Harley Davidson DUO-GLIDE 74 OHV. Service manual (1959) - page 1

 

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Harley Davidson DUO-GLIDE 74 OHV. Service manual (1959) - page 1

 

 

 

SERVICE MANUAL

1959 DUO-GLIDE 74 OHV

The maintenance and repair information in this manual applies directly to the 1959 Harley-Davidson 74 OHV Duo-Glide Model Motorcycle. Except for minor differences, it also applies to the 1958 Duo-Glide 74 OHV Model.
In general, this manual will also be useful in maintaining and repairing earlier 61 and 74 OHV Models. 

 

Foreword
Many thousands of Harley-Davidson motorcycles and Servi-Cars are purchased each year for pleasure and sport riding as well as for commercial use. All Harley-Davidson products have been designed and built to exacting specifications to give a maximum of reliability with a minimum of maintenance and repair.

This service and repair manual has been prepared with two purposes in mind. First, it will acquaint the reader with the construction of the Harley-Davidson product and assist him in performing basic maintenance and repair. Secondly, it will introduce to the professional Harley-Davidson mechanic the latest field-tested and factory-approved major repair methods. 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 Service Manual is arranged for quick, easy reference. The manual is divided into sections such as ’’Chassis,M ’’Engine” and ’’Transmission.” Sections are then divided into sub-sections. The Transmission section, for example, is made up of’’Clutch," ’’Starter” and ’’Gear Box” sub-sections. Sections are numbered and sub-sections are lettered. Manual pages are identified by section number and sub-section letter printed in upper and lower outside corners.

Use this manual as follows:

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

2. Page number is listed across from subject.

3. A card separator at beginning of each section is printed with section number for quick general location of subject. Page number consists of section number, sub-section letter and sub-section 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

 

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

As an aid in determining application of manual information to earlier than 1959 models, refer to the parts catalog for the specific model.

Questions regarding the application of manual information to any specific model should be referred to your Harley-Davidson dealer.

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.

 

 

TABLE OF CONTENTS

 

PRODUCT
GENERAL

Duo-Glide Specifications 1A-]

Sprocket and Gear Ratios 1A-]

Tire Data 1A-]

SERVICE

Servicing a New Motorcycle 1B-] Lubrication and Service 1B-J

LOCATING TROUBLES

Engine 1C-]

Generator 1C-1

Carburetor 1C-2

Transmission 1C-2

Clutch 1C-2

Brakes 1C-J

CHASSIS

DRIVE

Chain Adjustment 2B-1

Chain Lubrication 2B-1

Removing Front Chain 2B-2

WHEELS

Removing Wheels 2C-1

Wheel Hub 2C-3

Spoking Wheels 2C-4

Truing Wheels 2C-4

Tires 2C-6

HANDLEBAR

Spark and Throttle Controls 2D-1

FRAME

Basic Dimensions 2E-2

FORKS

Changing Front Fork Oil 2F-1

Disassembling Fork Slider 2F-5

Adjusting Steering Damper 2F-5

Adjusting Front Fork Trail 2F-6

Disassembling Front Fork 2F-6

Replacing Front Fork Slider Bushings 2F-7

Straightening Front Fork 2F-8

Rear Shock Absorbers 2F-1

Rear Fork 2F-1

BRAKES

Adjusting Front Brake 2G-1

Disassembling Brakes 2G-1

Adjusting Rear Brakes 2G-3

Rear Brake Master Cylinder 2G-3

SEAT

Seat Post 2H-1

ENGINE

GENERAL

Engine Specifications 3A-1

Engine Description 3A-1

Lubrication 3A-3

GENERAL (continued)

Servicing Oil Filter 3A-4

Pressure Oil System 3A-5

Return Oil System 3A-7

Engine Repair Procedure 3A-7

Stripping Motorcycle for Engine Repair 3A-7

CYLINDER HEAD

Removing Cylinder Head 3B-1

Replacing Valve Guides 3B-1

Replacing Valve Seats 3B-3

Grinding Valves 3B-3

Lapping Valves 3B-4

Adjusting Tappets 3B-4

CYLINDER

Disassembling Cylinder and Piston 3C-1

Refinishing Cylinder 3C-2

Fitting Piston Rings 3C-3

Replacing Rod Bushing 3C-4

Straightening Connecting Rods 3C-5

GEARCASE

Servicing Oil Pump 3D-1

Valve Tappets and Guides 3D-1 Disassembling Timing Gears 3D-5 Replacing Cover Bushings 3D-6

CRANKCASE

Disassembling Crankcase 3E-1 Lapping Connecting Rods 3E-3 Fitting Rod Bearing Races 3E-4 Lapping Main Bearing Races 3E-7 Fitting Main Bearings 3E-8

FUEL SYSTEM

Adjusting Carburetor 3F-1

Disassembling Carburetor 3F-1 Air Cleaner 3F-4

Fuel Strainer 3F-5

Fuel Tanks 3F-5

TRANSMISSION

GENERAL

Transmission Specifications 4A-1 Function of Transmission 4A-1 Stripping Motorcycle for Transmission Repair 4A-2

CLUTCH

Adjusting Clutch 4B-1

Disassembling Clutch 4B-2

STARTER

Disassembling Starter 4C-1

Disassembling Starter Clutch 4C-1

GEAR BOX

Adjusting Shifting Linkage 4D-1 Adjusting Foot Shifter Cover 4D-1 Replacing Main Drive Gear Oil Seal 4D-1

Disassembling Shifter Cover 4D-3
 

GEAR BOX (continued)

Disassembling Shifter Forks Disassembling Gear Box

ELECTRICAL

WIRING

Wiring Diagram with Key

SWITCHES

Disassembling Ignition-Light Switch

LAMPS

Removing Headlamp Adjusting Headlamp Beam Bulb Chart

GENERATOR (Model 58)

Testing Generator Output Testing Field Coils Testing Armature Disassembling Generator

GENERATOR (Model 58R) Testing Generator Output Testing Field Coils Testing Armature Disassembling Generator

CIRCUIT BREAKER

Adjusting Breaker Points Adjusting Ignition 5F-2,

Disassembling Circuit Breaker

IGNITION COIL Trouble Shooting Replacing Cables

SPARK PLUGS Removing

Cleaning, Inspecting and Repair Adjusting Electrode Gap Testing Installing

REGULATOR

Servicing

Testing Specifications

BATTERY

Battery Care Charging

Changing Electrolyte

HORN

General Information Disassembling Horn Adjusting Horn

MISCELLANEOUS

INSTRUMENTS

Servicing Speedometer

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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