-12
3
Chain adjuster shoe nut
21-29
-
28-39
Oil tank drain plug
14-21
-
19-28
Front axle nut
50-55
-
68-75
Rear axle nut
60
-
81
Transmission drain plug
14-21
-
19-28
Upper fork bridge
pinch bolts
FXDWG
30-35
-
41-47
All models except FXDWG
25-30
-
34-41
Spark plug
11-18
-
15-24
Table 7 FRONT FORK OIL CAPACITY AND OIL LEVEL DIMENSION
Model
Capacity oz. (ml)
Oil level dimension in. (mm)
1999 models
FXDWG
10.2 (302)
-
All models except FXDWG
9.2 (272)
-
2000-on models
FXD
10.6 (314)
6.69
(169.9)
FXDL
10.7 (316)
7.20
(182.0)
FXDS-CONV
11.5 (341)
6.10
(154.9)
FXDWG
12.0 (356)
7.28
(184.9)
FXDX, FXDXT
See text procedure
5.04 (128)
FXDP
NA
NA
NA = Information not available from the manufacturer.
Table 8 MAINTENANCE AND TUNE-UP SPECIFICATIONS
Item
Specification
Engine compression
90 psi (620 kPa)
Spark plugs
HD No. 6R12*
Gap
0.038-0.043 in. (0.097-1.09 mm)
Idle speed
950-1050 rpm
Ignition timing
Non-adjustable
Drive belt deflection
5/16-3/8 in. (8-10 mm)
Brake pad minimum thickness
1999
1/16 in. (1.6 mm)
2000-on
0.04 in. (1.02 mm)
Clutch cable free play
1/16-1/8 in. (1.6-3.2 mm)
*Harley-Davidson recommends that no other type of spark plug be substituted for the recommended H-D
type.
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