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Parts, Manuals, Links - Sub-01B


List of Factory Service Bulletins

  • Ever wonder just how many Service Bulletins were issued for Sportsters? The difficulty is that there was no numbering system involved to distinguish the separate models. Hence, the bulletin numbers related to all HD models skip around. A list of 'to date available' bulletins were published from time to time in the form of a Service Bulletin.
  • Below is a list of known Service Bulletins from the MoCo. More will be added when discovered. Those related to Sportsters or All Models are highlighted to be more searchable. The complete list also shows you what other issues the MoCo was dealing with at the time. 1) 2) 3)
Bulletin #DateModel(s)TitleSubject
121J2-20-1951FL, FLH3-Brush Fan-Cooled Heavy-Duty Generator Wiring Diagram
(Model 48) 1949 twins
Internal wiring connections
121K2-20-1951FL, FLH2-Brush Fan-Cooled Heavy-Duty Generator Wiring Diagram (Radio)1950-1951 Twins, (Model 48) internal wiring connections
121M11-14-1955K, KHTwo - Brush Fan-Cooled GeneratorDescriptions of wiring connections
121N11-14-1955FL, FLHStandard Generator, Big Twin, Diagram (Mode l 32E)1932-E1952 twins (except K & KH models}, internal wiring connections
121O11-14-1955FL, FLHModel 52 Standard Generator, DiagramLate 1952 and later twins (except K & KH models) internal wiring connections
2258-15-1941EL, UL, FL
FLH, KL
Oversize Wheel Mounting Socket Screw for
(61, 74 OHV's) & (80, 45 SV's)
Method for installing in stripped hole
2607-1-1947FL, FLH74 OHV Engine Fitting Specs
(1941-1947)
Piston, cam gear, piston pin, lower connecting rod bearing
260A7-1-1950EL61 OHV Engine Fitting Specs (1936-1947)Piston, oil pump drive shaft, flywheel, tappet guides
260B7-1-1947U, UH74 & 80 Side Valve Engine Fitting Specs
(1937 and later models)
Piston, ring gap, sprocket shaft
260C7-1-1947U, UH74 & 80 Side Valve Engine Fitting Specs (1930-1036)Bearing, sprocket shaft, valve tappets, piston, lower connecting rod
260D7-1-1947WL45 Side Valve Engine Fitting Specs(1937 and Later)Piston clearance, pinion gear shaft, sprocket shaft, tappet guides
260I1-3-1956EL, FL1948-1952 61 c.i. & 1948-1954 74 c.i. Engine Fitting Specs
260J1-3-1956FL, FLH74 OHV Engine Fitting Specs (1955 and Later)Piston clearance, lower connecting rod bearing, pinion gear shaft
26311-12-1947EL, FL, FLHService Info on Hydraulic Push Rods (1948 OHV Engines)Hydraulic pushrods, adjusting tappets, servicing pushrods
292A1-3-1956S125 Model Fitting SpecificationsPiston clearance, spark plug gap
29511-1-1949SFlywheel and Connecting Rod Assembly Tool Set for Model 125Description of tools and procedure
295A11-23-1955B, STAdapter Kit for Model 165 and Hummer FlywheelsDescription of tools and procedures
3013-1-1950AllFan-Cooled GeneratorAir intake screw installation causes damage if incorrectly installed
31010-1-1950FL, FLH
G, GA
Hydra-Glide Fork Slider Bushing ToolsTool set, removal and installation of slider bushings
32210-1-1951FL, FLH
G, GA
Filler Can for Re-oiling Hydra-Glide ForkHow to make and use filler cam components
32310-1-1951EL, FL, FLHOHV Model Foot ShiftTransmission foot shift cover assembly & disassembly
3304-18-1052FLScreen and Check Valve in Oil Passage to Overhead
Fittings & Hydraulic Push Rods
Purpose of screen, check valve in passage, servicing
3324-23-1952K1952 K Model Fitting SpecificationsEngine, transmission, frame, electrical
3451-15-1954K, KK, KRMServicing 1952-1953 K, KK, KRM TransmissionsModified transmission gears replacement
346A6-1-1954KH1954 Model Fitting SpecsEngine, transmission, frame, generator, brakes, etc
3489-27-1954EL, FL , FLHServicing 1954 and Earlier OHV Engine Pinion Shaft BearingBearing setups with part numbers
348A9-27-1954EL, FL, FLHPinion Shaft Roller Bearing on OHV ModelsDrill jig for locking right crankcase bushing, instructions
3491-15-1955KHDisassembly and Assembly 1955 Model Transmission
Equipped with Access Cover
Assembly and disassembly of transmission gears by removing access cover
35212-1-1954B, BT, S, STTele-Glide Fork Bushing Tool SetInstructions on removal and installation of bushings
3579-12-1955ST165 Spark CoilCorrection of ignition trouble due to dirty coil tower
36110-27-1955K, KH, XLEngine Sprocket and Clutch Hub Removal ToolsTools required for removing or installing primary drive parts
36211-11-1955KH, KHK1956 Model Rear Shock Absorber and SpringImproved load carrying capacity, spring tension, additional washers
36312-15-1955KH, KHK
KHRM
Clutch Release Rod-Oil SealMethod of sealing clutch release rod, parts needed when re-ordering
36411-16-1955K, KH, XLTool Set for Assembling Engine Sprocket Shaft BearingsDescription of tools and installation, Sprocket extensions, parts in crankcase
36512-5-1955GServi-Car Towbar Clamp Attachment 1955-1956 AutosAuto chart, clamp attachment to bumper, necessary parts
3681-3-1956AllCylinder Reboring
Piston Fitting Information
Dimensions for fitting cylinders and pistons
3691-3-1956ST165 Model Fitting SpecificationsEngine, Transmission, electrical specs
3721-6-1956FL, FLHTransmission Vent ScrewDrilled screw used in starter cover
3732-20-1956G, GA1956 Servi-Car Transmission Mainshaft Second Gear & Shifter ClutchNew parts needed, parts discontinued
3756-1-1956KH, KHKProcedure for Gear TimingBreather timing, valve timing
3766-8-1956KH, KHK, KHRMTransmission Mainshaft - Second and Third GearsRecommendation for installation of stronger mainshaft gears
37911-30-1956GServi-Car Towbar Clamp Attachment to 1957 AutosAuto chart, necessary parts, attachment
3811-31-1957XL1957 Sportster (XL) Fitting SpecsEngine, transmission, frame, generator, brakes, etc.
3822-8-1957FL, FLHBig Twin Valve GuidesSteel exhaust valve guides replacing bronze guides, intake valve guides
3833-1-1957FLHValve Springs for 74 OHV ModelStronger spring, servicing valves and valve guides
3843-8-1957FL1955 and Later Models with Timken Bearing
Removing and Installing Flywheels and Sprocket
Shaft Bearing in Crankcase
Tool set, for flywheel assembly into crankcase, assembly procedure, illustration
3853-15-1957FLTool - Removing Timken Bearing from Sprocket Shaft &
Compensating Sprocket Shaft Extension
Tool set, part numbers and use
3863-22-1957FL, FLH
Lapping Arbor Guide Sleeves on 1955 and later modelsTool set, part numbers, use
3873-29-1957FL, ELIgnition Circuit Breaker Bolt Wrench \ 61 & 74 OHVIllustration showing use, not necessary to disassemble other engine parts
3884-1-1957K, KH, XLFront Fork Slider Bushing ReplacementTools necessary for replacement, removal and installation of bushings
3895-1-1957Sportster Carburetor Float ValveChecking / setting float valve assembly, valve and seat
39211-27-1957XLH, XLInformation for Applying XLH Model Parts to XL ModelIntake valve piston & rings, spark plug and tappets
39311-29-1957G, GAServi-Car Towbar Clamp Attachment to 1958 AutosAuto chart, necessary parts, attachment
3983-15-1958FL, FLHBrake Drums and Shoes for Duo-GlideBrake shoes used with cast iron brake drum & pressed steel brake drum
3993-15-1958EL, FL, FLH, UL
K, KH, XL, XLH
Valve Spring Testing InformationValve spring testing, specs table for using valve spring tester
4005-1-1958FL, FLH
G, GA
Dou-Glide \ Servi-Car Fan-Cooled Generator Oil DeflectorIllustration, part numbers, changes
40212-9-1959GServi-Car Towbar Clamp Attachment to 1959 AutosTable of autos, parts needed, adjustments
40312-15-1958AllService ManualsExplaining the new HD service manual program
4041-15-1959AllSpecial Service Tools for All ModelsClutch gear reamer, chain tool, gear puller, clutch hub policy
4054-15-1959FL, FLHDuo-Glide Rail Type Piston Oil RingNew oil ring, installation instructions
4075-22-1959ST, FL, FLH
XLH, XLCH
G, GA
GeneratorCartridge type fuse installation \ precautions
4089-8-19591960 Duo-GlideSpark Control AdjustmentAdjustment of the coil control loop
40910-29-1959AllBattery Warranty and Adjustment PolicyPlacing battery in service, adjustment, battery codes
41011-20-1959GTowbar Clamp Attachment to 1960 AutosTable of car makes, parts needed, adjustments
41112-28-1959A, AUServicing Transmission Front Drive Assembly, Floating Flange Slide StripsReplacing ball slide strips
4131-29-1960Servi-CarTowbar Clamp InformationTowbar clamp lower jaw re-designed
4142-12-1960AllSpecial Service Tools for All ModelsFlywheel adapter kit, piston pin lock ring tool sleeve, valve seating gauge
4152-15-1960AllService Manuals1960 manual information
4162-1-1960TopperImproved Transmission LockoutNew improved lockout parts
