Index Harley Davidson Harley Davidson SS/SX-1975/250 (1974 to 1976). Service manual

Harley Davidson SS/SX-1975/250 (1974 to 1976). Service manual - page 1

1974-76
SS/SX-175/250
SERVICE

MANUAL
PRODUCT

CHASSIS

ENGINE

TRANSMISSION 4

ELECTRICAL 5

MISCELLANEOUS S

The SS and SX models are similar in most respects and the information in this manual applies to both unless otherwise specified. The specific year and model designations are as follows:
1976 & Later
1974
1975
SS/SX-175

SS/SX-250
SX-175
SX-175/250 SS-250

FOREWORD
This service manual has been prepared with two purposes in mind. First, it will acquaint the reader with the construction of Harley-Davidson products and assist him in performing basic maintenance and repair. Second, it will introduce the latest field-tested and factory-approved major repair methods to the professional Harley-Davidson mechanic. We sincerely believe that this manual will make your association with Harley-Davidson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL

Your sen/ice manual is arranged for quick, easy reference. It is divided into numbered sections such as: "Chassis," "Engine" and "Transmission." Sections are then divided into sub-sections. The engine section, for example, is made up of sub-sections such as "Cylinder," "Crankcase," etc.

Use this manual as follows:

1. Check the Table of Contents located in front of each section to find subject desired.

2. Page number is listed across from subject.

3. Each section is printed with section number for quick general location of subject. Page number consists of section number and page number.

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

Minor adjustments Minor maintenance or repair Complete disassembly Cleaning

Major maintenance or repair Assembly

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

All information for servicing a part should be read before repair work is started to avoid needless disassembly.

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

To insure 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 half 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.

Gasoline is extremely flammable and highly explosive under certain conditions. Always stop engine and do not smoke or allow open flame or sparks when refueling or servicing the fuel system or when using gasoline as a cleaning solvent where specified in this manual.
Harley -Davidson products are manufactured under one or more of the following patents: U.S. Patents -D-l 99,479,2510222, 2574739, 2770869, 2783927, 2788676, 2872660, 2986162, 2987934, 2998809, 3116089, 3144631, 3144860, 3226994, 3229792, 3434887, 3559773. Canadian Patents - 487981, 490652.

TABLE OF CONTENTS

PRODUCT

SPECIFICATIONS

Dimensions 1-1

Capacities 1-1

Engine 1-1

Ignition System 1-1

Transmission 1-1

Sprockets and Gear Ratios 1-1

Tire Data 1-2

Vehicle Identification Number 1-2

TORQUE SPECIFICATIONS Fastener Tightening Specifications 1-3

Metric Conversion Table 1-5

SERVICE

Servicing a New Motorcycle 1-6

Regular Service Intervals 1-6

Lubricants 1-6

Gasoline 1-6

Lubrication and Service Chart, 1975 L Earlier 1-8

Lubrication and Service Chart, 1976 L Later 1-9

LOCATING TROUBLES

Engine 1-10

Carburetor 1-11

Transmission 1-11

Clutch 1-11

Brake 1-11

CHASSIS

DRIVE

Chains 2-1

Drive Chain Adjustment 2-1

Removing and Installing Rear Chain 2-1

Front and Rear Chain Lubrication 2-2

WHEELS

Wheel Service Chart 2-3

Removing and Installing Front Wheel 2-4

Disassembling and Assembling Front Wheel Hub 2-5

Removing and Installing Rear Wheel Quick Detach 2-5

Removing and Installing Rear Wheel and Brake Sprocket Assembly 2-6

Disassembling and Assembling Rear Wheel Hub - Steel 2-6

Disassembling and Assembling Rear Wheel Hub - Aluminum 2-6

Disassembling and Assembling Rear Wheel Brake - Sprocket Assembly - Steel Hub 2-7

Disassembling and Assembling Rear Wheel Brake - Sprocket Assembly - Aluminum Hub 2-7

Spoking Front and Rear Wheel 2-8

Truing Wheel 2-9

Removing Tire and Tube From Rim 2-10

Installing Tire and Tube On Rim Tire Bead Clamps
HANDLEBAR

Removing and Installing Handlebar 2-13

Removing and Replacing Throttle Cable Assembly 2-13

Removing and Replacing Cables From Handlebar Levers 2-14
FORKS
Front Fork and Steering
Head Changing Fork Oil 2-15
Removing and Installing
Fork Side 2-15
Disassembling Marzocchi
Fork Side 2-15
Disassembling Ceriani
Fork Side 2-16
Disassembling Betor
Fork Side 2-17
Cleaning and Inspecting
Fork Side 2-19
Assembling Fork Side 2-19
Disassembling and Assem-
bling the Steering Head 2-19

FRAME AND REAR SUSPENSION Servicing Frame Basic Frame Dimensions Rear Suspension - General Disassembling and Assembling Rear Suspension Adjusting Rear Fork Pivot Pin

BRAKES

Servicing Brakes Adjusting Front Brkke Adjusting Rear Brake Replacing Front Brake Cable

Replacing Rear Brake Cable

Disassembling Front Brake Disassembling Rear Brake Cleaning and Inspecting Assembling Brakes

