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parts:partsplus-01b [2020/02/14 06:49]
ixl2relax [TSB 950-999]
parts:partsplus-01b [2020/02/24 06:20] (current)
hippysmack [TSB 700-749]
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 |<wrap hi>​**403**</​wrap>​| |12-15-1958|All|Service Manuals| |<wrap hi>​**403**</​wrap>​| |12-15-1958|All|Service Manuals|
 |  Notes: || Explaining the new HD service manual program||| |  Notes: || Explaining the new HD service manual program|||
-|<wrap hi>​**404**</​wrap>​| |1-15-1959|All|Special Service Tools for All Models| +|<wrap hi>**404**</​wrap>​ \\ \\ <wrap hi>​**404B**</​wrap>​| ​\\ \\ {{ :​pdf:​tsb0404b.pdf |Y}} |1-15-1959 ​\\ 8-5-1973 \\ 10-30-1974|All|Special Service Tools for All Models| 
-|  Notes: || Clutch gear reamer, chain tool, gear puller, clutch hub policy|||+|  Notes: || This Service Bulletin lists all special tools used to service Harley-Davidson products. ​|||
 |405| |4-15-1959|FL,​ FLH|Duo-Glide Rail Type Piston Oil Ring| |405| |4-15-1959|FL,​ FLH|Duo-Glide Rail Type Piston Oil Ring|
 |  Notes: || New oil ring, installation instructions||| |  Notes: || New oil ring, installation instructions|||
Line 294: Line 294:
 |493| |8-14-1964|M-50|Wheel Bearing Change| |493| |8-14-1964|M-50|Wheel Bearing Change|
 |  Notes: || Changed to more durable balls in the loose ball cone-type bearing cups||| |  Notes: || Changed to more durable balls in the loose ball cone-type bearing cups|||
-|<wrap hi>​**494**</​wrap>​| |9-15-1964|FLH/​XLH|Shock Absorber Change| +|<wrap hi>​**494**</​wrap>​| ​{{ :​pdf:​tsb0494.pdf |Y}} |9-15-1964|FLH/​XLH|Shock Absorber Change| 
-|  Notes: || Adjuster ​cam change|||+|  Notes: ||The adjusting cam used on the 1965 covered type shock absorbers have been changed by reducing the diameter to eliminate the step at the bottom end. This prevents contact between ​cam and cover when the shock telescopes to the compressed position.|||
 |<wrap hi>​**495**</​wrap>​| |9-18-1965|All|1965 Service Manuals| |<wrap hi>​**495**</​wrap>​| |9-18-1965|All|1965 Service Manuals|
 |  Notes: || Manual listing and prices||| |  Notes: || Manual listing and prices|||
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 |<wrap hi>​**501**</​wrap>​| |12-11-1964|All| |<wrap hi>​**501**</​wrap>​| |12-11-1964|All|
 |  Notes: || New Shop Service Tools||| |  Notes: || New Shop Service Tools|||
-|502| |12-11-1964|Electra Glide \\ Servi-Car|Starter Tests - With Sun Vat-26|+|502| {{ :​pdf:​tsb0502.pdf |Y}} |12-11-1964|Electra Glide \\ Servi-Car|Starter Tests - With Sun Vat-26|
 |  Notes: || Testing, troubleshooting & procedures||| |  Notes: || Testing, troubleshooting & procedures|||
 |<wrap hi>​**503**</​wrap>​| |12-31-1964|All|Generator Brushes - 12v. & 6v.| |<wrap hi>​**503**</​wrap>​| |12-31-1964|All|Generator Brushes - 12v. & 6v.|
Line 334: Line 334:
 |<wrap hi>​**515**</​wrap>​| |6-11-1965|XLH/​XLCH|Change to No. 4 Spark Plug| |<wrap hi>​**515**</​wrap>​| |6-11-1965|XLH/​XLCH|Change to No. 4 Spark Plug|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**516**</​wrap>​| |7-6-65|All|Chassis Service and Handling| +| <wrap hi>​**516**</​wrap> ​\\ <wrap hi>**516A**</​wrap>​| ​\\ {{ :​pdf:​tsb0516a.pdf |Y}} |7-6-65 \\ 10-15-1966|All|Chassis Service and Handling| 
-|  Notes: || ||| +|  Notes: || #516A addresses tire pressure specs, balancing, treadwear, loose spokes, rims/tire out of round, wheel alignment, bearing play, steering, faulty fork action, faulty steering and front end loading. ​|||
-|<wrap hi>**516B**</​wrap>​| |10-15-66|All|Chassis Service and Handling| +
-|  Notes: || |||+
 |517| |7-7-1965|M Models|Remove Engine Oil From 1966 M-50 Before Initial Startup| |517| |7-7-1965|M Models|Remove Engine Oil From 1966 M-50 Before Initial Startup|
 |  Notes: || Production models were treated with a rust preventative oil prior to shipment||| |  Notes: || Production models were treated with a rust preventative oil prior to shipment|||
-|<wrap hi>​**518**</​wrap>​| |9-10-1965|1966 ​XLH/XLCH|Change to Tillotson ​Carburetor| +|<wrap hi>​**518**</​wrap>​| ​{{ :​pdf:​tsb0518.pdf |Y}} |9-10-1965|1966 ​Sportster|Carburetor ​Service Information
-|  Notes: || |||+|  Notes: || Introducing the Tillotson Carburetor new for Sportters including operation, adjustments,​ troubleshooting and servicing. ​|||
 |519| |10-5-1965|FL/​FX|Primary Drive Chain Care| |519| |10-5-1965|FL/​FX|Primary Drive Chain Care|
 |  Notes: || Change to Duckworth (double row) primary chain with straight sides||| |  Notes: || Change to Duckworth (double row) primary chain with straight sides|||
 |<wrap hi>​**520**</​wrap>​| |9-27-1965|All|Tourist Motorcycle Warranty Procedure| |<wrap hi>​**520**</​wrap>​| |9-27-1965|All|Tourist Motorcycle Warranty Procedure|
 |  Notes: || Warranty will be honored by all dealers servicing motorcycles of tourists or other transient owners with a valid warranty (regardless of purchase place).||| |  Notes: || Warranty will be honored by all dealers servicing motorcycles of tourists or other transient owners with a valid warranty (regardless of purchase place).|||