4172-1-1960A, AUSpark PlugChange from #5 to #4 spark plug
4184-6-1960FL, FLH
G, GA
1951 models - Conversion of 3-Brush to 2-Brush GeneratorRegulator and generator installation and wire connections
4194-22-1960B, BT, ST
XLH, XLCH
A, AU
Servicing HD A-C SpeedometersWarranty and adjustment policy and how to obtain service
4205-31-1960A, AUFlywheel Shaft AssemblyServicing magneto shaft and trans shaft
4228-26-1960A, AUImportant Topper Info1960 model year changes
4238-26-1960A, AU1961 Topper Model ChangesFloating flange, exhaust system & wheels
42410-6-1060A, AUInformation for Servicing 1960 TopperTransmission slide strips, wheel bolt kit
42510-6-1960FL, FLHServicing Duo-Glide Brake Shoes & LiningsAvailable parts, use of hydraulic rear brake, H- D brake lining material
42610-21-1960GServi-Car Towbar Clamp Attachment to 1961 AutosTable of car makes, parts needed, adjustments
42711-14-1960A, AUInformation for Servicing 1960 TopperExhaust system kit
42812-15-1960FL, FLHCare of Wheels, Tires and Chassis AssembliesChecking for good handling, tire inflation chart, adjusting rear fork bearings
42912-16-1960FL, FLH
XLH, XLCH
G, GA
1961 model Regulator InformationUsing the correct regulator
43012-22-1960CBrake Preventive MaintenanceInspecting brake linings - 2500 miles
43112-23-1960SprintSprint Starter ModificationsStarter pedal rubber installation for a better foothold on kick starter pedal
4321-11-1961CSprint Special Service ToolsValve spring compressor, two jaw puller
4331-3-1961AllNew Procedure for Handling Return MerchandiseWarranty claims, service repairs, new parts return
4355-5-1961AHNew Topper 1961 ModelModel changes
4365-10-1961A, AUComplete New Transmission for the TopperTransmission conversion kit for 1961 models
4375-10-1961A, AUApplying New Topper Transmission and Drive Lockout to 1960 ModelsTransmission conversion kit
4383-28-1961FL, FLH
XLH, XLCH
G, GA
Signal Stat FlashersTwo different types used for turn signals & pursuit lamps
4393-29-1961FL, FLHDuo-Glide Speedometer Drive ChangeSpeedometer drive gear ratio change & identification
4403-30-1961A, AUPlastic Foam Air Cleaner for TopperCylindrical filter for air intake
4414-21-1960CWheel and Spoke Preventive MaintenanceRegular inspection every 2000 miles
4426-14-1961FL, FLH1960 Duo-Glide Dual Circuit Breaker / Spark Coil Ignition SystemTiming procedure, timing gauge
4435-12-1961AllSpecial Service Tools for All ModelsIgnition timing gauge, hub installing tool, ball bearing puller, needle bearing puller, brake drum turning arbor
4446-14-1961CValve Spring Upper CollarNew valve spring collars
4456-30-1961CSprint Special Service ToolsClutch lock tool, fork tube tool, crank­ case assembly screw, external lock-ring pliers
4478-25-1961CSprint Starter ModificationsNo longer necessary to remove tooth from starter sector gear
4489-22-1961FL, FLHMotorcycle Tires (5.00 x 16)Goodyear Eagle “100“ Tires original equipment
4498-28-1961AHCarburetor AdjustmentNormal settings for idle mixture screw
4509-5-1961CBosch Dry Battery for SprintService procedure, Warranty and Adjustment
45111-6-1961A, AUSteering Head Bearing Adjustment for Topper with SidecarCorrect steering dampening necessary
45211-13-1961GTowbar Clamp Attachment to 1962 AutosTable of Autos, necessary parts and adjustments
45310-13-1961XLCH, XLCHFuse EliminatedFuse no longer required
45412-4-1961XLCHSportster CH LubricationRecommendations on oil tank level, dipstick and bleeding the oil system of air
45512-6-1961FL, FLH
XLH, XLCH
BT, BTU,
BTH, BTF, C, AH, AU
1962 models - Gear Ratios and SprocketsSprockets and Drive Ratios
45612-7-1961AllService ManualsService manual policy, part numbers
45712-26-1961AllRebuilt Connecting Rod Exchange Service DiscontinuedRebuilt connecting rods no longer supplied
45812-29-1961AllService Bulletin IndexList of available bulletins as of January l2, 1962
4591-12-1962Duo GlideOil Return Line BlockageClearing blockage in oil return line
4601-31-1962Sprint/Model CDry Charged BatteryBattery Replacement Requirements
460A4-16-1962Sprint/Model C/HDry Charged Battery Replacement RequirementsEstablish policy (replaced TSB 460)
4614-16-1962Sprint/Model “H”Dry Charged Battery 31L-4 OEMWarranty and adjustments
4625-15-19621962 Duo Glide/Servi-CarSpeedometer Drive ChangesNew design with 1000 revs. / mile (change from 2000 revs. / mile)
4646-6-1962AllServicing Harley Davidson S-W SpeedometersStewart - Warner Central Distributor and Service Stations List
4657-9-1962XLCHServicing XLCH TachometerList of Nisonger Corporation Service Stations
4678-8-1962TopperTransmission & Lockout Conversion KitEarlier exchange offer now terminated
46910-26-1962Servi-CarTowbar Clamp Attachment to 1963 AutosParts and method of attaching towbar to 1963 autos
4701-31-1963All1963 Service ManualsManual listing and prices
4713-15-1963XLH/XLCHChange in 1963 Sportster Transmission 3rd Gear SetGear changes
4732-28-1963AllSignal Stat FlashersPart number change
4768-30-1963Servi-Car12 Volt Battery Warranty and Adjustment PolicyPolicy changes
4778-5-1963BT Series
(2 cycle)
Improved Starter Parts for Single ModelKickstarter ratchet gear & clutch sprocket change
48311-4-1963SprintSprint Gas Tank ValveValve handle maintenance to prevent leakage
48510-31-1963Servi-CarTowbar Clamp Attachment to 1964 AutosParts and method of attaching towbar to 1964 autos
4877-6-1964AllNew HD Motorcycle and Servi-Car Battery Warranty and Adjustment policyBattery policy statement for inspection, testing and replacement
487N3-15-1965AllList of Globe-Union plants for Service Bulletin #487
4887-6-1964XLH/Sprint H
Late Sprint C
12v Battery Warrant & Adjustment PolicyPolicy update
4898-14-1964M-50Stoplight Switch for M-50 ModelsA number of M-50 models left the factory without a stoplight switch installed
4928-14-1964M-50Tank Rear Mounting ChangeThe solid mount was changed to a flexible strap
4938-14-1964M-50Wheel Bearing ChangeChanged to more durable balls in the loose ball cone-type bearing cups
494FLH/XLH9-15-1964Shock Absorber ChangeAdjuster cam change
495All9-18-19651965 Service ManualsManual listing and prices
49810-23-1964Servi-CarTowbar Clamp Attachment to 1965 AutosParts and method of attaching towbar to 1965 autos
49911-20-1964M-50Fuel MixtureThe amount of oil used in the fuel mixture has been reduced from 6-1/2 oz to 5 oz per gallon to reduce the possibility of plug fouling
50011-20-1964AllElectric Starter WarningDisconnect the battery positive terminal before removing the primary cover. Recommended for all models but especially the Electra Glide since the solenoid shift lever will close the starter motor circuit and rotate the pinion & clutch ring gear.
50112-11-1964AllNew Shop Service Tools
50212-11-1964Electra Glide
Servi-Car
Starter Tests - With Sun Vat-26Testing, troubleshooting & procedures
50312-31-1964AllGenerator Brushes - 12v. & 6v.
5041-18-1965Servi-Car1964-1965 Electric Starter Service
5062-18-1965M-50Spoke Information
5072-18-1965AllBrake & Clutch Lever Changes
5083-19-1965FL/FXConverting Rear Siren & Signal Lamp to 1965Electra GlideParts necessary for conversion
5093-19-1965FL/FXTransmission Oil Seal
5125-18-1965FL/FXUpper Shock Stud ChangeStud size increased to 1-1/2”x20 (replacing the 3/8-24 stud)
5115-14-1965M-50Transmission Gears
5135-18-1965AllSeat Cover - Buddy SeatAdditional seatcover clips added
5146-11-1965M-50New Wheel BearingsChange to retainer type bearings in both hubs
5156-11-1965XLH/XLCHChange to No. 4 Spark Plug
5167-6-65AllChassis Service and Handling
516B10-15-66AllChassis Service and Handling
5177-7-1965M ModelsRemove Engine Oil From 1966 M-50 Before Initial StartupProduction models were treated with a rust preventative oil prior to shipment
5189-10-19651966 XLH/XLCHChange to Tillotson Carburetor
51910-5-1965FL/FXPrimary Drive Chain CareChange to Duckworth (double row) primary chain with straight sides
5209-27-1965AllTourist Motorcycle Warranty Procedure
52110-11-1965XLH/XLCH
FL/FX
Generator Brush Location
5229-30-1965Servi-CarTesting Servi-Car Elec. System
52310-18-1965XLH/XLCH
FL/FX
Servi-Car
Cylinder Base NutsCheck torque
52410-29-65FL/FXLubrication SystemDiagnosing lubrication problems
52712-1-1965XLH/XLCH
FL/FX
Two-piece Oil Ring
52511-16-1965M-50/M-50S2-Cycle Oil for Transmission2 cycle oil spec'd for tranny and engine
52612-1-1965SprintCarburetor Throttle Stop EliminatedThrottle stop bushing eliminated
52712-1-1965Electra Glide
Sportster
Two Piece Oil Control RingChane to a cast iron, double edged, scraper ring with a separate expander spring behind it.
