Harley Davidson Panhead. Service manual (1948-1957 Rigid) — page 1

тhis Service Manual is dedicated to attaining for Harley-Davidson motorcycle owners the highest degree of performance and satisfaction.

Except when a particular model or year model is indicated, the information in this manual applies to O.H.V. Twin Models back to 1948.

This Service Manual is dedicated to attaining for Harley-Davidson motorcycle owners the highest degree of performance and satisfaction.

Except when a particular model or year model is indicated, the information in this manual applies to O.H.V. Twin Models back to 1948.

Product
General Specifications 1948-1954.. 4

General Specifications 1955-1957.. 6

Lubrication Chart . . . . . . . ..8

Signal Lights . . . . . . . . . ..9

Starting Engine . . . . . . . . ..9

Stopping Engine . . . . . . . . 9

Running in New Engine . . . . . 9

High Speed Tips . . . . . . . . 10

Trouble Shooting Charts. . . . . 10

engine . . . . . . . . . . . ..10

generator . . . . . . . . . . 11

carburetor . . . . . . . . . . 11

transmission . . . . . . . . . 11

brakes . . . . . . . . . . . ..12

General Lubrication . . . . . . ..12

Lubrication Chart . . . . . . . ..13

Servicing Air Cleaner . . . . . . 14

Initial Servicing of New Motorcycle. 14

first 250 miles . . . ... 14

first 750 miles . . . ... 14

first 1500 miles . . . . . . . ..15

Regular Interval Inspection &

Maintenance . . . . . . . . 15

Care & Lubrication of Drive Chain. 16

adjusting drive chain . . . . . 16

adjusting front chain. . ... 16

adjusting rear chain . . ... 16

lubrication front chain. . . . . 16

lubrication rear chain . . . . . 17

repairing drive chain. . . . . ..17

Clutch & gear shifter . . . . . . 18

Compensating sprocket (early style). 18

Chassis

Wheels . . . . . . 20

general . . . . . .. 20

removal . . . . . .. 20

removal (side car) . . . . 21

servicing wheel hubs . . .. 22

replacing rear wheel sprocket ... 23

spoking wheels . . . ... 23

truing wheels . . . . . 24

removing & installing tires. .. 25

Shop Data

wheels . . . . . ... 26

Servicing Handlebar Controls . . 28

early model . . . . .. 28

late model . . . . ... 29

Removing & Installing Forks. .. 29

springers . . . . . . 31

Fork Frame & Handlebar Alignment. 34 rough check for fork alignment... 34

rough check for frame alignment. 34

frame alignment diagram. ... 35

springer shock. . . . 36

Glide Forks. . . . . . 37

general . . . . . .. 37

changing oil . . . . .. 37

glide fork diagram . . . 39

glide fork diagram (adjustable) .. 40 disassembling fork sliders & tubes 41

adjusting steering damper. .. 41

adjusting fork trail (adjustable)... 42

disassembling front fork. . 42

steering head bearings. . . 43

replacing slider bushings. ... 43

inspecting & servicing fork. . 44

straightening fork tubes . . 44

straightening fork stem & bracket

assembly . . . . ... 45

assembling fork . . . ... 46

assembling fork (adjustable) . 47

Brakes. . . . . . . 48

disassemble front brake (glide) .. 48 inspection & servicing (glide) ... 48 assembling front brake (glide) ... 48 adjusting front brake cable (glide) 48 adjusting front brake shoes (glide) 48

glide brake diagram . . ... 49

springer brake diagram . . 49

rear brake diagram . . . 50

adjusting rear & springer brakes. 51 servicing rear & springer brakes. 51

Servicing Saddle Spring Post. . 52

Engines

general . . . . . .. 54

engine diagram . . . ... 55

lubrication . . . . ... 56

winter lubrication . . . .. 57

changing oil . . . . .. 57

oil pressure signallight. . . 57

operating oil pressure. . .. 57

oil filter . . . . . .. 57

pressure oil system. . . 58

return oil system . . . .. 59

engine repair procedure. . 59

pressure oil system diagram . 61

return oil system (early). . 62

return oil system (late) . . . 63

disassembling cylinder & piston.. 64

refinishing cylinders . . ... 65

fitting piston rings . . . . 66

connecting rod bushings . ... 67

straightening connecting rods ... 68 assembling cylinder & piston ... 69

Shop Data

cylinder reboring & piston fitting.. 70 pistons & rocker arms. . .. 72

removing cylinder head assembly. 73

disassembling cylinder head----73

replacing valve guides. . . 73

cylinder head diagram . . . 74

replacing valve seats . . .. 75

grinding valve faces & seats . 75

lapping valve faces & seats. . 76

assembling cylinder head. ... 76

adjusting tappets. . . .. 76

Shop Data

valve guides. . . . .. 77

installing high lift cam . . . 78

intake valve guides . . . 79

valve guide sizes. . . .. 80

exhaust valve rotating mechanism 81 valve spring testing information.. 82

FLH valve springs . . . . 83

hydraulic pushrods . . . 84

adjusting hydraulic pushrods . 85 servicing hydraulic pushrods . 86 tappet check valve servicing . 88 misc. clearances & oil pressure.. 89