-|<wrap hi>​**521**</​wrap>​| |10-11-1965|XLH/​XLCH ​\\ FL/FX|Generator Brush Location| +|<wrap hi>​**521**</​wrap>​| ​{{ :​pdf:​tsb0521.pdf |Y}} |10-11-1965|Electra Glide \\ Sportster|Generator Brush Location| 
-|  Notes: || ||| +|  Notes: || The 1966 generator used on Electra Glide and Sportster models (model 65A) has the positions of the positive and negative brush holders reversed so that when the generator is mounted on the motorcycle, the positive brush will be toward the top instead of the bottom to protect the positive brush holder from accumulated moisture and possible grounding of the positive brush holder. ​||| 
-|522| |9-30-1965|Servi-Car|Testing Servi-Car ​Elec. System| +|522| {{ :​pdf:​tsb0522.pdf |Y}} |9-30-1965|Servi-Car|Testing ​the Servi-Car ​Delcotron Electrical ​System| 
-|  Notes: || ||| +|  Notes: || Late 1965 and 1966 Servi-Cars have the alternator type (Delcotron) 12-volt charging system. This bulletin gives testing instructions for using the Sun VAT-26 voltage-ampere tester for trouble shooting the alternator, regulator; battery and associated wiring. ​||| 
-|<wrap hi>​**523**</​wrap>​| |10-18-1965|XLH/​XLCH ​\\ FL/FX \\ Servi-Car|Cylinder Base Nuts| +|<wrap hi>​**523**</​wrap>​| ​{{ :​pdf:​tsb0523.pdf |Y}} |10-18-1965|Electra Glide \\ Sportster ​\\ Servi-Car|Cylinder Base Nuts| 
-|  Notes: || Check torque|||+|  Notes: || Check tightness of all cylinder base nuts on these motorcycles when received from the factory before motorcycle is put into operation.|||
 |524| |10-29-65|FL/​FX|Lubrication System| |524| |10-29-65|FL/​FX|Lubrication System|
 |  Notes: || Diagnosing lubrication problems||| |  Notes: || Diagnosing lubrication problems|||
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 |<wrap hi>​**534**</​wrap>​| |2-17-1966|XLH/​XLCH \\ FL/FX  Servi-Car|Drive Chain - Press Fit Link| |<wrap hi>​**534**</​wrap>​| |2-17-1966|XLH/​XLCH \\ FL/FX  Servi-Car|Drive Chain - Press Fit Link|
 |  Notes: || All parts order and new production motorcycle 5/8" chains are now supplied with a press fit connecting link side-plate for improved durability||| |  Notes: || All parts order and new production motorcycle 5/8" chains are now supplied with a press fit connecting link side-plate for improved durability|||
-|535| |2-17-1966|Sprint|Spoke Tightness| +|535| {{ :​pdf:​tsb0535.pdf |Y}} |2-17-1966|Sprint|Spoke Tightness| 
-|  Notes: || Necessity ​to check spoke tightness|||+|  Notes: || We again call your attention ​to the necessity for regular inspection of the spoke tightness ​on Sprint motorcycle wheels. ​|||
 |536| |3-7-1966|FL/​FX \\ Servi-Car|New Starter| |536| |3-7-1966|FL/​FX \\ Servi-Car|New Starter|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**537**</​wrap>​| |3-22-1966|XLH/​XLCH|Transmision Countershaft Low Gear| +|<wrap hi>​**537**</​wrap>​| ​{{ :​pdf:​tsb0537.pdf |Y}} |3-22-1966|XLH/​XLCH|Transmision Countershaft Low Gear| 
-|  Notes: || fillet ​was added to right crankcase ​and the countershaft low gear has a counterbore at fillet area|||+|  Notes: ||Starting with engine No. 66XLCH 6117 on January 13, 1966, a fillet ​has been added at the base of the countershaft low gear boss of the right crankcase. Also, the countershaft low gear has a counterbore ​to provide clearance ​at this point.|||
 |538B| |9-25-1969|FL/​FX|Chain Housing Vent Kit| |538B| |9-25-1969|FL/​FX|Chain Housing Vent Kit|
 |  Notes: || ||| |  Notes: || |||
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 |544A| |12-1-1966|1967 Sprint|Pre-Delivery and Service| |544A| |12-1-1966|1967 Sprint|Pre-Delivery and Service|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**545A**</​wrap>​| |6-7-1968|XLH/​XLCH|Rear Wheel Tube Flap (43148-67)| +|<wrap hi>​**545A**</​wrap>​| ​{{ :​pdf:​tsb0545a.pdf |Y}} |6-7-1968|XLH/​XLCH|Rear Wheel Tube Flap (43148-67)| 
-|  Notes: || |||+|  Notes: || From September 20, 1966 through the 1969 model season, a wide rubber protection band was installed between the inner tube and tire bead on all Sportster rear wheel steel rims only. |||
 |<wrap hi>​**546A**</​wrap>​| |1-8-1969|All|Gas Line Hose Changes| |<wrap hi>​**546A**</​wrap>​| |1-8-1969|All|Gas Line Hose Changes|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**547**</​wrap>​| |10-24-1966|XLH/​XLCH ​\\ FL/FX|Tillotson Carburetor Inlet Valve| +|<wrap hi>​**547**</​wrap>​| ​{{ :​pdf:​tsb0547.pdf |Y}} |10-24-1966|Sportster ​\\ Electra Glide|Tillotson Carburetor Inlet Valve| 
-|  Notes: || |||+|  Notes: || Sportster and Electra Glide models above engine No.'s 66XLCH-10611 and 67FLH-1448 produced after August 10, 1966 have a new carburetor inlet valve lever, needle and seat assembly. ​|||
 |549| |2-8-1967|FL/​FX|Police Solo Recommendations| |549| |2-8-1967|FL/​FX|Police Solo Recommendations|
 |  Notes: || ||| |  Notes: || |||
