Harley Davidson military motorcycle model 42WLA-Solo. Operation and maintenance Manual (August, 1942) — page 1

OPERATION and MAINTENANCE MANUAL

HARLEY-DAVIDSON MILITARY MOTORCYCLE
Model 42WLA-Solo *

Built for the United States Army *

Contract Numbers:

W-398-QM-10530 W- 398-QM-1T782

U.S. A, Registration Numbers: W69,888-W69,999 Incl.

W610,000-W614,687 Incl.

616,923-637,235 Incl.

671,621-686,620 IncL
Harley-Davidson Motor Co.

Milwaukee, Wisconsin/ U.S.A.
ТМ 10-1175

Reprinted August, 1942

ТМ 10-1175
WAR DEPARTMENT Washington, September 11,1941

TM-10-1175, Maintenance Manual, Motorcycle, Solo, Harley-Davidson (Model 42-WLA) published by the Harley-Davidson Motor Company ie furnished for the information and guidance of all concerned.

(AG 062.11 (4/26/41) PC (C).

June 10, 1941.)

By order of the Secretary of War:

G. C. MARSHALL,

Chief of Staff

Official:

E. S. ADAMS,

Major General,

The Adjutant General

HARLEY-DAVIDSON MILITARY MOTORCYCLE MODEL 42 WLA—SOLO BUILT FOR THE UNITED STATES ARMY

CONTRACT NUMBERS: W-398-QM-10530 AND W-398-QM-11782 U. S. A. REGISTRATION NUMBERS W69.888 TO W69.999 INCLUSIVE W610.000 TO W614,687 INCLUSIVE 616.923 TO 637.235 INCLUSIVE 671.621 TO 686.620 INCLUSIVE

ТM10-1175

REPRINTED AUGUST, 1942
GENERAL INDEX Page 3
OPERATION AND CARE Pages 8 to 14
PREVENTIVE MAINTENANCE, Pages 14 to 19
LIGHT MAINTENANCE Pages 20 to 25
ENGINE LUBRICATION

Pages 25 to 27

t
ENGINE OVERHAUL Pages 28 to 45
ELECTRICAL SYSTEM Pages 46 to 58
CARBURETOR SERVICE Pages 58 to 61
TRANSMISSION AND CLUTCH, Pages 62 to 70
WHEELS, HUBS AND TIRES, Pages 70 to 72
CHASSIS ALIGNMENT Pages 72 and 73
SPECIAL TOOLS Pages 75 to 80
This Manual supersedes

GENERAL INDEX
OPERATION AND CARE. . . . . . . . . ...Section One

Pages 7 to 17 Incl.

MAINTENANCE. . . . . . . . . . . ...Section Two

Pages 18 to 80 Incl.
Pages

Air Cleaner. . . . . . . . . . . . . . . . . . . . . 10, 16

Battery, Care of. . . . . . . . . . . . . . . . . . . . 12, 52

Brakes, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9, 22

Capacities, Gasoline and Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Carburetor, Adjusting. . . . . . . . . . . . . . . . . . ... 23,61

Chains, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Chains, Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..20

Chains, Repairing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Circuit Breaker and Timer . . . . . . . . . . . . . . . . . 24,31,40

Clutch Controls, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,21

Damper, Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..9, 24

Lamps. . . . . . . . . . . . . . . . . . . . . . . 57, 58

Lubrication, Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..9, 25

Lubrication, Transmission. . . . . . . . . . . . . . . . . ... 12, 15

Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..15

Plugs, Spark. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..12

Points, Circuit Breaker. . . . . . . . . . . . . . . . . . .. 24, 40

Shifter, Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..9, 21

Signal Lights, Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Specifications, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6

Strainer, Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Switch, Ignition-Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..9, 53

Tank, Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6, 9

Tank, Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 9

Tappets, Valve. . . . . . . . . . . . . . . . . . . . . 12, 23

Tire Inflation Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6, 72

Trouble Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Wheels, Hubs and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..70

Wiring Diagrams Г. . . . . . . . . . . . . . . . . . . .54 to 56

INDEX TO SECTION ONE (Operation and Care)
Pages

Air Cleaner. . . . . . . . . . . . . . . . . . . . . .10, 16

Battery, Care of. . . . . . . . . . . . . . . . . . . . ... 12

Controls and Their Operation (Top View, Details 1 to 18). . . . . . . . . . . . . . . . . . . . . . . 8

Daily Maintenance Schedule, Operator . . . . . . . . . . . . . . . . 14

Engine, Running in New. . . . . . . . . . . . . . . . . . ... 13

Engine, Starting. . . . . . . . . . . . . . . . . . . . ... 13

Engine, To Stop. . . . . . . . . . . . . . . . . . . . ... 13

Left Side Description (Left Side View, Details 19 to 38). . . . . . . . . . . . 10

Lubrication Chart . . . . . . . . . . . . . . . . . . . . . 15

Operating Instructions, Summary of . . . . . . . . . . . . . . . . 14

Right Side Description (Right Side View, Details 39 to 58) . . . . . . . . . . . . 11

Signal Lights, Instrument Panel. . . . . . . . . . . . . . . . . . 12

Switch, Ignition-Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Tank, Gasoline. ... . . . . . . . . . . . . . . . . . . . 6, 9

Tank, Oil . . . . . . . . . . . . . . . . . . . . . . .6, 9

Trouble Chart. . . . . . . . . . . . . . . . . . . . . . 13

INDEX TO SECTION TWO
(Maintenance)

Alignment, Frame and Fork

Alignment, Wheel Rim. . .