528All12-31-19651966 Service ManualsManual list and prices
5311-15-1966Procedure for Handling Return MerchandisePolicy and forms
5321-17-1966FL/FXCircuit Breaker ProtectionThermal overload switch added
5342-17-1966XLH/XLCH
FL/FX Servi-Car
Drive Chain - Press Fit LinkAll parts order and new production motorcycle 5/8“ chains are now supplied with a press fit connecting link side-plate for improved durability
5352-17-1966SprintSpoke TightnessNecessity to check spoke tightness
5363-7-1966FL/FX
Servi-Car
New Starter
5373-22-1966XLH/XLCHTransmision Countershaft Low GearA fillet was added to right crankcase and the countershaft low gear has a counterbore at fillet area
538B9-25-1969FL/FXChain Housing Vent Kit
539A11-29-1967M ModelsFactory Repair
540A6-6-1980AllSpeedometer / Tachometer Warranty Service
5417-15-1966XLH/XLCHTransmission Shifter Cam Assembly
5427-15-1966FL/FXNew Gas Line Filter
5438-8-1966FL/FXStarter Change - Drain Holes
544A12-1-19661967 SprintPre-Delivery and Service
545A6-7-1968XLH/XLCHRear Wheel Tube Flap (43148-67)
546A1-8-1969AllGas Line Hose Changes
54710-24-1966XLH/XLCH
FL/FX
Tillotson Carburetor Inlet Valve
5492-8-1967FL/FXPolice Solo Recommendations
5512-20-1967FL/FXStarter Relay Conversion Kit
5522-21-1967FL/FXMotor Sprocket Spacer
5532-24-19671967 XLCHSpark Plug Cable Guide (Recall 001)
5544-28-19671967 SprintOptional Gearing and Ignition Timing
5556-19-1967M-125Exhaust Port Seal
5567-21-19671967 FLRear Brake Hose Guide (Recall 002)
55910-13-1967SprintCircuit Breaker Timing
56010-13-1967Sprint500 Mile Service
56110-16-1967AllOil Recommendations
562A5-11-1969XLH/XLCH FL/FX
Servi-Car
Set Timing in Advance PositionChanged method of setting timing to in the advanced position
56311-29-1967XLH/XLCH/M-125Hydraulic Fork Oil Capacity
5641-15-1968XLH/XLCH
FL/FX
Tillotson Carburetor Service-ability
565A3-1-19681968 M-125/ RapidoStoplight Switch Rubber Boot (Recall 003)
5661-25-19681968 M-125/RapidoThrottle Control Grip Retaining Screw (Recall 004)
5673-25-1968FL/FXClutch Lever Pin and Bushing Changes
5684-5-1968SprintAir Filter Stud
5694-12-1968XLH/XLCH
FL/FX
Oil Filter Kit
5715-21-1968XLH/XLCH
FL/FX
Tillotson Carburetor Accelerator Pump Changes
5726-10-1968XLH/XLCH
FL/FX
Control Cable Anchor Pin
5737-11-1968FL/FXClutch Throwout Bearing
5747-12-1968FL/FXExhaust Pipe Gasket Seal (64834-68)An asbestos gasket seal ring is assembled in the exhaust port to port joint to prevent exhaust leaks
5768-25-1968FL/FXCylinder Base Nuts
5779-13-1968FL/FX5.10 x 16 Replaces 5.00 x 16 Tire
5789-25-19681969 MLS/RapidoTail Lamp Wiring (Recall 005)
579A1-8-1969Sprint/RapidoGas Tank Valve
58010-18-19681969 LightweightsEngine Numbering System Changed
58112-15-1968FL/FXOil Pump Nut & Bolt Tightness
58212-17-1968XLH/XLCHSprocket Changes - 20-19 Teeth
58312-15-1968Siren Pivot Shafts
5841-10-19691969 SprintTune-Up Information
5852-14-1969Sprint SSNew Fuse Holder
5862-14-1969SprintExhaust Valve Clearance
5872-28-1969FL/FXOil in Clutches
588A10-9-1969AllFront Brake Light Switches
5897-3-19691967-1968 FLRear Brake Pedal Lever (Recall 006)
590A8-24-1970SprintGenerator Armature & Shaft Taper
5916-23-1969XLH/XLCH
FL/FX
Sprocket Shaft Bearing Endplay
5926-17-1969XLH/XLCH
FL/FX
Oil Filter Vent Hole
5936-17-1969XLH/XLCH FL/FXRocker Arm Cover Gasket
5947-15-1969M ModelsNew Spark Plug
5959-16-1069SprintFlywheel Endplay - Spring Washer
5969-16-1969AllNew Numbering System - VIN
5979-16-1969XLH/XLCHTapered Bead Tires/Rims
5989-29-1969XLH/XLCHFiberglass Seats
59911-7-1969FL/FXCam Seal Relief Hole
60011-7-1969FL/FXAlternator System Checks
6012-6-19701969-1970 SprintStarter Gears
60311-26-19691970 MLS/M65S1970 MLS Electrical System
6044-9-19701970 SprintFork Vent Valve
60511-28-1969XLH/XLCH
FL/FX
Idle Mixture Screw
60611-28-1969XLH/XLCHRear Brake Light Switch Kit (72004-67)
6072-6-19701969-70 SprintRear Brake Switch
6084-9-1970AllLoose Fuel Valve HandlesA loose handle on the gas tank valve will not allow enough fuel flow to the engine, possibly resulting in engine slowdown especially at high speeds. There should be no more than .010“ clearance between the lock ring and the handle when the valve is closed. .006” shims (6160 P) are available to decrease the clearance and tighten up the handle. Add enough shims to provide only a slight clearance when the valve is closed to obtain maximum diaphragm opening when the valve is open
6095-11-19701969-1970 FLWheel Bearing Locknut (Recall 008)
6105-20-1970BajaFront Fork Oil Seals
6115-20-1970FL/FXCarburetor Jet
6126-16-1970All LightweightsThrottle Cable
6138-24-1970BajaRings/Piston Change
614A4-14-1971FL/FXCarburetor/Timing Marks/Compensating Sprocket
6159-28-1970AllNew Service Tools
6169-30-1970AllTire Balance/Wheel WeightsWheel balancing is recommended by the MoCo and because automotive wheel weights would not fit the Sportster aluminum rims and later type steel rims, HD released spoke balancing weights (which surround and press onto the spoke nipple) and are approved as a wheel balancing alternative.
618C12-17-1974XLH/XLCHKicker Gear KitsStarting July 1, 1973, there was a new Kick Starter Gear Assembly installed with new kick starter gear, bushing and spacer. The new 'pressed in' bushing has a Teflon coated lead bearing surface on a steel ball shell. The gear has a groove for the starter gear spring and the spacer length (and diameter) were increased to fit the new gear.
6191-25-19711971 FXRear Brake Rod Clevis (Recall 009)
6203-25-1971FXLicense Plate Support Bracket
6216-9-19711971 SprintDesign Changes
6226-9-1971XLH/XLCHClutch Improvements
6234-15-1971AllSpark Plug Heli-Coil Kit
6244-30-19711971 XLH/XLCHRear Wheel Hub (Recall 012)
6258-2-1971AllLow Lead GasolineAt this time, it is not recommended to use (low leaded) or (non leaded) gas in any of our 2 or 4 cycle engines. The octane is substantially lower than regular and premium leaded gasoline. The new fuels contain additives such as phosphorous (which replaced tetra-ethyl-lead) and tests reveal that these additives may not provide the same performance and engine protection received from leaded fuel. Extensive use of these new fuels may cause piston damage in both 4 and 2 cycle engines and accelerate wear and scuffing of the valves in 4 cycle engines. It is recommended to use regular or premium leaded gas as specified in the respective owner's manuals.
6268-2-19711971 SprintCharging System
62710-11-1971XLH/XLCH
FL/FX
Point Cam and LubricationThe circuit breaker cam, or ignition timer cam, (newly designed for the 1971 model year) was redesigned for the 1972 model year and was recommended as a replacement for parts order on 1971 model Sportster, Electra Glide and Super Glide models.
62810-19-19711972 ShortsterFront Wheel and Axle (Recall 014)
62911-9-19711971 RapidoMagneto/Generator
63011-8-19711971-1972 FL/FXRear Brake Hydraulic Line (Recall 013)
6332-15-1972FLFront Disc Brake Information
6342-18-1972XLH/XLCHClutch AdjustmentThe MoCo revealed an easier way to make clutch adjustments by removing the access plug from the chain compartment cover instead of the need to remove the cover (as outlined in the FSM) and owners manuals for 1971 and later Sportsters.
6352-18-1972FL/FXSprocket Shaft Bearing Oil Hole
6364-27-19721972 XL/XLCHRear Fork Bearing (Recall 015)
6377-7-19721972 MC-65/ShortsterFront Fork Slider (Recall 016)
6388-14-19721972 XLH/XLCH/FXFront Wheel Hub Lockring (Recall 017)
6399-25-1972All LightweightsSilver Gas Tank Trim
6404-25-19731973 Z-90Front Axle Assembly
64111-15-19721973 Z-90Rear Brake Sideplate
64212-13-19721973 SprintTune-Up Information
64312-18-19721973 FL/FLH/FXDisc Brakes (Recall 018)
6443-26-19731973 X-90/Z-90/TX-125Injection Oil Pump
645
646
4-5-19731973 SprintHigh Output Alternator
6474-10-1973FL/FXOil Pumps
6484-25-731973 Z-90Front Brake Sideplate Retainer (Recall 019)
6495-25-1973Z-90Front Axle Locknut Kit
6505/15/19731973 XL/XLCHTail Lamp Wiring (Recall 020)
6516-27-19731973 XL/XLCH/FXFront Fork Lower Bracket (Recall 021)
6527-30-1973XLH/XLCHHead and Cylinder ChangesLate 1973 models (produced after May 1, 1973) received a top end make-over with new heads, head gaskets, cylinders and head bolts. Late 1973 engines are identifiable by looking at the head bolts which have 12 point 7/16” bolts. Early 1973 and prior heads were held on by 6 point 9/16“ bolts. These new parts are not interchangeable with older engines due to the different bolt pattern up top.