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 |552| |2-21-1967|FL/​FX|Motor Sprocket Spacer| |552| |2-21-1967|FL/​FX|Motor Sprocket Spacer|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**553**</​wrap>​| |2-24-1967|1967 XLCH|Spark Plug Cable Guide (Recall 001)| +|<wrap hi>​**553**</​wrap>​| ​{{ :​pdf:​tsb0553.pdf |Y}} |2-24-1967|1967 XLCH|Spark Plug Cable Guide (Recall 001)| 
-|  Notes: || |||+|  Notes: || New spark plug cable guide (31630-67) installed on all XLCHs at the factory starting with engine No. 67XLCH 3989 to hold cables in the correct position away from carburetor preventing possible cable interference with the carb throttle lever. ​|||
 |554| |4-28-1967|1967 Sprint|Optional Gearing and Ignition Timing| |554| |4-28-1967|1967 Sprint|Optional Gearing and Ignition Timing|
 |  Notes: || ||| |  Notes: || |||
Line 418: Line 416:
 |560| |10-13-1967|Sprint|500 Mile Service| |560| |10-13-1967|Sprint|500 Mile Service|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**561**</​wrap>​| |10-16-1967|All|Oil Recommendations| +|<wrap hi>​**561**</​wrap>​| ​{{ :​pdf:​tsb0561.pdf |Y}} |10-16-1967|All ​4 Strokes|Oil Recommendations| 
-|  Notes: || ||| +|  Notes: || Change in lubricating oil recommendations for all Harley-Davidson 4-cycle motorcycles. ​||| 
-|<wrap hi>​**562A**</​wrap>​| |5-11-1969|XLH/XLCH FL/FX \\ Servi-Car|Set Timing in Advance Position|+|<wrap hi>​**562A**</​wrap>​| ​{{ :​pdf:​tsb0562a.pdf |Y}} |5-11-1969|Electra Glide \\ Sportster ​\\ Servi-Car|Set Timing in Advance Position|
 |  Notes: || Changed method of setting timing to in the advanced position||| |  Notes: || Changed method of setting timing to in the advanced position|||
 |<wrap hi>​**563**</​wrap>​| |11-29-1967|XLH/​XLCH/​M-125|Hydraulic Fork Oil Capacity| |<wrap hi>​**563**</​wrap>​| |11-29-1967|XLH/​XLCH/​M-125|Hydraulic Fork Oil Capacity|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**564**</​wrap>​| |1-15-1968|XLH/​XLCH \\ FL/​FX|Tillotson Carburetor Service-ability| +|<wrap hi>​**564**</​wrap>​| ​{{ :​pdf:​tsb0564.pdf |Y}} |1-15-1968|XLH/​XLCH \\ FL/​FX|Tillotson Carburetor Service-ability| 
-|  Notes: || |||+|  Notes: || Recommendations for correcting 'minor faults'​ adjusting, diagnosing, disassembly,​ cleaning and assembling before sending the carb back for replacement. ​|||
 |565A| |3-1-1968|1968 M-125/ Rapido|Stoplight Switch Rubber Boot (Recall 003)| |565A| |3-1-1968|1968 M-125/ Rapido|Stoplight Switch Rubber Boot (Recall 003)|
 |  Notes: || ||| |  Notes: || |||
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 |<wrap hi>​**569**</​wrap>​| |4-12-1968|XLH/​XLCH \\ FL/FX|Oil Filter Kit| |<wrap hi>​**569**</​wrap>​| |4-12-1968|XLH/​XLCH \\ FL/FX|Oil Filter Kit|
 |  Notes: || ||| |  Notes: || |||
 +|<wrap hi>​**570**</​wrap>​| {{ :​pdf:​tsb0570.pdf |Y}} |5-21-1968|Sportster \\ Electra Glide|Oil Tanks Drained for Shipment|
 +|  Notes: || Starting on May 1, 1968 all oil is being drained from oil tanks of Electra Glides and Sportsters before shipment. |||
 |<wrap hi>​**571**</​wrap>​| |5-21-1968|XLH/​XLCH \\ FL/​FX|Tillotson Carburetor Accelerator Pump Changes| |<wrap hi>​**571**</​wrap>​| |5-21-1968|XLH/​XLCH \\ FL/​FX|Tillotson Carburetor Accelerator Pump Changes|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**572**</​wrap>​| |6-10-1968|XLH/​XLCH \\ FL/FX|Control Cable Anchor Pin| +|<wrap hi>​**572**</​wrap>​| ​{{ :​pdf:​tsb0572.pdf |Y}} |6-10-1968|1968 XLH/XLCH \\ 1968 Electra Glide|Control Cable Anchor Pin| 
-|  Notes: || |||+|  Notes: || 1968 Electra Glide and Sportster models have a new type clutch and brake control cable anchor pin located in the hand lever. ​|||
 |573| |7-11-1968|FL/​FX|Clutch Throwout Bearing| |573| |7-11-1968|FL/​FX|Clutch Throwout Bearing|
 |  Notes: || ||| |  Notes: || |||
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 |576| |8-25-1968|FL/​FX|Cylinder Base Nuts| |576| |8-25-1968|FL/​FX|Cylinder Base Nuts|
 |  Notes: || ||| |  Notes: || |||
-|577| |9-13-1968|FL/FX|5.10 16 Replaces 5.00 x 16 Tire+|577| {{ :​pdf:​tsb0577.pdf |Y}} |9-13-1968|1969 Electra Glide|SIZE 5.10 16 Tires
-|  Notes: || |||+|  Notes: || 5.10 x 16 Replaces 5.00 x 16 Tire. Also addresses tubes and air pressure. ​|||
 |578| |9-25-1968|1969 MLS/​Rapido|Tail Lamp Wiring (Recall 005)| |578| |9-25-1968|1969 MLS/​Rapido|Tail Lamp Wiring (Recall 005)|
 |  Notes: || ||| |  Notes: || |||
 |579A| |1-8-1969|Sprint/​Rapido|Gas Tank Valve| |579A| |1-8-1969|Sprint/​Rapido|Gas Tank Valve|
 |  Notes: || ||| |  Notes: || |||
-|580| |10-18-1968|1969 ​Lightweights|Engine Numbering System Changed| +|580| {{ :​pdf:​tsb0580.pdf |Y}} |10-18-1968|1969 ​Sprint \\ 1969 Rapido \\ 1969 M Model|Engine Numbering System Changed| 
-|  Notes: || ||| +|  Notes: || Starting with the 1969 season, the model year designation is being omitted from the engine and frame serial numbers on Aermacchi Harley-Davidson models. The model letters only will be used as a prefix to the serial number. Numbers will run consecutively regardless of model year. ||| 
