Harley Davidson CLE/TLE Sidecar Models; 1979-1984 CLE; 1983 & 1984 TLE. Service manual

FOREWORD
This manual contains service and repair information for Harley-Davidson sidecars and instructions for attaching and removing sidecars.
HOW TO USE YOUR SERVICE MANUAL

Your Service Manual is arranged for quick, easy reference. This manual is divided into numbered sections. Sections are then divided into subjects. Use this manual as follows:

1. Check the TABLE OF CONTENTS located in the front of each section to find subject desired.

2. Page number is listed across from subject. Page number consists of section number and page number.

3. Information is presented in a definite order as follows:

Adjustments

Removal

Disassembly

Cleaning, Inspection and Repair

Assembly

Installation

In figure legends, the number following a name of a part indicates the quantity necessary for one complete assembly.

Procedures that only apply to one model are identified with that models’s designation.
SERVICE BULLETINS

In addition to the information given in this Service Manual, Service Bulletins are issued to Harley-Davidson Dealers from time to time, which cover interim engineering changes and supplementary information. Service Bulletins should be consulted for complete information on the models covered by this manual.
USE GENUINE REPLACEMENT PARTS

WARNING

When replacment parts are required, use only genuine Harley-Davidson parts or parts with equivalent characteristics including type, strength and material. Failure to do so may result in product malfunction and possible injury to the operator and/or passenger.

To ensure a satisfactory and lasting repair job, follow the manual instructions carefully and use only genuine Harley-Davidson replacement parts. Behind the emblem bearing the words GENUINE HARLEY-DAVIDSON is more than three-quarters of a century of designing, research, manufacturing, testing, and inspecting experience.

This is your insurance that the parts you are using will fit right, operate properly and last longer. When you use genuine Harley-Davidson parts, you use the best.
PRODUCT REFERENCES

When reference is made in this manual to a specific brand name product, tool or instrument, an equivalent product, tool or instrument may be used in place of the one mentioned.

All tools mentioned in this SERVICE MANUAL with HD or J preceding the part number must be ordered through:

Kent-Moore Tool Division 29874 Little Mack Roseville, Michigan 48066

CONTENTS

All photographs and illustrations may not necessarily depict the most current model or component, but are based on the latest production information available at the time of publication.

Harley-Davidson Motor Co., Inc., reserves the right to change specifications, equipment, or designs at any time without notice and without incurring obligation.
WARNINGS AND CAUTIONS

Statements in this manual preceded by the words WARNING or CAUTION and printed in bold face are very important.

WARNING

Means there is the possibility of personal injury to yourself or others.

CAUTION

Means there is the possibility of damage to the vehicle.

We recommend you take special notice of these items.

SECTION 4 — FIBERGLASS

REPAIR Page No.

Fiberglass Body Care and Repair 4-1

Types of Finishes. . . . . . . ..4-1

Care of Finishes. . . . . . . ...4-1

Repairs . . . . . . . . . ..4-1

Surface Finishing. . . . . . . ..4-1

SECTION 5 — INSTALLING CONNECTION KITS ON MOTORCYCLES

FLH (CLE) Connection Kit . . . ...5-1

Kit Contents. . . . . . . . ..5-1

Installing Connections . . . . . . .5-1

Installing Sidecar Harness. . . . . ..5-1

FLT (TLE) Connection Kit. . . . 5 3

Kit Contents. . . . . . . . ..5-3

Installation. . . . . . . . ...5-4

SECTION 6 — ATTACHING, ADJUSTING AND REMOVING SIDECARS

CLE Sidecar Installation and Removal .61

Adjustable Front Fork. . . . . . ..6-1

Adjusting Steering Damper. . . . . ..6-1

Attaching Sidecar to Motorcycle. . . . .6-1

Adjustments. . . . . . . . ..6-2

Filling Hydraulic Brake System . . . . ..6-3

Adjusting Sidecar Brakes. . . . . ...6-3

Disconnecting Sidecar . . . . . . .6-3

TLE Sidecar Installation

and Removal (FLT). . . . . . 6-5

Attaching Sidecar to Motorcycle. . . . .6-5

Adjustments. . . . . . . . ..6-6

Attaching Steering Damper

to Motorcycle and Sidecar. . . . . .6-6

Adjustment of Steering Damper. . . . ..6-7

Filling Hydraulic Brake System . . . . ..6-7

Disconnecting Sidecar . . . . . . .6-7

SERVICE
REGULAR SERVICE INTERVALS

Regular lubrication and maintenance will help you keep your new Harley-Davidson operating at peak performance, and will give you lower operating costs, longer
motorcycle/sidecar life and greater riding pleasure. Your Harley-Davidson dealer knows best how to service your motorcycle/sidecar with factory approved methods and equipment assuring you of thorough and competent workmanship for every job.