6537-30-1973XLH/XLCH
FL/FX
Disc Brake Caliper Mounting Pin Kit A disc brake caliper (stud type) mounting pin was made available by the MoCo for replacement of the original (riveted type) pin that could work it's way loose. This (pin, nut and washer) was suggested for FL, FLH, FX, CL and XLCH.
6548-27-19731973 XL/XLCHRear Brake Lever (Recall 022)
65511-15-1973XLH/XLCHDirectional Arrow - Rear TireBeginning with the 1974 year model XL & XLCH, a directional arrow was incorporated into the design of the rear tire which mandated pointing the arrow toward the forward rotation upon installation to assure the best performance of the tread under severe acceleration.
6562-11-19741973 XL/XLCHFrame Reinforcement of Tail Lamp Wiring (Recall 023)
65712-17-19731974 SX-175Oil/Spark Plug
6581-7-1974FLBattery Support Bracket
6593-6-1974XLH/XLCH
FL/FX
Fusible WireA 2“ long 20 gauge wire (70105-73) was added on FL,FLH, FX, FXE, XL and XLCH models to act as a fuse-able link. The fuse wire protects wiring between the battery and the lighting, ignition and accessory circuit breakers. In place of this HD part, any 20 gauge braided wire will work also.
6603-4-19741974 SX-175Specs / Clutch / Rear Wheel
6614-15-1974XLH/XLCH/FXRear Fender ReinforcementBeginning with production XL and XLCH models (L1974) during March and FX and FXE models during April in 1974, a spot-welded reinforcement section was added underneath the fender at the license plate bracket mounting holes. This was done to strengthen that area on the fender where the security system alarm is mounted to protect against cracking of the mounting holes in the fender. Bolt on versions were made available for already shipped / sold XL/XLCH (59770-73A) and FX/FXE (59714-74) model motorcycles. The bolt on version was recommended to install on all 1973 and E1974 motorcycles equipped with the security system. Late 1974 fenders (having the factory installed reinforcement) are easily identified by noting the new license plate bracket as having three mounting bolts instead of two.
6624-29-19741973-1974 FL/FLH/FX/FXERear Brake Caliper (Recall 024)
6634-29-1974XLH/XLCHClutch ChangesLate 1974 clutch changes include a new pressure plate and six spacers over the studs between the pressure plate and the releasing disc to set spring set-up pressure to a controlled amount. A conversion kit was available to convert 71-E73 models to the new 74 style set-up.
6644-29-19741974 SX-175Fuse
6656-10-19741973 Z-90Front Brake Sideplate (44143-73)
6667-10-19741974 SX-175Ignition System
6676-21-19741974 SX-175Air Cleaner Care
6688-26-19741974 SX-175Front Wheel Tire Bead Clamp / Rear Brake Sideplate (Recall 025)
6698-16-1974XLH/XLCH
FL/FX
Servi-Car
Ignition CoilsThrough an error with HD suppliers, an unknown quantity of ignition coils were mislabeled as 12V coils but were actually 6V coils which possibly affected some 1973-1974 FL, FLH, FX, FXE, XL, XLCH and GE models. To prevent failed coils and poor ignition troubles, the MoCo suggested the dealers test all of their stock supply and all 1973 and 1974 motorcycles (in for servicing) that were suspect of having ignition problems.
67010-7-1974SX-175Exhaust System Cleaning
67110-7-1974SX-175Rear Wheel Spokes
67210-9-1974SX-175Carburetor Modification
67310-9-1974FL/FXOil Ring Change
67410-14-19741974 X-90/Z-90Air Cleaner & Carburetor
67510-14-1974XLH/XLCH/FXIgnition SwitchDue to a production oversight, lubricant was omitted on the ignition key switch indexing plate which could cause the switch to bind up. The remedy was for the dealer to remove the switch, punch a small hole in the switch body and add silicone lubricant into the hole and possibly add also to the 1/8” tumbler lubrication hole in the mounting thread area.
67610-14-1974FXJiffy Stand Support Plate
67710-14-1974FXFoot Shifter Timing
67812-17-1974XLH/XLCHRocker Arm Covers “ M”A certain number of 1974 and 1975 XL & XLCH models were produced with modified rocker arms and rocker covers. These were machined to prevent interference between the rocker arm and the inside of the rocker cover due to a thickness variation in the covers.
67912-17-1974X-90High Voltage Problem
6801-31-1975FL/FXSpark Plug Change
6811-31-19751973-1974 SprintElectric Starter Motor
6821-31-1975SprintSpoke Maintenance
6831-31-1975X-90/Z -90
SX-125/TX-125
Throttle Grip Fix (44186-74P)
6842-13-1975SX-175/250Reinforced Crankcase Cover
6853-20-19751972 and Earlier FL/FLHLiberator Fairing Handlebar Mounting Bolts (Recall 026)
6864-8-1975XLH/XLCHTransmissionDuring the 1975 season, the MoCo received several reports of XL & XLCH transmissions with a blocked oil transfer hole in the trapdoor (resulting in little to no oil supply to the transmission).
Also, between December 16, 1974 and January 7, 1975, a total of 63 mainshaft low gears were inadvertently installed in XL/XLCH transmissions without prior heat treatment which gave to noisy gear movement due to accelerated tooth wear.
6874-8-1975FL/FXClutch Throwout Bearing Change
6885-12-1975XLH/XLCHRear Fork Bearing KitBearing Kit (47550-74) (replaced the single bearing part # 47521-52) contains 2 bearings which are 0.100“ narrower than the original bearing dims used in Sportsters up to February of 1974. The kit also contains a new pivot bolt nut (47512-74), bearing locknuts (L - 47514-74, R - 47515-74) and an outer spacer (47521-74) - clearanced for the new bearings.
6895-5-1975All lightweightsService Tools - Lightweights
6905-12-1975SXT-125Air Filter Cover 1975
6915-12-1975SS-250Jiffy Stand Bracket
6926-27-19751975 SS-250Rear Brake Pedal Lever (Recall 027)
6939-9-19751975 SXT-125Frame (Recall 028)
6947-23-1975All LightweightsIgnition Switches
11-7-1975FL/FXKeihin Carburetor
69511-7-19751975 XL/XLCH
FX/FXE
Wheel Spokes (Recall 029)
69611-7-1975SS-250High Idle
6973-29-1976XLH/XLCH
FL/FX
Bendix Carburetor JetsHD issued a chart listing for the Bendix carburetor main jet size identifications since the jets are not labeled by jet size but only the Bendix part number that is stamped on the hex head section of the jet.
6983-29-1976All LightweightsRear Brake Switch Kit (72200-75))
6998-16-19761975 SX-250S & 175Carburetor Modification
700A8-16-1976MX-250Service Information
7015-26-1976FL/FXRear Disc Brake Service Information
7025-28-19761976 XL/XLCHRear Brake Shoes (Recall 030)
703A9-3-1976SS / SXT-125Oil Supply Fitting
7048-16-19761975-1976 SS/SXT-125Spark Plug
70511-11-1976XLH/XLCH
FL/FX
Ignition Advance Unit LubricationThere was a change in the ignition advance lubrication procedure. Since August, on all production engines, the timer weight assemblies and breaker cam posts have been sprayed with “Never-Seez”, a spray can type lubricant when making timer adjustments. Never Seez or Locktite Anit-Sieze was suggested for dealer use along with a high temp grease on the point cam rubbing block.
70610-15-19761974-1976 FL/FLH/FX/FXERear Disc Brake (Recall 031)
M-70712-1-1976FL/FXKeihen Carburetor/Adjustment/Modification
M-70812-1-1976XLH/XLCHBreather ValveA newly designed breather valve was installed on engines produced around October 15, 1976. All 1000cc engine numbers (3A, 4A or 2G) 27940H7 and above had the new breather valve. It serves the same function as the gear driven breather valve used on 1976 and earlier engines but due to it's improvements in doing so, it was suggested to be retrofitted to all 1977 XL & XLCH engines.
7093-22-19771975-1977 XL/XLCH/XLT
FX/FXE
Front Brake Caliper Mounting Bolts (Recall 032)
7105-6-1977FL/FXClutch Push Rod Thrust Washers
M-7116-3-1977XLH/XLCHOil PumpNew oil pump design fitted with gerotors instead of gears and consisting of two gerotor pumps in the same pump housing. The feed pump forces oil to the engine while the scavenger pump collects and returns oil back to the oil tank. In a gerotor type pump, oil is transferred from the inlet to the outlet as it is trapped between the rotating inner and outer gerotors.
M-7126-16-1977AllHydraulic Brake System MaintenanceBrake fluid inspection intervals, changing from DOT 3 to to DOT 5 brake fluid, master cylinder inspection / operation, brake calipers, pads and discs.
M-7136-10-1977XLH/XLCH
FL/FX
Keihin CarburetorList containing part numbers and adjustments for the variable components used on 76-77 1000 and 1200cc engines.
M-7148-16-1977XLH/XLCH
FL/FX
Piston Pin Retaining Ring ChangesStarting June 10, 1977 new (Truarc) piston pin retaining rings were installed on 1000 and 1200cc models. This Truarc type lock ring has holes for Truarc Pliers (96215-49). The groove in the piston pin bore has been changed to accommodate the new pin lock ring (22588-78) which replaces the Spirolox retaining ring (22582-52).
M-7158-12-1977FL/FXAir Cleaner Gasket and Heat Spacer
M-7168-26-19771977 XL-1000Showa Rear Shock Absorber (Recall 033)
M-7179-13-1977FLFront Fork Change
M-7189-13-1977FL/FXTransmission & Cam / Pinion Changes
M-7199-13-1977XLT 1000Rear Fender / XLT-1000Rear fender cracking at the turn signal mounting holes
M-72010-11-1977MX-250Front Fender Installation
M-72110-21-19771978 FX/FXE/FXSRear Brake Master Cylinder O-Ring (Recall 034)
M-72211-4-19771976 SS/SX-175/250Auto Retard Alternator
M-7231-13-19781978 LightweightsFlasher
M-7242-7-1978FL/FXElectronic Ignition Timer Wires
M-7252-14-1978AllEPA ChangesHD outlined the Clean Air Act of 1978 as it affected the company and it's customers.