-|581| |12-15-1968|FL/FX|Oil Pump Nut & Bolt Tightness| +|581| {{ :​pdf:​tsb0581.pdf |Y}} |12-15-1968|Electra Glide|Oil Pump Nut & Bolt Tightness| 
-|  Notes: || ||| +|  Notes: || Bolts and nuts must be drawn down evenly to approximately 50 in/lbs. but no more than 60 in/lbs. of torque. ​||| 
-|<wrap hi>​**582**</​wrap>​| |12-17-1968|XLH/XLCH|Sprocket Changes - 20-19 Teeth+|<wrap hi>​**582**</​wrap>​| ​{{ :​pdf:​tsb0582.pdf |Y}} |12-17-1968|1969 XLCH|Gearing Change to 19 tooth Sprocket
-|  Notes: || |||+|  Notes: || Starting November 4, 1968, with engine serial No. 69XLCH 5921, all model XLCH motorcycles are being equipped with a 19 tooth transmission sprocket (35197-52). ​|||
 |583| |12-15-1968|Siren Pivot Shafts| |583| |12-15-1968|Siren Pivot Shafts|
 |  Notes: || ||| |  Notes: || |||
-|584| |1-10-1969|1969 Sprint|Tune-Up Information| +|584| {{ :​pdf:​tsb0584.pdf |Y}} |1-10-1969|1969 Sprint|Tune-Up Information| 
-|  Notes: || |||+|  Notes: || New center bowl-dual float Dell'​Orto Carburetor with instructions for jetting, tuning including timing / point gap and tappet clearance. ​|||
 |585| |2-14-1969|Sprint SS|New Fuse Holder| |585| |2-14-1969|Sprint SS|New Fuse Holder|
 |  Notes: || ||| |  Notes: || |||
-|586| |2-14-1969|Sprint|Exhaust Valve Clearance| +|586| {{ :​pdf:​tsb0586.pdf |Y}} |2-14-1969|1969 Sprint|Exhaust Valve Clearance ​Pocket \\ Exhaust Valve Spring Shim
-|  Notes: || |||+|  Notes: || Starting with 1969 Sprint Serial No. 69SS 3699, the pistons will have an exhaust valve clearance pocket cut into the dome to prevent possible interference with the valve head. Also a .040" thick shim (6020P) was added underneath the exhaust valve spring lower collar starting with Serial No. 69SS 3962.|||
 |587| |2-28-1969|FL/​FX|Oil in Clutches| |587| |2-28-1969|FL/​FX|Oil in Clutches|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**588A**</​wrap>​| |10-9-1969|All|Front Brake Light Switches| +|<wrap hi>​**588**</​wrap>​ \\ <wrap hi>​**588A**</​wrap>​ | \\ {{ :​pdf:​tsb0588a.pdf |Y}} \\ 10-9-1969|All|Front Brake Light Switches| 
-|  Notes: || |||+|  Notes: || To conform with Federal Motor Vehicle Safety standards, all motorcycles and Servi -Cars shipped after January 1, 1969, are equipped with a stoplight switch on the front brake control handlever to actuate the rear stoplight when the front brake is applied. ​|||
 |589| |7-3-1969|1967-1968 FL|Rear Brake Pedal Lever (Recall 006)| |589| |7-3-1969|1967-1968 FL|Rear Brake Pedal Lever (Recall 006)|
 |  Notes: || ||| |  Notes: || |||
 |590A| |8-24-1970|Sprint|Generator Armature & Shaft Taper| |590A| |8-24-1970|Sprint|Generator Armature & Shaft Taper|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**591**</​wrap>​| |6-23-1969|XLH/​XLCH ​\\ FL/FX|Sprocket Shaft Bearing Endplay| +|<wrap hi>​**591**</​wrap>​| ​{{ :​pdf:​tsb0591.pdf |Y}} |6-23-1969|Electra Glide \\ Sportster|Sprocket Shaft Bearing Endplay| 
-|  Notes: || ||| +|  Notes: || The sprocket shaft bearing (Timken) used on Sportster and Electra Glide engines must have slight operating clearance (endplay) to function correctly. This bulletin gives instructions for checking the endplay.||| 
-|<wrap hi>​**592**</​wrap>​| |6-17-1969|XLH/​XLCH \\ FL/FX|Oil Filter Vent Hole| +|<wrap hi>​**592**</​wrap>​| ​{{ :​pdf:​tsb0592.pdf |Y}} |6-17-1969|XLH/​XLCH \\ FL/FX|Oil Filter Vent Hole| 
-|  Notes: || |||+|  Notes: || Starting with production Electra Glides and Sportster XLH models on June 9, 1969, a vent hole has been added to the filter cup as shown in the illustration in this bulletin. ​|||
 |<wrap hi>​**593**</​wrap>​| |6-17-1969|XLH/​XLCH FL/​FX|Rocker Arm Cover Gasket| |<wrap hi>​**593**</​wrap>​| |6-17-1969|XLH/​XLCH FL/​FX|Rocker Arm Cover Gasket|
 |  Notes: || ||| |  Notes: || |||
 |594| |7-15-1969|M Models|New Spark Plug| |594| |7-15-1969|M Models|New Spark Plug|
 |  Notes: || ||| |  Notes: || |||
-|595| |9-16-1969|Sprint|Flywheel Endplay - Spring Washer| +|595| {{ :​pdf:​tsb0595.pdf |Y}} |9-16-1969|Sprint|Flywheel Endplay - Spring Washer| 
-|  Notes: || ||| +|  Notes: ||In some cases, the crankshaft endplay on Sprint engines has become excessive and the spacing shims used between the right side crankshaft bearing and shaft lock ring have pounded out possibly causing further damage to the engine. ​||| 
-|<wrap hi>​**596**</​wrap>​| |9-16-1969|All|New Numbering System - VIN| +|<wrap hi>​**596**</​wrap>​| ​{{ :​pdf:​tsb0596.pdf |Y}} |9-16-1969|All|New ​Vehicle ​Numbering System - (VIN)
-|  Notes: || ||| +|  Notes: || For the 1970 season, a new numbering system for both engines and frames is being used on all HD vehicles. ​||| 
-|<wrap hi>​**597**</​wrap>​| |9-16-1969|XLH/​XLCH|Tapered Bead Tires/​Rims| +|<wrap hi>​**597**</​wrap>​| ​{{ :​pdf:​tsb0597.pdf |Y}} |9-16-1969|XLH/​XLCH|Tapered Bead Tires/​Rims| 
-|  Notes: || |||+|  Notes: ||Special Goodyear tires and "​C"​ section rims on std 1970 Sportster (high ground clearance) models. ​|||