Oil Pump. . . . . ... 90

servicing oil pump. . . . 90

installing oil pump. . . . 91

Shop Data

oil control . . . . . 92

oil pump charges. . . .. 94

late oil pump . . . . . 96

oil pump flow diagram. . . 97

1948-1954 Lower End Diagram. . 98

Disassembling Lower End . . 99

installing timing gears . . .100

installing timing gear case cover. 100 1948-1954 gear & crankcase data

procedures . . . . .100

truing & sizing main bearing

races . . . . . ..101

fitting main bearings. . ...102

servicing flywheels & installing

crankpan . . . . ...102

truing & sizing connecting rod

lower races . . . . 102

determining correct lower

bearing fit. . . . ..103

assembling connecting rods &

flywheels . . . . ...103

truing flywheels . . . ...104

assembling crankcases. . .105

installing generator . . . 106

Shop Data

removing & replacing pinion

shaft gear . . . . ..1P7

crankcase drilling procedures ...109

connecting rod roller & retainer

size chart . . . . ..111

engine fitting specifications. .112

servicing pinion shaft rollers ... .113

pinion shaft assembly diagram.. .114

1955-1957 oil pump diagram . 115

1953-1957 Valve Tappets & Guides.. 116

1954-1957 Gear Case Diagram ____118

1954-1957 Gear Case Timing Cases. 119

1955-1957 Crankcase . . . 122

1955-1957 Complete Lower End
Shop Data
engine fitting data ’55 & later____131

roller bearing roller guides. ..132

identification of roller retainers. .134
Adjusting Carburetor . . . 136

disassembling carburetor. ...136

carburetor diagram . . . 137

cleaning & repairing carburetor.. 138

assembling carburetor . . .139

air cleaner . . . . ...139

fuel strainer . . . . ..140

fuel tanks . . . . . 140
Shop
servicing notes for carburetor.. .141 specification chart for carburetor. 142

float bowl . . . . . 143

adjusting carburetor on engine ..144

carburetor conversions. . .145

manifold . . . . . .146

carburetor specifications. . 147

general . . . . . ..148

clutch general . . . . 151

adjusting foot clutch control----151

adjusting hand clutch control ...151

adjusting clutch . . . ...152

disassembling clutch . . ..152

cleaning & inspecting clutch . 153

assembling clutch . . . .154

disassembling starter . . ..155

cleaning & inspecting starter ... .155

assembling starter. . . .155

disassembling starter clutch . .155 cleaning & inspecting starter

clutch . . . . . .155

assembling starter clutch . .. .156

starter diagram . . . ...156

adjusting shifting linkage . ...157

adjusting foot shifter cover. .157

replacing main drive gear oil

seal . . . . . ...157

removing shifter cover . . .158

disassembling shifter cover. .159

cleaning & inspection shifter

cover . . . . . ..159

assembling shifter cover. . 159

shifter cover diagram

(footshift) . . . . ..160

replacing shifter cover. . ..162

removing shifter forks. . ..162

disassembling shifter forks. ..162

cleaning & inspection shifter

forks . *. . . . ..162

assembling shifter forks. . 163

disassembling gear box. . 163

counter shaft assembly diagram. .164

disassembling mainshaft . ...165

disassembling main drive gear... 166

assembling main drive gear. .167

assembling main shaft . . .167

assembling counter shaft. ...167

transmission vent screw. . 168

Electrical

wiring diagram for 1948 model . .170

wiring diagram for 1949-54 . .171

wiring diagram for 1955-57

(standard) . . . . .172

wiring diagram for 1955-57

(radio special). . . ..173

Ignition Light Switch. . . .176

Button Switch . . . . ..177

Headlamp Dimmer & Horn Switch.. 177
Data

Headlamps . . . . . .178

3 Brush 32E Generator Diagram.. .179 radio 2 brush generator diagram. 181 trouble shooting & repairing

generator . . . . ..183

removing generator. . . 184

testing field colls & brush holders

assembled. . . . ..184

disassembling generator. . 186

testing armature . . . ..188

turning down commutator. ..189

undercutting commutator. ...189

reassembling generator . . 189

assembling generator to engine.. 190

generator charging rate. . 190

replacing generator brushes____190

cleaning commutator . . ..190

lubricating commutator end

armature bearing . . . 191

cut out relay . . . . .191

generator brush diagram. ...192

current & voltage regulator. .193

fan cooled generator . . ..194

fan cooled generator diagram .. .195

Shop Data

fan cooled generator . . ..198

model 32E 2R radio generator

diagram . . . . . 199

model 48 3 brush fan cooled

generator diagram . . ..200

model 48 2 brush fan cooled

generator diagram . . ..201

model 51 *52 & later 2 brush fan

cooled generator diagram____202

model 32E standard 3 brush

generator diagram . . ..203

model 52 standard 3 brush generator diagram . . ..204

Circuit Breaker Description . ...205

single contact point manual

advance . . . . ...205

double contact point manual

advance . . . . ...205

adjusting circuit breaker points..206 checking & adjusting ignition

timing . . . . . .206

circuit breaker diagram . . 208

removing circuit breaker . ...210

inspection & replacement of

parts circuit breaker. . .210

Ignition Coil . . . . . 212

Spark Plugs . . . . . 213

Shop Data

regulator service information____215

Battery. . . . . . .217

Horn . . . . . . ...218

Miscellaneous

removing side car from

motorcycle . . . . .222

attaching side car to

motorcycle . . . . .222

side car wiring digram. . .222
Servicing Speedometer . . ..223