M-7263-30-19781978 FX/FXE/FXSFront Brake Caliper Bolt Washer (Recall 035)
M-7274-11-19781979 XLH-1000Rear Brake Control Linkage (Recall 036)
M-7284-28-19781978 MX-250Flywheel Assembly
M-7296-13-1978FLH-80Carburetor Low Speed Setting
M-7306-15-19781078 FLH-80
1978-1/2 FLH 1200
FX/FXE\FXS-1200
1979 XLH (XL)/XLCH
XLCR-1000
High Altitude Carburetor Kits / 1978-1/2 & 1979 ModelsCarburetor modification kits (including jet(s) and an accelerator pump stop screw) were made available for 1200cc, 1340cc and 1000cc models to provide leaner fuel mixtures when operating at elevations above 4000 feet sea level.
M-7316-20-19781000, 1200
1340 Models
Tire FitmentList of all 16”,18“ & 19” wheels supplied by the MoCo as standard or accessories. Correct matching of tire, tubes and wheels
M-7326-27-1978FL/FXHydraulic Lifters
M-7337-7-19781978 LightweightsGas Caps / Mounting Screws / Rear Chain
M-7347-5-1978All V-TwinsWheel Bearing Spacers / V-TwinsBearing spacer lengths changed. For proper handling and to minimize bearing & tire wear, wheel bearing endplay should be within .004“-.018”. Check bearing endplay, with the wheel off the ground, at the brake disc or wheel hub with a dial indicator. When bearing endplay doesn't come within specs, use the correct longer or shorter (color coded) spacer to achieve the correct specs.
M-7357-14-1978FL/FX/XLFlywheel AssemblyUse of lockplates and screws no longer used in production
M-7367-31-19781978-79 XLH/XLCH
FL/FX
Front Brake (Recall 037)
M-7378-3-1978FL/FX/XLDisc Brake ChangesHarder stainless steel discs, brake pad replacement & (caliper parts - only 1200 & 1340 models)
M-73810-17-1978All models w/ 16“ wheelsLacing 16” Wheels (New Hub)The procedure for lacing 16 inch wheels changed to make them easier to lace in production. The relationship of the spoke flanges on the wheel hubs changed to match the new lacing pattern. Rims, spokes and nipples did not changed.
M-73911-3-1978All 1200/1340/1000Carburetion and IgnitionCountering excess lean condition due to EPA conformity. Recommendation for corrective measures regarding carburetion and the new (breakerless) electronic ignition system on (1100, 1200 and 1340cc) models and emissions control design changes. They operate with leaner air/fuel mixtures and are more sensitive to carburetor mixture settings / ignition spark.
M-74011-30-1978FL/FXPrimary Chain Tensioner (black)
M-7411-12-19791979 FLH/FLH-80Front Brake Caliper (Recall 038)
M-7421-31-19791979 FLH/FLH-80Classic King Tour Pak
M-7434-3-19791200/1340/1000Cam Gear SelectionCam gear selection method for quieter operation
M-7444-3-1979E1979 1000cc enginesTransmission ChangesChanges to improve the engagement of the clutch teeth between the mainshaft 2nd gear and the clutch gear
M-7454-24-1979FL/FXImproving Oil Mileage
M-7465-11-1979FL/FXPush Rod Covers (loss of vacuum)
M-7475-1-19791979 1200/1340/1000cc enginesFront Brake Master Cylinder (Recall 039)
M-7485-18-19791979 modelsMiscellaneous Information
M-7496-12-19791977-78 XLCR -1000Rear Brake Master Cylinder Pushrod (Recall 040)
M-7506-15-1979FL/FXTappet Guide Blocks
M-7516-29-791979 XLH/XLSRear Brake Pedal Stop Bolt Jam-nut (Recall 041)
M-7527-6-19791979 FLH/FLH-80Frame Mounted Seat (Recall 042)
M-7538-14-1979FL/FXRear Brake Master Cylinder Change
M-754A3-21-19801979 XLH/XLCH/XLS
FL/FX
Rear Brake Master Cylinder Piston (Recall 044)
M-7559-7-19791978-1979
XLH/XLCH/XLS
Rear Brake Pedal (Recall 043)
M-75610-16-1979FLFrame Mounted Seat Reinforcement Kit
M-75710-19-1979Early 1980 XLH/XLSCam TimingSome 1980 Sportster were built with incorrect front exhaust cam gear timing.
M-75810-23-19791978-1979 1200/1340/1000cc modelsRear Brake Pedal (Recall 043)
Rear brake master cylinder (Recall 044)
M-75910-16-19791980 XLH/XLSBattery PositionOn a number of 1980 XLH/XLS models, the battery may have been mis-positioned. The pad the battery rests on is thick enough to allow the battery to be pushed over the carrier retaining edge until the battery vent tube fitting is wedged against the oil tank which could break the fitting. The fix was to glue 2 battery cover pads together and attach them the oil tank to create separation of the tank and the battery.
M-76011-16-1979All 1980 HD ModelsResistor Plugs & Ignition Rotor Bolt“R” (resistor) type spark plugs are now used on all 1980 models to provide radio ignition noise suppression, improve the reliability and prevent a possible malfunction of the transistorized Magnavox ignition system. Sportster engines changed from the old type 4 or 5 to the new 4R5. The original 4R5 still had the 4-5 markings, but carried a black terminal at the end to distinguish it as the new resister type plug until the supply ran out. Then they were marked as 4R5 with the same gap as before (.040'). This was also a warranty replacement item.
Also, the ignition rotor on early 1980 models were attached with a “Pozidriv” cross-slot screw (2611). Starting in, July of 1979, this screw was replaced with a large hex head screw (2611A) to provide for a means of an accurate torque measurement (75-80 in lb) and the threads were sealed with Loctite Lock 'N Seal. Dealer were to replace the old screw 'if' they ended up working on a motorcycle that had one.
M-76111-30-1979Early 1980 FL/FXPiston Replacement
M-762A4-1-1980FL/FXFront Chain Housing
M-76312-21-19791074-1979
1200/1340/1000cc
Starter RelayIn some cases, the 1974-1979 starter relay used on 1200, 1340 and 1000cc models may develop corroded contacts because of moisture under wet road conditions. This bulletin was issued for testing and installation procedures.
M-763A3-21-19801975-1980 FLFront Fender Mounting (Recall 045)
M-76412-21-19791000cc modelsShock Absorber Rubber BushingsThe condition of the rear shock absorber upper and lower mounting bushings should be checked at least every 5,000 miles since excessive looseness of the bushings could affect proper shock absorber function.
M-7653-14-19801980 FLTRear Brake Caliper (Recall 046)
Letter3-7-19801980 FLTSprocket Mounting Screws (Recall 047)
M-7662-29-1980FL/FX
Servi-Car
Brake Fluid / SidecarReaffirming the service procedures in TSB M-712 for changing DOT 3 to DOT 5 when attaching an earlier sidecar (one using DOT 3 Glycol type fluid) to a current production vehicle (one using DOT 5 solicone type fluid).
M-7673-4-1980FL/FXSquare Seal Brake Caliper
M-7683-18-19801954-1979 XL
1958-1978 XL
Crank Pin
Chain Adjuster
Some parts stock crankpins (date stamped 11/79) used on '54-'79 XLs are missing a weld
Some parts stock chain adjuster linings (39978-58) used on '58-'78 XLs are brittle
M-7694-18-1980AllService Information - 1980
M-7703-31-19801980 FLTIgnition Switch/Fork Lock Assembly (Recall 048)
M-7715-9-1980FL/FX/FLTOil Pump Gasket & Cover Changes
M-7724-22-1980FL/FX/FLT1340cc Low Compression Pistons
M-7734-25-19801980 XLShock AbsorbersSome XLs have XLCR shocks factory installed. These XLCR shocks were modified to incorporate the same spring and damping rate of the XL shocks but were chrome instead of the standard XL black shocks so the only difference is appearance.
The affected VINs are: (3A) 27367J0-30533J0
M-7744-25-1980FL/FXGear Shaft 1958-1972
M-7755-6-1980FXBBelt Adjustment and Alignment Procedure
M-7765-9-19801977-1980 XLSolenoid CoverSome solenoid covers used since 1977 have the ability to conduct electricity.
M-7775-13-19801980 XLCylinder Head GasketsStarting with crankcase #780-024-024, oil return holes in the cylinder head gasket have been elongated (egg-shaped) to prevent blockage from slight alignment differences possible when installed The part number (16769-73) didn't change for the new gasket.
M-7785-13-1980XL/XLH/XLCH/XLSCrankcase Cover GasketThere is a possibility of high pressure oil leakage around the oil passage between the upper crankcase cover and the crankcase. Since November of 1979, the crankcase castings have been reworked and modified to eliminate this possibility. As a part of that revision, the crankcase cover gaskets used in production and in stock have been modified to not only fit the revised castings but also to eliminate the possibility of oil leakage on earlier crankcases. The oil passage hole in the top (middle) of the gasket was elongated (slotted). The old parts stock at the dealer (without the slots) had to be elongated using a template supplied from the factory.
M-7795-23-19801980 XL/XLSRear Brake Clevis Rod EndInspect brake stop bracket (welded to muffler) for the correct bend periodically. The bracket should form a 90° angle out from the muffler. If the motorcycle should fall on it's right side or the muffler and bracket should hit the curb, the brake stop bracket could be inadvertently bent. This could then allow the brake pedal to travel past it's stop and could result in the distort­ing or bending of the clevis rod end (42445-80). Although the bend in the clevis rod end will not adversely affect the brake function, it could allow increased brake pedal free play. This condition would cause the brake pedal to travel further when applying the brake.