 |<wrap hi>​**598**</​wrap>​| |9-29-1969|XLH/​XLCH|Fiberglass Seats| |<wrap hi>​**598**</​wrap>​| |9-29-1969|XLH/​XLCH|Fiberglass Seats|
 |  Notes: || ||| |  Notes: || |||
-|599| |11-7-1969|FL/​FX|Cam Seal Relief Hole| +|599| {{ :​pdf:​tsb0599.pdf |Y}} |11-7-1969|FL/​FX|Gearcase Cover Oil Relief Hole| 
-|  Notes: || |||+|  Notes: || Starting with Electra Glide engine serial No. 12974, a hole has been added through the gear case cover flywheel shaft bushing boss to relieve possible pressure buildup in the pocket between the bushing and seal. |||
  
 ====== TSB 600-649 ====== ====== TSB 600-649 ======
-|TSB_#​|PDF?​|Date|Model(s)|Title - Short Notes (Add'l Notes on Next Line)|+|TSB_#​|PDF?​|Date|Model(s)|Title - Short Notes|
 |600| |11-7-1969|FL/​FX|Alternator System Checks| |600| |11-7-1969|FL/​FX|Alternator System Checks|
 |  Notes: || ||| |  Notes: || |||
Line 503: Line 503:
 |604| |4-9-1970|1970 Sprint|Fork Vent Valve| |604| |4-9-1970|1970 Sprint|Fork Vent Valve|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**605**</​wrap>​| |11-28-1969|XLH/​XLCH \\ FL/FX|Idle Mixture ​Screw+|<wrap hi>​**605**</​wrap>​| ​{{ :​pdf:​tsb0605.pdf |Y}} |11-28-1969|XLH/​XLCH \\ FL/FX|Idle Mixture ​Adjusting Needle- \\ (Tillotson)
-|  Notes: || ||| +|  Notes: || A quantity of Tillotson HD carburetors with defective idle mixture needles were received from the supplier and were used in production. \\ These needles have an incorrectly formed blunt end instead of the correct tapered end. ||| 
-|<wrap hi>​**606**</​wrap>​| |11-28-1969|XLH/​XLCH|Rear Brake Light Switch Kit (72004-67)| +|<wrap hi>​**606**</​wrap>​| ​{{ :​pdf:​tsb0606.pdf |Y}} |11-28-1969|XLH/​XLCH|Rear Brake Light Switch Kit (72004-67)| 
-|  Notes: || ||| +|  Notes: || The 1970 type Sportster rear stoplight switch is being supplied with mounting parts for replacement of earlier switches used back to 1967. ||| 
-|607| |2-6-1970|1969-70 Sprint|Rear Brake Switch| +|607| {{ :​pdf:​tsb0607.pdf |Y}} |2-6-1970|1969-70 Sprint|Rear Brake Switch| 
-|  Notes: || ||| +|  Notes: ||The rubber protective cover for the rear brake stoplamp switch plunger has been changed to make it more flexible. This allows the plunger to operate more freely and makes the switch action more positive. ​||| 
-|<wrap hi>​**608**</​wrap>​| |4-9-1970|All|Loose Fuel Valve Handles+|<wrap hi>​**608**</​wrap>​| ​{{ :​pdf:​tsb0608.pdf |Y}} |4-9-1970|All|Gas Tank Valve - (addressing loose handles)
-|  Notes: || 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|||+|  Notes: ||Too loose and it will not allow enough fuel flow to the engine especially at high speeds. ​Clearance specs given.|||
 |609| |5-11-1970|1969-1970 FL|Wheel Bearing Locknut (Recall 008)| |609| |5-11-1970|1969-1970 FL|Wheel Bearing Locknut (Recall 008)|
 |  Notes: || ||| |  Notes: || |||
 |610| |5-20-1970|Baja|Front Fork Oil Seals| |610| |5-20-1970|Baja|Front Fork Oil Seals|
 |  Notes: || ||| |  Notes: || |||
-|611| |5-20-1970|FL/​FX|Carburetor Jet| +|611| {{ :​pdf:​tsb0611.pdf |Y}} |5-20-1970|FL/​FX|Carburetor Jet| 
-|  Notes: || |||+|  Notes: || The main fuel jet of the 74 OHV FL and FLH carburetor has been changed from size No. 53 (27616-66) to No. 59 (27619-66) starting on February 23, 1970, with VIN 2A 20684 H0. |||
 |612| |6-16-1970|All Lightweights|Throttle Cable| |612| |6-16-1970|All Lightweights|Throttle Cable|
-|  Notes: || |||+|  Notes: ||  |||
 |613| |8-24-1970|Baja|Rings/​Piston Change| |613| |8-24-1970|Baja|Rings/​Piston Change|
 |  Notes: || ||| |  Notes: || |||
-|614A| |4-14-1971|FL/​FX|Carburetor/Timing Marks/Compensating Sprocket+|614A| ​{{ :​pdf:​tsb0614a.pdf |Y}} |4-14-1971|FL/​FX|1971 ELECTRA GLIDE / SUPER GLIDE - \\ (carburetor/timing marks/compensating sprocket)
-|  Notes: || |||+|  Notes: ||Performance mod on Bendix (13479) (13479B) models and float tang clearance adjustment. \\ Added a rear cylinder timing mark and increased thickness on the compensating sprocket.|||
 |<wrap hi>​**615**</​wrap>​| |9-28-1970|All|New Service Tools| |<wrap hi>​**615**</​wrap>​| |9-28-1970|All|New Service Tools|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**616**</​wrap>​| |9-30-1970|All|Tire Balance/​Wheel Weights|+|<wrap hi>​**616**</​wrap>​| ​{{ :​pdf:​tsb0616.pdf |Y}} |9-30-1970|All|Tire Balance/​Wheel Weights|
 |  Notes: || Wheel 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.||| |  Notes: || Wheel 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.|||
-|<wrap hi>​**618C**</​wrap>​| |12-17-1974|XLH/​XLCH|Kicker Gear Kits| +|<wrap hi>​**618C**</​wrap>​| ​{{ :​pdf:​tsb0618C.pdf |Y}} |12-17-1974|XLH/​XLCH|Kicker Gear Kits| 
-|  Notes: || Starting 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.||+|  Notes: || Starting July 1, 1973, there was a new Kick Starter Gear Assembly ​(kick starter gear, '​pressed in' ​bushing and spacer). The 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.|||
-|  Notes: || ||| +
-|619| |1-25-1971|1971 FX|Rear Brake Rod Clevis (Recall 009)| +
-|  Notes: || ||| +
-|620| |3-25-1971|FX|License Plate Support Bracket| +
