PRE-RIDE / DAILY INSPECTION
Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
Tires - check condition and pressures
Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank
All brakes - check operation (includes auxiliary brake)
Throttle - check for free operation
Engine stop switch - check for proper function
Wheels - check for loose wheel nuts
Air cleaner element - check for dirt or water; clean or replace
Steering - check for free operation, noting any unusual looseness in any area
Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
Engine coolant - check for proper level at the recovery bottle
FUEL LINES
1. Check fuel lines for signs of wear, deterioration, damage or leakage. Replace if necessary.
2. Be sure fuel lines are routed properly and secured with cable ties. CAUTION: Make sure lines are not kinked or pinched.
3. Replace all fuel lines every two years.
VENT LINES
1. Check fuel tank, oil tank, carburetor, battery and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years.
2. Be sure vent lines are routed properly and secured with cable ties. CAUTION: Make sure lines are not kinked or pinched.
FUEL FILTER
The fuel filter should be replaced in accordance with the Periodic Maintenance Chart. The fuel filter is located between the fuel pump and carburetor.
1. Shut off fuel supply at fuel valve.
2. Remove line clamps at both ends of the filter.
3. Remove fuel lines from filter.
4. Install new filter and clamps onto fuel lines with arrow pointed in direction of fuel flow.
5. Install clamps on fuel line.
6. Turn fuel valve ON.
7. Start engine and inspect for leaks, refer to Harley manual for more information.
CARBURETOR DRAINING
The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl, or before extended periods of storage.
1. Turn fuel valve to the off position.
2. Place a clean container beneath the bowl drain spigot or bowl drain hose.
3. Turn drain screw out two turns and allow fuel in the float bowl and fuel line to drain completely.
4. Inspect the drained fuel for water or sediment.
5. Tighten drain screw.
6. Turn fuel valve to “ON”.
7. Start machine and check for leaks.
NOTE: If there is a tube attached, it must be reattached as this will effect engine performance.
SHIFT LINKAGE ADJUSTMENT
1. Inspect shift linkage tie rod ends, clevis and pivot bushings and replace if worn or damaged.
2. Place gear selector in neutral.
3. Loosen rod end adjuster jam nuts on both ends of linkage rod.
NOTE: The jam nut closest to the knurled end is Left Hand thread.
4. Turn linkage rod to shorten or lengthen rod until the shift lever is centered on hole in the fender.
5. Hold rod end parallel to mounting surface and tighten jam nuts securely.
THROTTLE OPERATION
Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must return freely without binding.
1. Place the gear selector in neutral.
2. Set parking brake.
3. Start the engine and let it idle.
4. Turn handlebars from full right to full left. If idle speed increases at any point in the turning range, inspect throttle cable routing and condition. If cable is routed properly and in good condition, repeat adjustment procedure.
5. Replace the throttle cable if worn, kinked, or damaged.
CHOKE (ENRICHER) ADJUSTMENT
If the choke knob does not stay out when pulled, adjust the choke tension by tightening the tensioner located under the rubber boot between the choke knob and nut. Firmly grasp the rubber boot and tighten until the choke slides freely but stays out when pulled. Verify free play of (see reference manual links) and smooth operation of choke cable. If smooth choke operation is not obtainable, inspect
choke cable for kinks or sharp bends in routing.
PILOT SCREW
The pilot systemsupplies fuel during engine operation with the throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into themain bore through the pilot outlet.
PILOT SCREW ADJUSTMENT
1. Start engine and warm it up to operating temperature (about 10 minutes).
2. Turn pilot screw in (clockwise) until lightly seated. Turn screw out the specified number of turns.
NOTE: Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be permanently damaged.
3. Connect an accurate tachometer that will read in increments of + or -- 50 RPM.
4. Set idle speed to 1200 RPM. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.
5. Slowly turn mixture screw clockwise using the pilot screw wrench until engine begins to miss.
6. Slowly turn mixture screw counterclockwise until idle speed increases to maximum RPM. Continue turning counterclockwise until idle RPM begins to drop.
7. Center the pilot screw between the points in Step 5 and 6.
8. Re adjust idle speed if not within specification.
IDLE SPEED ADJUSTMENT
1. Start engine and warm it up thoroughly.
2. Adjust idle speed by turning the idle adjustment screw in (clockwise) to increase or out (counterclockwise) to decrease RPM. (reference links).