M-7805-23-19801000/1340cc enginesRevised Ignition TimingSome engines (built since January) knock or “ping” due to poor octane gas. Reduce timing 1°-10° as a possible solution to help eliminate the problem
M-7815-23-19801980 1000/1340cc modelsIgnition Timing MarksTiming marks have been revised to enable to be electronically set at the factory and reduce setup time for dealers
M-782A6-20-1980FL/FX/FLTThree Angle Valve Seats
M-7835-23-1980FLTAccessory Gauge Kit Installation
M-7845-23-1980FLTService Procedure
M-7856-10-19801979 XL/FL/FXRear Brake Master Cylinder Piston (Recall 044 - addendum)
M-7868-29-19801972-E1980 FL/FXInterchangeable Front Brake Piston
M-7876-3-19801980 FLTFork Lock Adjusting Screw (Recall 049)
M-7886-3-1980FL/FX/FLTCylinder Heads, Intake Manifold & Clamps
M-7896-6-1980Pre-1980 FL/FXCast Iron Valve Guides
M-7906-10-19801980 FL/FX/FLTService Information 1980
M-7917-25-1980FL/FXCylinder Head Temperature Gauge Kit (75000-69A)
M-7927-3-1980FLTElectrical Charging System Diagnostic Procedure
M-7937-3-1980All 1980 modelsIgnition CoilsA number of ignition coils have failed at low mileage due to an internal breakdown in the windings
M-7947-14-19801980 FXWGRear Brake Control Mounting Bolts (Recall 050)
M-7957-22-19801980 FLTSprocket Mounting Bolts (Recall 051)
M-7969-16-1080FLTFront Fork Lock
M-79710-10-19801980-1981 FLTService Information
M-79810-7-1980FLH/FLTRear Brake Caliper Maintenance
M-79910-17-1980FL/FXService Information 1981
M-80010-10-1980All 1981 models17 Digit VIN SystemThe Vehicle Identification Number (VIN) was expanded to 17 digits including codes for country of origin, maker, bike weight, engine displacement, introduction date, a check digit and which factory made it.
M-80111-14-1980Models covered under
Service Bulletins
Service Bulletin IndexIndex of all Motorcycle Service Bulletins which may be of current interest to dealers (does not include bulletins which are no longer applicable such as former warranty policies and literature lists).
M-80411-4-1980AllThrottle Cable AdjustmentAll 1981 model motorcycles are equipped with a dual cable (pull-pull) throttle assembly. The throttle cable pulls the throttle butterfly open when turned counter-clockwise (as on previous models) while the idle cable pulls the butterfly closed when the grip is turned clockwise. The carburetor is equipped with a return spring which closes the throttle when grip is released (as on previous models).
M-80411-21-1980All models affectedSafety Recall Campaign IndexSimple list of safety recalls from the beginning of the recall campaign up to 7-14-1980 (recall numbers 001-050).
M-80612-5-19801971 and up FX but pertains to all HD model seats containing buttonsSeat RepairTwo front tabs on 1971 and up FX seats are now replaceable using a seat repair kit and a rivet tool. Three styles of replacement buttons are now available in three different lengths to accommodate the varying thicknesses of the different seats available (One piece: XL - cloth, XL - King / Queen, XLS - two piece).
M-807A10-14-1984All models affectedSafety Recall Campaign IndexSimple list of safety recalls, arranged per model affected, from the beginning of the recall campaign up to 5-2-1984 (recall numbers 001-058).
M-8131-30-1981XLH/XLSService Information1972-1981 piston ring kits (date code 4-80 and 5-80) with a possibility that the oil control rings in the kits were the wrong size. Check ring gap for proper measurement when installing (.012“-.025”).
The MoCo also issued a warning regarding brake line maintenance on 80 and 81 XLH/XLS models. Avoid bending or kinking and use caution when routing around the solenoid (electrical shortage) and rear exhaust / heat shield (wearing a hole in brake line).
The torque value in the service manual for rocker arm acorn nuts is incorrect. The correct torque value is 15-20 ft-lbs.
Always check the fitment of battery covers and avoid contact to the battery positive terminal.
The transmission vent hose routing was changed on late 1981 models and was suggested as a practice for E1981 models as well. The hose should now be routed under the starter, over all of the oil lines and the rear brake line, and down between the pivot bolt and swingarm.
M-8142-6-1981All1981 Service Update:
Ignition Module

The ignition modules, with the part number suffix -80 (Sportster part number 32410-80), 4) have a time delayed protective control circuit that stops current flow to the ignition coil if the engine is not running. This prevents overheating the ignition coil and limits the drain on the battery. With the time delay, (four seconds) the module will only start fir­ing on the second or third stroke, which may present a problem with kick-start motorcycles. This causes a problem on kick-start motorcycles, where there may be a pause between kicks. Although either module can be reset, if the protective circuit shuts off current flow, by turning the ignition switch or engine stop switch off, then back on again, newer modules, with part number suffix -80A (Sportster part number 32410-80A, 5) ) have a 6 second delay, will fire on the first compression stroke will work in 1980 and E1981 applications without modification.
FL SidecarSidecar Wheel LubricationFL model sidecar wheel bearings should be checked for wear and repacked with grease every 10,000 miles. We recommend using the new wheel bearing grease (99855-80), for all wheel bearings.
1981 FXWG/FXB/FXS-8OExhaust SystemThe 1981 shorty dual exhaust system for these models is shown in the 1981 FX models Parts Catalog (99455-81). The new system has separate exhaust pipes and mufflers rather than a one-piece welded assembly. Additional support brackets and tabs have been added.
The 1980 FXWG exhaust system is no longer available, the 1981 system must be used in it's place. Besides the pipes mufflers and hardware, bracket (65399-81) and muffler support tube (65615-80A) must be used. The bracket is mounted behind the rear footpeg and the support tube is mounted to the frame.
FLH HeritageSeat Bar LubricationParts and Accessories Bulletin (129) lists the special parts used on the 1981 Heritage Edition motorcycle. The parts list for the seat and seat post calls out a grease fitting (9851 - Item # 15). This fitting is only to be used for lubricating the seat bar pivot point. The original plug (51988-66) must be installed after lubrication is completed. If the grease fitting is not removed, it will interfere with and possibly damage the wiring harness.
M-815 FL/FXRear Brake Anti-Vibration Kit
M-815A12-18-19811973-1980 FL/FXRear Brake Anti-Vibration KitThe instructions with bulletin M-815 for the anti-vibration kit (41670-73) has been revised. Originally, the instructions show the rear brake hose routed on the inside of the swing arm. The new revised instructions show the correct brake hose routed on the outside of the swing arm.
M-8244-17-19811200/1340/1000 modelsCrankshaft Bearing Race ToolA new tool is available to press out the crankshaft bearing race. Two sizes available. One for 1200cc/1340cc and one for 1000cc engines. Tool is a shouldered split bushing with a hole in the center for the driver.
M-8254-21-1981FLTFLT Wheel Alignment ToolThe MoCo recommended bending an aluminum welding rod to make a wheel alignment tool as an alternative to step 4 in the rear wheel alignment procedure in the latest FLT FSM.
M-8274-24-19811981 XLThree Angle Valve SeatsThe MoCo issued a bulletin M-782 in June of 1980 stating that all 1980 production models incorporate three angle valve seats on the (intake and exhaust) ports on the heads. In April of 1981, this was reiterated for XL Models starting with cracnkcase (781012001).
M-8284-21-1981AllVIN Character IdentificationThe “6” and “9” characters used in the stamping of engine and crankcase numbers could be interchanged. If that turned out to be the case on factory stamped numbers, this would still be a legitimate and acceptable number. Also included with this bulletin is a chart showing legitimate characters used for VINs by the MoCo.
M-8295-19-19811200/1340/1000Commonized FlywheelsCommonized flywheel taper design on 1200/1340 and 1000cc engines. All tapers have were communized at 6° and all keyways were standardized.
M-829A5-19-19811200/1340/1000Commonized FlywheelsUpdate to M-829 to include part numbers
M-8306-30-19811200/1340/1000Color Coded Cam Gear SelectionParts and part number changes for cam gears and components
M-830A6-30-19811200/1340/1000Color Coded Cam Gear SelectionReplacing parts and part numbers from Bulletin #830 for 1000cc engines
M-8316-12-19811980-1981 FLT
1981 FXE/FXEF/FXS/XLH/XLS
1981 Service Information80-81 FLT wheel needle bearings are to be lubricated with UNIREX N-3 grease.
Also, app. 800 motorcycles were assembled with washers under the lower handlebar clamps due to the risers being made too short.
M-8326-12-1981XL/FX/FLTFront BrakesA special foam tape was made available for XL/FX/FLT models front brake calipers. Applied to the front of the outer caliper half, it helps to prevent caliper rattle.
M-83710-2-1981XL1982 Model Service Information* New 13 amp generators for XLs feature thrust washers (4 thicknesses to adjust armature endplay from .004“-0.010”) between the rear end cover and rear ball bearing.
* New rear brake caliper with the same square seal design but the brake pads are now supported on the caliper bracket to make changing pads easier.
All* 1982 batteries require less maintenance of electrolyte levels than earlier models. Check fluid level after 1st 500 miles then every 5000 after.
* All 1982 models feature new hand levers and switches.
1000/1200/1340ccRocker arm shafts now have a 45° angle cut into the end of the shaft on E1982 models. A 0.015“ spacer was made available for 1973-Very Early 1982 models, with the flat cut rocker arm shafts, to prevent O-ring distortion and oil leaks in this area. The washer fits inside the O-ring under the right end screw of the rocker arm shaft. E1982 models, with the new 45° shafts do not need the washer. Never use more than 1 washer on the shaft
FXRThe rear caliper is identical to one on XL models except it is located on the right side of the motorcycle.