-|  Notes: || ||| +
-|621| |6-9-1971|1971 Sprint|Design Changes|+
 |  Notes: || ||| |  Notes: || |||
 +|619| {{ :​pdf:​tsb0619.pdf |Y}} |1-25-1971|1971 FX|Rear Brake Rod Clevis (Recall 009)|
 +|  Notes: ||Some early 1971 Super Glide motorcycles were produced and shipped with the clevis hole too close to the end which resulted in a weakness at this point, with possibility of failure and loss of rear braking. New part number added.|||
 +|620| {{ :​pdf:​tsb0620.pdf |Y}} |3-25-1971|FX|License Plate Support Bracket|
 +|  Notes: ||Starting in February production of 1971 FX models, a license plate support bracket is being installed between the rear fender support and the license plate bracket to reduce vibration and possible breakage. |||
 +|621| {{ :​pdf:​tsb0621.pdf |Y}} |6-9-1971|1971 Sprint|Design Changes|
 +|  Notes: ||Idle Jet, float and throttle slide changes on the Dellorto carburetor, kickstarter and clutch friction disc changes. |||
 |<wrap hi>​**622**</​wrap>​| |6-9-1971|XLH/​XLCH|Clutch Improvements| |<wrap hi>​**622**</​wrap>​| |6-9-1971|XLH/​XLCH|Clutch Improvements|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**623**</​wrap>​| |4-15-1971|All|Spark Plug Heli-Coil Kit|+|<wrap hi>​**623**</​wrap>​| ​{{ :​pdf:​tsb0623.pdf |Y}} |4-15-1971|All|Spark Plug Heli-Coil Kit|
 |  Notes: || This kit is for repairing damaged spark plug threads in the head. It consists of  a reamer / tapping tool w / Heli-Coil pilot, tap guide and key-ring seating tool, Heli-Coil installation tool, (12) 3/8" Reach inserts w / lock-rings (95544-71) and 1 tube of thread paste (95545-71).||| |  Notes: || This kit is for repairing damaged spark plug threads in the head. It consists of  a reamer / tapping tool w / Heli-Coil pilot, tap guide and key-ring seating tool, Heli-Coil installation tool, (12) 3/8" Reach inserts w / lock-rings (95544-71) and 1 tube of thread paste (95545-71).|||
-|<wrap hi>​**624**</​wrap>​| |4-30-1971|1971 XLH/​XLCH|Rear Wheel Hub (Recall 012)| +|<wrap hi>​**624**</​wrap>​| ​{{ :​pdf:​tsb0624.pdf |Y}} |4-30-1971|1971 XLH/​XLCH|Rear Wheel Hub (Recall 012)| 
-|  Notes: || ||| +|  Notes: || It has been determined that some 1971 Sportster motorcycles produced between February 2 and February 26, 1971 may have been assembled with defective rear wheel hubs. ||| 
-|<wrap hi>​**625**</​wrap>​| |8-2-1971|All|Low Lead Gasoline| +|<wrap hi>​**625**</​wrap>​| ​{{ :​pdf:​tsb0625.pdf |Y}} |8-2-1971|All|Low Lead Gasoline| 
-|  Notes: || At 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.|||+|  Notes: || At this time, it is not recommended to use (low leaded) or (non leaded) gas in any of our 2 or 4 cycle engines.|||
 |626| |8-2-1971|1971 Sprint|Charging System| |626| |8-2-1971|1971 Sprint|Charging System|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**627**</​wrap>​| |10-11-1971|XLH/​XLCH \\ FL/FX|Point Cam and Lubrication| +|<wrap hi>​**627**</​wrap>​| ​{{ :​pdf:​tsb0627.pdf |Y}} |10-11-1971|XLH/​XLCH \\ FL/FX|Point Cam and Lubrication| 
-|  Notes: || The 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.||| +|  Notes: || The 1972 design ​circuit breaker cam, part no. 32542-70A is recommended for replacement of cam, part no. 32542-70 ​on 1971 and later Sportsters1970 and later Electra ​Glides and 1971 and later Super Glides. ||| 
-|628| |10-19-1971|1972 Shortster|Front Wheel and Axle (Recall 014)| +|628| {{ :​pdf:​tsb0628.pdf |Y}} |10-19-1971|1972 Shortster|Front Wheel and Axle (Recall 014)| 
-|  Notes: || |||+|  Notes: ||Early 1972 Shortster minicycles have open slots in the front fork slider ends to receive the front wheel axle.|||
 |629| |11-9-1971|1971 Rapido|Magneto/​Generator| |629| |11-9-1971|1971 Rapido|Magneto/​Generator|
 |  Notes: || ||| |  Notes: || |||
-|630| |11-8-1971|1971-1972 FL/FX|Rear Brake Hydraulic Line (Recall 013)| +|630| {{ :​pdf:​tsb0630.pdf |Y}} |11-8-1971|1971-E1972 Electra Glide \\ 1971-E1972 Super Glide|Rear Brake Hydraulic Line (Recall 013)| 
-|  Notes: || |||+|  Notes: ||The hydraulic brake line (42305-71) support bracket welded to it. Due to it's construction,​ vibration induced stress may cause cracks in the metal tubing in the area near the rear of this bracket. ||| 
 +|<wrap hi>​**632**</​wrap>​ \\ <wrap hi>​**632A**</​wrap>​ | \\ {{ :​pdf:​tsb0632a.pdf |Y}} |1-15-1972|All|Procedure for Handling Export Warranty| 
 +|  Notes: || Warranty and Adjustments ​|||
 |633| |2-15-1972|FL|Front Disc Brake Information| |633| |2-15-1972|FL|Front Disc Brake Information|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**634**</​wrap>​| |2-18-1972|XLH/​XLCH|Clutch Adjustment|+|<wrap hi>​**634**</​wrap>​| ​{{ :​pdf:​tsb0634.pdf |Y}} |2-18-1972|XLH/​XLCH|Clutch Adjustment|
 |  Notes: || The 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.||| |  Notes: || The 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.|||
-|635| |2-18-1972|FL/​FX|Sprocket Shaft Bearing Oil Hole| +|635| {{ :​pdf:​tsb0635.pdf |Y}} |2-18-1972|FL/​FX|Sprocket Shaft Bearing Oil Hole| 