Battery, Care of. . . ...

Bearings, Engine Main. .

Bearings, Connecting Rod Lower Bearings, Transmission . ...

Brakes, Adjusting . . . . . . . 22

Bushings, Connecting Rod Upper. . . ... 44

Bushings, Timing Gear Shaft. . . . .. 33

Carburetor, Adjusting. . . . . . . 23

Carburetor Service. . . . . . ... 58

Chains, Adjusting. . . . . . . 20

Chains, Lubricating . . . . . . .. 20

Chains, Repairing. . . . . . . 20

Circuit Breaker and Timer. . . . 24, 30, 40

Clutch Adjusting. . . . . . . . 21

Clutch, Disassembling . . . . . . 22

Clutch, Reassembling. . . . . . .22

Clutch Assembly Illustration . . . . .. 63

Clutch Hub, Removing. . . . . . 67

Clutch Hub, Installing. . . . . . . 68

Coil, Ignition. . . . . . . . . 52

Connecting Rods, Aligning. . . . . 41

Control Wire, Front Brake, Replacing. . .. 24

Control Wires, Throttle and Spark, Replacing ... 24

Crankcases, Assembling. . . . . .. 36

Cylinders, Reboring and Rehoning. . . . 32

Damper, Steering. . . . . . . . 24

Electrical System. . . . . . . . 48

Engine, Overhauling. . . . . . .. 29

Engine, Disassembling. . . . . . 29

(Top Overhaul Only)

Engine, Removing (Assembled). . . . 30

Engine, Disassembling. . . . . . 30

(For Complete Overhaul)

Engine, Fitting and Reassembling. . . .. 31

Engine, Installing. . . . . . . . 43

Flywheels, Assembling . . . . . ... 35

Flywheels, Truing. . . . . . . 36

Generator Assembly Illustration. . . ... 46

Generator, Removing. . . . . . . 48

Generator, Testing. . . . . . 48 to 50

Generator, Disassembling. . . . . . 49

Generator, Reassembling . . . . . . 50

Generator, Installing . . . . . ...37, 51

Guides, Valve ...:. . . . . . . 32

Guides, Valve Tappet . . . . . . 33

Handlebar Controls, Servicing. . . .:... 24

Horn . . . . . . . . . . 57

Inspection, Higher Echelon. . . . . 19

Lamps . . . . . . . . . 57, 58

Lubrication, Engine. . . . . . ... 25

Maintenance, Regular Interval . . . . 18

New Motorcycle, Initial Servicing of. . . 18

Pistons, Fitting Oversize . . . . . .. 32

Pistons, Removing and Installing. . . .. 43

Piston and Ring Service, Emergency. . ... 43

Points, Circuit Breaker. . . . . . 24

Pump, Oil Feed. . . . . . ..25, 30, 40

Pump, Oil Scavenger. . . . . 25, 30, 37

Radio Interference Suppression. . . ..57, 74

Relay, Cut-out. . . . ...". . . . 52

Rings, Piston. . . . . . . ...43, 44

Saddle Spring Post Assembly. . . . . 25

Shifting Controls. . . . . . ...21, 68

Signal Lights, Instrument Panel . . . . 25

Specifications, Engine . . . . . . 45

(Fitting and Adjusting)

Specifications, Transmission. . . . ... 70

(Fitting and Adjusting)

Specifications, Lubricant . . . . . .. 15

Springs, Valve. . . . . . . ... 33

Switch, Ignition-Light . . . . . . . 53

Tappets, Valve (Adjusting). . . . . 23

Tappets, Valve (Servicing) . . . . . 33

Timing Crankcase Breather Valve. . . . 37

Timing Ignition. . . . . . . ... 40

Timing Gears. . . . . . . . 40

Timing Mark, Flywheel. . . . . .37, 40

Tires and Tubes. . . . . . . .. 71

Tools, Manufacturer's Special. . . . . 75

Transmission Assembly Illustration. . . 62

Transmission, Removing . . . . . .. 66

Transmission, Disassembling. . . . .. 66

Transmission, Assembling. . . . . . 67

Transmission Endplay Adjustments. . . 67

Transmission, Installing. . . . . ... 69

Valve, Crankcase Breather. . . . . 37

Valves, Intake and Exhaust. . . . ... 32

Valve Seats, Cylinder. . . . . . 32

Wheels, Removing and Installing . . . . 70

Wheels, Hubs and Tires. . . . . .. 70

Wiring Details. . . . . . . ... 54

GENERAL SPECIFICATIONS

FOREWORD

The more satisfactory and dependable performance of one motorcycle over another, when both are in the same type of service, is not generally due to any appreciable variation in original quality and construction. Experience has proven that it is usually the direct result of the operator's knowledge of correct operating methods and his diligence in applying this knowledge.