FL/FX/FLT/FXRNew E1982 inner and outer valve springs.
FLT* New pushbutton saddlebag locks
* Rear sprocket housing has been changed and no longer requires the one piece seal.
New tapered roller wheal bearings and reduced wheel endplay
M-83810-2-1981All1980-1982 Motorcycle Tire FitmentNew tire and wheel combinations
M-83910-2-19811982 XLBattery Cable RoutingOn Vins prior to (1HD1CAH15CY111159) the positive battery cable may contact the leading edge of the oil tank. Inspect and re-route the cable if necessary.
M-84010-2-19811982 XL1982 Service Information* New 13 amp generator can be retrofitted to 1965 models with some guidelines for retrofitting.
* After engine VIN (1HD1CAH1XCY111183) the torque spec was lowered for the oil separator washer nut to 6-8 ft/lbs in order to prevent bowing of the oil separator washer (which can lead to generator noise). Engines exhibiting unusual generator 'whistling' should be checked for this condition. If the washer is found to be deformed it must be replaced.
* A limited number of E1982 XL engines (782216009-782237017) were assembled without the communized flywheel taper design.
M-84410-30-1981AllStandard Piston GradingAll standard sized pistons are graded for size in .00025” increments. This is done for production purposes on­ly and does not apply to oversized (.010“-.070”) pistons.
M-84511-17-19811982 XLInformation UpdateSportster fuels requirements have changed. A lower compression ratio was achieved by the addition of a thicker head gasket. This allowed for the use of regular grade unleaded fuel (89 octane) as opposed to the unleaded premium stated in the current service and owner's manuals. Testing has shown that prolonged use of unleaded fuel is bad on the valve train. Dealers were advised to relay this information to their customers.
1982 FLT* Incorrect (3/4”) windshield mounting screws were factory installed on some early models. Replace the incorrect screws with 10-32×1“ screws to 4 in/lbs.
* The model designation number has changed in VIN
M-8484-9-1982XLCrankcase Breather ValveLate 1982 - the internal crankcase breather valve in the cover was redesigned to incorporate a rubber umbrella valve attached to the base plate along with a larger diameter (1-3/4” O.D.) oil separator washer on the generator armature.
8492-16-19821200/1340ccValve Guide ReplacementsIntroduction of new valve guides with seals to help improve oil consumption
M-851A3-23-1982XLInformation UpdateThe one piece (welded) rear exhaust & muffler assembly (65600-80A) and one piece front exhaust pipe & muffler assembly (65605-80A) is no longer available after the current stock is used up. These are being replaced by the new clamp-on two piece system. Due to size differences, parts from the two different exhaust systems cannot be interchanged.
AllThe old oil tank drain plug washer, .640“ I.D. (6700B), has been replaced with a new fiber washer, .515” I.D. (26231-78) to improve sealing.
M-8533-19-1982AllFront Brake Stoplight Switch
M-8557-19-19821982 XLFootrest Chain ProtectorA foot rest chain protector (50943-82) is now available that fits over the footrest bracket to prevent contact between the final drive chain and the passenger footrest bracket. This can be installed with channel lock pliers with the open section facing the swingarm to prevent rotation of the protector.
M-8568-6-19821983 XLService Information* Oil tank drain method: Using hose clamp pliers (HD-84 04), loosen and slide the clamp from the oil drain hose to the plug bracket. Disconnect the hose and drain the oil from tank into suitable drain pan. Upon reinstallation of the drain hose, connect the hose to the plug bracket and secure it with the clamp. Fill oil tank with 3 quarts of HD Power Blend Super Premium oil. If the oil pressure light stays on, air may have been introduced in the oil system making it necessary to prime the oil pump.
* Higher compression ratio (8.8-1) achieved through new piston design and the use of the earlier style thinner head gasket. This higher compression ratio along with a new two stage ignition system (VOES), provides increased performance while allowing use of leaded regular grade gasoline.
* Pistons upgraded with a .040“ higher crown surface which adds to the compression ratio. The piston is identified by a chamfered edge on the crown.
* Piston rings now include a beveled barrel-faced moly-filled top ring, a taper-faced second ring and a three piece oil control ring with chrome plated rails and a corrugated expander.
* A 2-stage computerized microprocessor module including a Vacuum Operated Electric Switch (VOES) added to the ignition system and is programmed with 2 spark advance timing curves to meet varying engine loads.
* An access Plug Removal Tool (33186) is available to remove the access plugs from the primary cover. A round disc with raised center slots on each side, one side is for '76 and earlier and the other side is for '77 and later primary cover plugs. The tool has a square cut into the center for use with a standard 3/8“ socket wrench.
* Also instructions for indicator lamp replacement on XLX/XLS models.
M-85710-5-1982L1982 & E1983 XLTumbling Stone ContaminationReports were received indicating that tumbling stone contamination may have been existent in Late 1982 - Early 1983 engines with crankcase VINs (782025001-783200001). Tumbling stones are used in the polishing process of tappet bodies and occasionally can become wedged within the tappet body. The retention of a tumbling stone in the tappet assembly will cause premature tappet wear. If contamination has occurred and tumbling stone material is allowed to circulate through the engine for an extended period of time, some engine damage will eventually occur. Affected engines will first show excessive wear of one tappet guide assembly.
M-85810-7-1982XLService InformationChecking VOES operation on 1983 and later models and the number of transmission mainshaft (R) shims for parts order increased to a total of 10 sizes (these parts will retrofit Sportster transmissions back to 1954 K Models).
M-85910-29-1982XL/FXR/FLT/FLHTScrew Type Fuel CapAll 1983 XL/FXR models produced after VIN (1HD1CCH17DY113282) and FL/FX models pro­duced after VIN (1HD1AKK16DY011657) use a new low pressure fuel tank cap. The vent relief pressure has been reduced on the screw type fuel caps by utilizing a softer spring and should help eliminate a lean condition.
M-86011-12-1982XLService Information* Camshaft shims (6769 & 6770), used to control maximum camshaft end play have been discontinued in production engines. It was determined through testing that an increase in the maximum allowable cam gear shaft end play does not contribute to an increase in noise or prove to be detrimental to component operation.
* New finish to cylinder and head gaskets. The gasket surface has a new finish appearing similar to the grooves of a phonograph record. The soft copper head gasket conforms to the finish and prevents oil leakage at the oil return passages. Torque values stayed the same at 55-65 ft-lbs.
* Oil pump gerotor gears now fabricated without the chamfered top and bottom on the outer diameters as was in the E1983 and earlier gerotors.
(See also Late 1983 oil pump assembly design modification )
* 1983 ignition module plugs are of a new design to prevent intermixing with the earlier type Magnavox modules and sensors.
M-8673-11-1983AllTire FitmentCorrect matching of tire, tubes and wheels
M-8704-15-1983XLNew Valve Guides / Transmission Mainshaft Shims / Ignition Module / Sensor ConnectionsValve Guides: New valve components including:
* New shoulder-less intake and exhaust valve guides for 1000cc engines (beginning with crankcase number 783). New (flat) lower spring collars and longer inner springs and outer springs to provide increased spring tension. The new style valve guides will also be used for service replacement of the old style shouldered guides on all XL 1000cc engines. Spring data and installation instructions also included with this bulletin.
* A new style thrust washer is used on Late 83 XL production engines to control transmission mainshaft endplay. The new washer is thicker than the old style thrust washer to allow the use of one instead of two washers. Also, the new washer has no tang to prevent rotation as the old style thrust washer has. The roll pin in the crankcase has also been eliminated. The new thrust washer is available in four thicknesses (.098”, .107“ & .116”). A single thrust washer can now replace the earlier style thrust washers if the endplay is great enough to support the use of the new ones. Although the mainshaft endplay limits (.003“ min. w/ pre-load, .020” unloaded) remain the same, the earlier style thrust washers (.030“-.085”) with the tang are still available for earlier engines requiring the thinner thrust washers.
* Late 83 XL ignition modules (32410-84) and sensor assemblies (32400-84) are being made with rubber rather than plastic components to improve service life and avoid possible separation of the connectors in the field resulting from loose fitting components. The Late 83 ignition module and sensor assembly will fit Early 83 engines when replaced as a set or replaced individually which requires changing one or the other connector halves).
M-870A5-10-1983XLNew Valve Guides / Transmission Mainshaft Shims / Ignition Module / Sensor ConnectionsResending to add further information to M-870:
* New shoulder-less intake and exhaust valve guides for 1000cc engines (beginning with crankcase number (783 101037). When using new guides to replace the old style guides, it is not necessary to replace the old upper and lower spring collars, inner and outer springs or valve keys. However, the new components - lower collar (18220-83), longer inner spring (18204-83) and outer spring (18203-83) parts can only be used with the new shoulder-less guides. If replacement springs or lower collars are needed (on pre case #783 engines), the old style part numbers for these will be required.
M-8716-7-19831982 and later FXR/XL
1983 FXSB/FXWG/FLHS
Late 1983 FXE
Girling Rear Brake Service* The stainless steel abutment shim (41665-82) used on Girling rear brake calipers is now available for parts order along with detailed installation instructions.
* The Girling rear brake requires the use of 5/8“ dia. master cylinder piston rather than the 3/4” piston used on other models since the Girling system is more efficient and requires less fluid displacement. Because of the smaller fluid volume in the master cylinder, a smaller amount of air bubbles present will have a greater affect on brake performance so it may be necessary to bleed the system more than once.
M-8728-18-1983XLService InformationBeginning with crankcase (#784174011), a production change incorporates a new crankcase set (35105-83) and a pressed in mainshaft bearing (12049) while using the same transmission mainshaft, roller bearing and retaining ring as before. The new crankcase set will also be sold as replacement parts for 82-84 XLs. The new seal and bearing race are not interchangeable with earlier crankcase components. When replacing seals during transmission work, the new seal is installed (flush to .010“) below the face of the crankcase boss surface.