-|  Notes: || ||| +|  Notes: ||The crankcase oil hole which lubricates the sprocket shaft Timken bearing has been increased from 3/16" to 1/4" on late 1972 FL, FLH, and FX engines. Also, minimum end play has been increased from .0005" to .001"||| 
-|<wrap hi>​**636**</​wrap>​| |4-27-1972|1972 XL/​XLCH|Rear Fork Bearing (Recall 015)| +|<wrap hi>​**636**</​wrap>​| ​{{ :​pdf:​tsb0636.pdf |Y}} |4-27-1972|1972 XL/​XLCH|Rear Fork Bearing ​Adjustment ​(Recall 015)| 
-|  Notes: || ||| +|  Notes: || The rear fork bearing, left-side lock nut is staked in 3 places to prevent it from backing out and causing bearing looseness. ​||| 
-|637| |7-7-1972|1972 MC-65/​Shortster|Front Fork Slider (Recall 016)| +|637| {{ :​pdf:​tsb0637.pdf |Y}} |7-7-1972|1972 MC-65/​Shortster|Front Fork Slider (Recall 016)| 
-|  Notes: || ||| +|  Notes: ||1972 Shortster minicycles from SC 10000 H2 through SC 11500 H2 incorporate front fork sliders which may have an inadequate weld joint which secures the axle mounting clip to the slider tube. ||| 
-|<wrap hi>​**638**</​wrap>​| |8-14-1972|1972 XLH/​XLCH/​FX|Front Wheel Hub Lockring (Recall 017)| +|<wrap hi>​**638**</​wrap>​| ​{{ :​pdf:​tsb0638.pdf |Y}} |8-14-1972|1972 XLH/​XLCH/​FX|Front Wheel Hub Lockring (Recall 017)| 
-|  Notes: || |||+|  Notes: || The front wheel bearing retaining ring, part No. 11035, is flat on one side and has a bevel on the other side. This retaining ring is assembled in the hub with the flat side toward the bearing, part No. 9009. |||
 |639| |9-25-1972|All Lightweights|Silver Gas Tank Trim| |639| |9-25-1972|All Lightweights|Silver Gas Tank Trim|
 |  Notes: || ||| |  Notes: || |||
Line 574: Line 576:
 |642| |12-13-1972|1973 Sprint|Tune-Up Information| |642| |12-13-1972|1973 Sprint|Tune-Up Information|
 |  Notes: || ||| |  Notes: || |||
-|643| |12-18-1972|1973 FL/FLH/FX|Disc Brakes (Recall 018)| +|643| {{ :​pdf:​tsb0643.pdf |Y}} |12-18-1972|1973 FL \\ 1973 FLH \\ 1973 FX|Disc Brakes (Recall 018)| 
-|  Notes: || |||+|  Notes: || Safety defect issued on models produced before November 15, 1972 which have the front brake calipers installed on the rear brake and vice versa. Subsequently it was also discovered that some FX motorcycles were assembled during the same period with inadequate rear brake master cylinder operating piston clearance. ​|||
 |644| |3-26-1973|1973 X-90/​Z-90/​TX-125|Injection Oil Pump| |644| |3-26-1973|1973 X-90/​Z-90/​TX-125|Injection Oil Pump|
 |  Notes: || ||| |  Notes: || |||
 |645 \\ 646| |4-5-1973|1973 Sprint|High Output Alternator| |645 \\ 646| |4-5-1973|1973 Sprint|High Output Alternator|
 |  Notes: || ||| |  Notes: || |||
-|647| |4-10-1973|FL/FX|Oil Pumps+|647| {{ :​pdf:​tsb0647.pdf |Y}} |4-10-1973|1973 FL \\ 1973 FLH \\ 1973 FX|Oiling System Changes
-|  Notes: || |||+|  Notes: || This bulletin outlines changes incorporated in the oiling system of 1200 cc models for 1973, i.e. oil pump (w pressure relief), right crankcase, gearcase cover, pinion shaft cover bushing, and flywheel gear shaft. These parts are new and non-interchangeable with earlier parts, and carry 1973 part numbers|||
 |648| |4-25-73|1973 Z-90|Front Brake Sideplate Retainer (Recall 019)| |648| |4-25-73|1973 Z-90|Front Brake Sideplate Retainer (Recall 019)|
 |  Notes: || ||| |  Notes: || |||
Line 590: Line 592:
 ====== TSB 650-699 ====== ====== TSB 650-699 ======
 |TSB_#​|PDF?​|Date|Model(s)|Title - Short Notes (Add'l Notes on Next Line)| |TSB_#​|PDF?​|Date|Model(s)|Title - Short Notes (Add'l Notes on Next Line)|
-|<wrap hi>​**650**</​wrap>​| |5-15-1973|1973 XL/​XLCH|Tail Lamp Wiring (Recall 020)| +|<wrap hi>​**650**</​wrap>​| ​{{ :​pdf:​tsb0650.pdf |Y}} |5-15-1973|1973 XL/​XLCH|Tail Lamp Wiring (Recall 020)| 
-|  Notes: || ||| +|  Notes: || Initial production of 1973 Models XL/​XLCH-1000 motorcycles were produced without a retaining clip to hold the wires against the fender near the tail lamp bulb socket. ​||| 
-|<wrap hi>​**651**</​wrap>​| |6-27-1973|1973 XL/​XLCH/​FX|Front Fork Lower Bracket (Recall 021)| +|<wrap hi>​**651**</​wrap>​| ​{{ :​pdf:​tsb0651.pdf |Y}} |6-27-1973|1973 XL/​XLCH/​FX|Front Fork Lower Bracket (Recall 021)| 
-|  Notes: || ||| +|  Notes: || A certain number of 1973 Models XL, XLCH and FX motorcycles were assembled with defective lower fork brackets between October 31, 1972 and March 25, 1973. Quench cracks occurred in a critical area of some bracket forgings during heat treatment performed by our supplier. ​||| 
-|<wrap hi>​**652**</​wrap>​| |7-30-1973|XLH/​XLCH|Head and Cylinder Changes| +|<wrap hi>​**652**</​wrap>​| ​{{ :​pdf:​tsb0652.pdf |Y}} |7-30-1973|XLH/​XLCH|Head and Cylinder Changes| 
-|  Notes: || Late 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.||| +|  Notes: || Model XL/XLCH motorcycles ​produced after May 1, 1973 incorporate ​new cylinder ​heads, ​cylinders, cylinder ​head gaskets and head bolts which reflect a change in the bolt hole spacing.||| 