NOTE: Adjusting the idle speed affects throttle cable freeplay and electronic throttle control adjustment. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.
THROTTLE OPERATION
To remove the ETC cover:
1. Use a medium flat blade screwdriver and insert blade into the pockets of the cover starting on the #1 position.
2. Twist screwdriver slightly while lifting on the cover to release snap.
3. Repeat procedure at the other five locations as shown.
NOTE: Do not attempt to remove cover until all latch points are released. Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must return freely without binding. Replace the throttle cable if worn, kinked, or damaged.
SPARK PLUG
1. Remove spark plug high tension lead. Clean plug area so no dirt and debris can fall into engine when plug is removed.
2. Remove spark plug.
3. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes.
4. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used.
5. Measure gap with a wire gauge. Refer to specifications for proper spark plug type and gap. Adjust gap if necessary by bending the side 0electrode carefully.
6. If necessary, replace spark plug with proper type. CAUTION: Severe engine damage may occur if the incorrect spark plug is used.
7. Apply a small amount of anti-seize compound to the spark plug threads.
8. Install spark plug and torque to 9--11 ft. lbs (12--14 Nm).
NGK BR9EG-N8
NGK BR8EG
NGK BR8EIX
NGK Double Platinum Spark Plug
NGK honda spark plug
IGNITION TIMING
Refer to Electrical chapter for ignition timing procedure.
AIR FILTER/PRE-FILTER SERVICE
It is recommended that the air filter and pre filter be replaced annually. When riding in extremely dusty conditions, replacement is required more often. The pre filter should be cleaned before each ride using the following procedure:
1. Lift up on the rear of the seat.
2. Pull the seat back and free of the tabs. NOTE: When reinstalling seat, make sure the slots in the seat engage the tabs in the fuel tank.
3. Remove clips from air box cover and remove cover. Inspect the gasket. It should adhere tightly to the cover and seal all the way around.
4. Loosen clamp and remove air filter assembly
Cleaning:
5. Slip the pre-filter element off of main element. Clean the pre filter with hot soapy water.
6. Rinse and dry thoroughly.
7. Inspect element for tears or damage.
8. Inspect main filter and replace if necessary. If the filter has been soaked with fuel or oil it must be replaced.
Installation:
9. Reinstall pre-filter element over main filter. Be sure the element covers entire surface of main filter without folds, creases, or gaps.
10. Reinstall filter on main filter mount. Place filter clamp over the assembly and tighten. NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling. NOTE: The air filter should rest on the filter support. Proper placement of the air filter is important to prevent rattles and air leaks. See Illustration above.
11. Install air box cover and secure with clips.
ENGINE OIL LEVEL
To check the oil level:
1. Set machine on a level surface.
2. Start and run engine for 20-30 seconds. This will return oil to its true level in the engine sump.
3. Stop engine, remove dipstick and wipe dry with a clean cloth.
4. Reinstall dipstick, screwing into place.
5. The dipstick must be screwed completely in to ensure accurate measurement.
6. Remove dipstick and check to see that the oil level is in the normal range. The oil should be between the top of the bottom crosshatched area and the bottomof the top crosshatched area. Add oil as indicated by the level on the dipstick. Do not overfill. NOTE: Do not fill the over the normal oil operating range. Filling over the normal operating range could cause a mist of oil to enter the air box. NOTE: Rising oil level between checks in cool weather driving, can indicatemoisture collecting in the oil reservoir. If the oil level is over the full mark, change the oil.
VALVE CLEARANCE
Inspect and adjust valve clearance while the engine is cold and the piston positioned at Top Dead Center (TDC) on compression stroke.
1. Remove the seat.
2. Remove body panels and fuel tank as necessary to gain access to valve cover.
3. Remove the spark plug high tension lead and remove the spark plug. CAUTION: Place a clean shop towel into the spark plug cavity to prevent dirt from entering.
4. Remove plastic valve plugs.
5. Remove timing inspection plug from recoil housing. CAUTION: Failure to position the crankshaft at TDC on compression stroke will result in improper valve adjustment.
6. Rotate engine slowly with recoil rope, watching the intake valve(s) open and close. NOTE: Observe the intake valve closing and then start to open, continue to rotate until the “T” aligns with pointer. The camshaft lobes should be pointing downward.
7. Verify accurate TDC positioning by observing the “T” mark aligned with the pointer in the timing inspection hole. In this position there should be clearance on all valves.