M-87312-9-1983All except FLHBattery Vent Hose ClampDue to a number of plastic vent hoses coming off the battery hose nipple, starting in mid December (83), motorcycles shipped from York will be fitted with a battery hose clamp (10067). Also, as P&A batteries are received from the vendor, a clamp will be included with the hose. Clamps were sent to each dealer to install on motorcycles for before delivery and during servicing. Instructions for installing the clamp are included in this bulletin
M-87510-11-1983All 1982 and later motorcyclesBrake Pad InspectionThe normal brake pad inspection interval is 2500 miles for all 1982 and later models. This is adequate under normal riding conditions. More frequent inspections should be made if the motorcycle is ridden under more adverse conditions (steep hills, heavy traffic, etc.). Although we do not recommend it, some riders prefer to use the rear brake only . This also will require more frequent brake pad inspections. A letter was sent to all registered owners of 1982 and later vehicles urging them to monitor their brake pad wear on both front and rear wheels. A dial vernier caliper may be easier to use than a 6” ruler as suggested in the letter.
M-8761-13-1984XL/XR-1000Transmission InformationGear changes:
* Mainshaft 1st gear (35277-52A) is now flat on both sides (allowing it to be installed with either face toward the crankcase) instead of one side having a recess on the rear face. This new gear will retrofit 54 and up models. It also requires the removal of the crankcase roll pin and the replacement of the hooked thrust washer to the new circular thrust washers.
* Countershaft 4th gear (35695-58) also has been redesigned to eliminate the recess on the surface away from the access cover. The shoulder must face the access cover to prevent damage to the cover. This new gear will also retrofit 1954 and up models.
* Additional undersize and oversize shifter forks are now available for more precise spacing of the sliding mainshaft 2nd gear and countershaft 3rd gear. The new forks are identified with a stamped (P) for plus or (M) for minus (instead of the + or - symbols) as well as the dimension. The ID number is stamped on the inside of the fork. The dim range is measured from the center of the fork bore to the inside face of the fork
M-876A2-7-1984XL/XR-1000Transmission InformationResending to fix a typo on TSB M-876 regarding the part number for the +.020“ fork to (34292-72) instead of -84.
M-8813-9-1984(FL (except FLT)/FX/XLWheel WeightsA number of 1984 16” laced wheels were manufactured without a radius on the outer rim flange. Consequently, the automotive type wheel weights used for factory balancing of 16“ laced wheels may not stay on the rim at normal operating speed. On the affected wheels, the automotive type weights must be replaced with spoke weights or sticky back weights. In measuring the wheel's overall (outside dim.) width from flange to flange, wheels with a width of 3-15/16” or less should not use an automotive type weight. If the rim measures 4-3/16“, then automotive wheel weights are permissible.
M-8833-13-1984All 1984 modelsTire FitmentCorrect matching of tire, tubes and wheels
M-8854-10-1984* All 1984 models
(except FLH and
1983 XR-1000)
Information Update* Front caliper mounting bolts: The torque specs for the front caiper mounting bolts have changed from 40-45 ft lbs. to 25-30 ft lbs.
* All* The rear axle nut torque specs have been changed from 45-50 ft lbs. to 65-70 ft lbs. Wheel bearing endplay, however, remains the same. Bearing endplay must be checked after tightening the axle nut.
* 1340 Shovelhead
1340 Evo
1000 Sportsters
To aid the stamping operation, the locations of the crankcase numbers on the following case halves were changed to a different location on that case half (opposing case half numbers remained the same as before):
1340 Shovelhead - Left Case (1484 044001 and up)
1340 Evo - left case (1584 044003 and up)
1000 Sportster - right case (784 044001 and up)
M-8864-6-1984XL/XRSprocket NutA L84 replacement mainshaft sprocket nut (35049-71) has been developed to prevent transmission oil leaks from the sprocket splines on 71-84 XL/XR models. The new sprocket shaft nut encloses the end of the mainshaft and creates a metal to metal seal between the sprocket, lockwasher and nut when torqued to 35-65 ft lbs. To use this nut on 71-E84 models, a modification to the inner or outer sprocket cover (respectively) will have to be made to prevent interference between the nut and the cover. This bulletin also includes dims for modifying 71-E84 sprocket covers to accept the new sprocket nut.
M-8865-18-1984AllBattery ElectrolyteMany hard starting and / or electrical problems may be caused by a battery with acid that has low specific gravity readings. Automotive quality battery acid (with a specific gravity of 1.255 - 1.265) will not provide full battery potential. Because of their small size, motorcycle batteries require a sulfuric acid solution having a specific gravity of 1.270 - 1.280. Depending on the battery's condition, use of acid with a specific gravity of 1.280 will increase amperage output of the battery up to 20%. Accurate specific gravity readings can't be made with a floating ball type hydrometer. Use a Kent Moore hydrometer (HD-96910-35). This bulletin comes with warnings for working with battery acid.
M-8926-22-1984XL1000cc Engines* Announcing the retirement of the 77-E83 oil pump assembly with the new L83 style pump along with service instructions for retrofitting the new pump/ parts to 77-E83 pumps. (See also Late 1983 oil pump assembly design modification )
* The L1984 alternator / clutch transmission access door (34847-84) utilizes two slots for removal. An alignment tool (SNAP-ON 1650) or (MAC LF-12) or equivalent in the shape of a crowbar is recommended to draw the access door from the dowel pins. You can use a propane torch to carefully apply heat to the access door dowel pin area. Do not allow flame to rest on any one area for a prolonged period of time and wipe all the oil from access door prior to heating. Insert the hook end into each slot and gently alternate between the slots to evenly remove the door from the dowel pins.
M-8949-7-1984XLProduction Changes on XL
Transmission Cover
Alternator Stator Mounting
Beginning with crankcase (785 208001) manufactured after July 26,1984, the mainshaft fourth gear bearing assembly is now retained within a shoulder in the new trapdoor.
The stator is now attached directly to the trapdoor (cover) as well. The L84 cover is also available for parts order.
M-89911-30-1984XLMidyear Production Changes to
XL Pistons and Oiling System
* Beginning with crankcase (785 306029) manufactured after November 1, 1984, pistons have a new style cam ground, barrel shape. Because of their complex design, the pistons must be measured 90° from the piston pin and .890” above the bottom of the piston.
* Piston rings include a moly-filled top ring, a taper-faced second ring and a corrugated expander ring.
* The piston pin retaining ring (22589-83) (same as used on EVO 1340 and XR-1000 pistons) requires a modification to be done on the piston pin retaining ring installer (HD-34623) to extend it's use to the new style pistons (requires cutting a flat area (.250“ from the outer edge) out of the diameter of the business end of the tool.
* Beginning with crankcase (785 303002) manufactured after October 29, 1984, a cam gear oiler has been added inside the gearcase to direct oil from the top top end oil passage to the gear mesh between first / second gears and third / fourth gears. Direct lubrication of the gear teeth allows tighter gear fitment and gear backlash and noise are reduced (a slight gear whine is normal and does not indicate gears are too tight). The cam gear oiler will not retrofit to earlier engines.
M-9012-22-1985L84 and later BTsDiaphragm Clutch AdjustmentDetails adjusting procedure for 4 and 5 speed models.
M-9026-4-1985AllLocking/Sealing Compounds
and Tire Fitment
* List of recommended threadlocker and sealant compounds for various applications
* Correct matching of tire, tubes and wheels
M-902A12-20-1985AllLocking/Sealing Compounds
and Tire Fitment
This bulletin was re-issued to add further information. Inclusions were:
* A warning to not use Loctite on thermoplastic parts like fairings, saddlebag lids, seat pans and etc. Exposure to Loctite can cause thermoplastics to become brittle.
* A caution when using Hylomar due to an EPA investigation into the chemical ingredient (Methylene Chloride (MC)) in 1985. M.C. has been around since the 1950's and an ingredient in most aerosol propellants and in all Hylomar currently in the field. Until the EPA establishes safety guidelines, it should be considered a hazardous substance. This bulletin also contains precautions, handling, exposure and treatment guidelines for working with Hylomar.
M-9045-31-19851986 XLH 883Pre-Delivery SetupAddition to the 1985 Motorcycle Setup Manual providing information for the 1986 XLH 883 including mounting the horn and throttle cable brackets (to the gas tank front mount), mirrors, bench charging the battery to 1.270-1.280 specific gravity, checking throttle cable routing, instrument indicator lights operation and ignition timing.
M-9058-26-1985All with California
Emissions Control
Fuel Supply ClosureDiagrams the 3 position petcock (main, reserve and off) suggesting the importance of the 'off' position when used with a California Emissions Control kit. With this kit, the overflow hose from the carburetor is removed and the carb's overflow outlet capped off (preventing excess fuel from leaving the carb to atmosphere). This will also increase the possibility of fuel seepage (flooding) into the engine if the fuel supply valve is not turned to the off position each time the engine is shut off.
M-9614-8-1988AllScreaming Eagle Carb Kit - Accelerator Pump LengthA number of Screaming Eagle carb kits (91731-85A), packaged during March of 1988 (3/88 date code), contained carburetors with accelerator pump rods that were too short. The incorrect pump rods were only 2.35” long, end to end, and completely disabled the accelerator pump and caused the engine to stumble upon fast acceleration. The correct length pump rod (27374-88) is 2.55“.


Return to Sportster Parts, Manuals, Links & Terminology Go To Welcome Page

1)
HD Service Bulletin #458 dated January 12, 1962 pgs 1-6
2)
HD Service Bulletin #M-801 dated November 14, 1980
3)
HD original Service Bulletins as described herein
4)
1979-1980 HD Sportster Parts Catalog pg 23
5)
1979-1982 HD Sportster Parts Catalog pg 31
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