TOOLS

ENGINE

GENERAL

Specifications Connecting Rod Description

ENGINE REMOVING AND INSTALLING General

Stripping Motorcycle Engine for Repair Reinstalling Engine

CYLINDER AND PISTON General

Disassembling Cylinder Head, Cylinder and Piston

Cleaning and Inspecting 3-6
Checking Clearances and
Fits 3-6
Piston - Cylinder 3-6
Piston Rings 3-7
SX-175 Cylinder - Piston
Color Code 3-8
SX-250 Cylinder - Piston
Color Code 3-9
Assembling Cylinder and
Piston 3-10
Piston Component
Clearances 3-10

CRANKCASE

Disassembling 3-13

Exploded View of Crankcase Parts 3-13

Partial Engine Disassembly 3-14 Splitting Crankcase Without Special Tools 3-16

Cleaning and Inspecting 3-16

Assembling 3-17
CRANKSHAFT

Disassembling 3-19

Cleaning and Inspecting 3-19

Assembling Crankshaft 3-19

Truing Crankshaft Assembly 3-20

Installing Crankshaft Assembly in Crankcase 3-21

Adjusting Crankshaft End Play 3-22

Crankshaft Clearances 3-22
FUEL SYSTEM

Carburetor 3-23

General 3-23

Starting 3-23

Low Speed Operation 3-23

High Speed Operation 3-24

Adjusting 3-24

Removing and Partial Disassembling of Carburetor 3-25

Complete Disassembling of Carburetor 3-25

Exploded View of SS/

SX-175 Carburetor 3-26

Exploded View of SS/

SX-250 Carburetor 3-27

Cleaning, Inspecting and Repairing 3-28

Checking Float Level 3-28

Assembling Carburetor 3-28

Remounting 3-29

Gas Tank 3-29

General 3-29

Disassembling 3-29

Repairing Leaking Tanks .3-29

Cleaning and Inspecting 3-30

Assembling 3-30

Fuel Supply Valve

General 3—30

Cleaning and Inspecting 3^30

LUBRICATION SYSTEM

General 3-31

Precautions 3-32

Adjusting Oil Pump 3-32

Removing and Installing Oil Pump 3-32

Bleeding Oil Pump 3-33

Oil Tank 3-33

Cleaning and Inspection 3-33

EXHAUST SYSTEM

Muffler 3-35

General 3-35

Disassembling 3-35

Cleaning and Inspecting 3-35

Assembling 3-35

AIR CLEANER

General 3-37

Cleaning and Repla6ing 3-37

Alternate Air Cleaner Arrangement 3-38

TOOLS 3-39

TRANSMISSION

GENERAL

Specifications 4-1

Description 4-1

Transmission Gear Ratios 4-1

CLUTCH

General Clutch Description 4-3 Disassembling 4-3

Clutch Adjusting 4-6

Diagnosis Chart 4-6

Cleaning and Inspecting 4-7

Assembling'. 4-8

Disassembling and Assembling Later Clutch 4-8

Removing Plates of Later Clutch Using Special Tool 4-9

STARTER

General 4-11

Dlsassemblng 4-12

Cleaning and Inspecting 4-12

Assembling 4-13

Starter Clearances 4-13

SHIFTER

Disassembling Cleaning and Inspecting Assembling

TRANSMISSION COMPONENTS Transmission Disassembling Roller Bearing Type Exploded View of Later Transmission (SX-250) Cleaning and Inspecting Assembling Lubrication

Disassembling and Assembling Roller Bearing Transmission (Later SX-250)

TOOLS
ELECTRICAL

SPECIFICATIONS

WIRING

1974 and Early 1975, Type A Handlebar Switch/ 71505-:73P Key Switch Late 1975, Type В Handlebar Switche8/71505-73PA Key Switch Late 1975, Type В Handlebar Switches/71505-75P Key Switch Late 1975, Type С Handlebar Switches/71505-75P, 71514-75P Key Switch 1976 and Later

ELECTRICAL SYSTEM General

ALTERNATOR

Alternator

Removing and Installing Alternator Troubleshooting Ignition Timing

IGNITION MODULE Ignition Module Troubleshooting

RECTIFIER

Rectifier

Troubleshooting

IGNITION COIL Description Troubleshooting Replacing Spark Plug Cable

BATTERY General Battery Case Charging Battery Load Testing of Battery Reclaiming Sulphated Battery Changing Electrolyte

IGNITION - LIGHT KEY SWITCH ' Ignition - Light Key Switch Troubleshooting

HANDLEBAR SWITCHES Handlebar Switches

SPARK PLUG Spark Plug

HEADLAMP

Headlamp

fOOLS
MISCELLANEOUS

INSTRUMENTS

Speedometer

General

Removing and Servicing

TACHOMETER

General

Removing and Servicing

PRODUCT
TABLE OF CONTENTS

PAGE

General .......................1-1

Torque Specifications .................1-3

Service........................1-6

Locating Troubles ...................1-10

GENERAL

CHASSIS
TABLE OF CONTENTS

PAGE

Drive ........................2-1

Wheels ........................2-3

Handlebar ......................2-13

Front Fork & Steering Head .............2-15

Frame & Rear Suspension ..............2-21

Brakes .......................2-25

Tools .......................2-29

Content .. 1 2 ..

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