-|<wrap hi>​**653**</​wrap>​| |7-30-1973|XLH/​XLCH \\ FL/FX|Disc Brake Caliper Mounting Pin Kit|+|<wrap hi>​**653**</​wrap>​| ​{{ :​pdf:​tsb0653.pdf |Y}} |7-30-1973|XLH/​XLCH \\ FL/FX|Disc Brake Caliper Mounting Pin Kit|
 |  Notes: || 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.||| |  Notes: || 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.|||
 |<wrap hi>​**654**</​wrap>​| |8-27-1973|1973 XL/​XLCH|Rear Brake Lever (Recall 022)| |<wrap hi>​**654**</​wrap>​| |8-27-1973|1973 XL/​XLCH|Rear Brake Lever (Recall 022)|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**655**</​wrap>​| |11-15-1973|XLH/​XLCH|Directional Arrow - Rear Tire|+|<wrap hi>​**655**</​wrap>​| ​{{ :​pdf:​tsb0655.pdf |Y}} |11-15-1973|XLH/​XLCH|Directional Arrow - Rear Tire|
 |  Notes: || Beginning 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.||| |  Notes: || Beginning 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.|||
 |<wrap hi>​**656**</​wrap>​| |2-11-1974|1973 XL/​XLCH|Frame Reinforcement of Tail Lamp Wiring (Recall 023)| |<wrap hi>​**656**</​wrap>​| |2-11-1974|1973 XL/​XLCH|Frame Reinforcement of Tail Lamp Wiring (Recall 023)|
-|  Notes: || |||+|  Notes: ||All l973 XL and XLCH motorcycle frames will require corrective modification as specified in this bulletin to prevent possible breakage at the welded junction of the frame tubes and the rear fender and shock absorber support bracket. ​|||
 |657| |12-17-1973|1974 SX-175|Oil/​Spark Plug| |657| |12-17-1973|1974 SX-175|Oil/​Spark Plug|
 |  Notes: || ||| |  Notes: || |||
 |658| |1-7-1974|FL|Battery Support Bracket| |658| |1-7-1974|FL|Battery Support Bracket|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**659**</​wrap>​| |3-6-1974|XLH/​XLCH \\ FL/​FX|Fusible Wire| +|<wrap hi>​**659**</​wrap>​| ​{{ :​pdf:​tsb0659.pdf |Y}} |3-6-1974|XLH/​XLCH \\ FL/​FX|Fusible Wire| 
-|  Notes: || Addition of fuse wire. - [[techtalk:​ih:​elec02#​fuse_wire|Read more about the Fuse Wire here]] in the Ironhead Electrical section of the Sportsterpedia. - A 2“ long 20 gauge wire (70105-73) was added in the wiring circuit ​on FL,FLH, FX, FXE, XL and XLCH models to act as a fuse wire. The fuse wire protects wiring between the battery ​and the lighting, ignition and accessory circuit breakers. Because the motorcycle wiring is heavier gauge, this fuse will burn out first in case of a short or overload and open the circuit. **Caution**:​ Do not use heavier gauge wire for a fuse wire. In place of this HD part, any 20 gauge braided wire will work also. Before replacing the fuse wire, check for short circuits in the wiring and ignition switch to determine the cause of burnout. When troubleshooting the electrical system for loss of power, check this wire for burnout at the following locations; FL/FLH: The fuse wire is connected to the starter relay terminal (#1) and to the connector in the conduit leading to the battery positive terminal. FXE: The fuse wire is connected to the starter solenoid (long) terminal and to the connector in the conduit leading to the starter relay tan wire terminal. FX: The fuse wire is connected to the battery positive terminal and to the tan wire connector in the conduit. The tan wire terminates at the "​B"​ terminal on the ignition switch. XL: The fuse wire is connected to the regulator "​BAT"​ terminal and to the red wire connector in the conduit leading to the starter solenoid (long) terminal. XLCH: The fuse wire is connected to the battery positive terminal and to the red wire connector in conduit leading to the regulator "​B+"​ terminal. [[techtalk:​ref:​elec07#​sportster_xl|Click here to see the wiring diagrams in the Sportsterpedia]] showing the location of the fuse wire.||| +|  Notes: || A 2" ​long 20 gauge wire is located ​in the wiring circuit ​of the FL, FLH, FX, FXE, XL and XLCH models to act as a fuse and protect ​the wiring. Because the motorcycle wiring is heavier gauge, this fuse wire will burn out first in case of a short or overload and open the circuit. ||| 
-|660| |3-4-1974|1974 SX-175|Specs / Clutch / Rear Wheel| +|660| {{ :​pdf:​tsb0660.pdf |Y}} |3-4-1974|1974 SX-175|Specs / Clutch / Rear Wheel| 
-|  Notes: || ||| +|  Notes: ||This bulletin contains information regarding fitting specifications and tightening torque specifications for the 1974 SX-175 model. ​||| 
-|<wrap hi>​**661**</​wrap>​| |4-15-1974|XLH/​XLCH/​FX|Rear Fender Reinforcement| +|<wrap hi>​**661**</​wrap>​| ​{{ :​pdf:​tsb0661.pdf |Y}} |4-15-1974|XLH/​XLCH/​FX|Rear Fender Reinforcement| 
-|  Notes: || Beginning 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.||| +|  Notes: || Beginning 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 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.||| 
-|662| |4-29-1974|1973-1974 FL/​FLH/​FX/​FXE|Rear Brake Caliper (Recall 024)| +|662| {{ :​pdf:​tsb0662.pdf |Y}} |4-29-1974|1973-1974 FL/​FLH/​FX/​FXE|Rear Brake Caliper (Recall 024)| 
-|  Notes: || ||| +|  Notes: ||Rear brake fluid leakage may develop on certain 1973 and early 1974 FLH, FL, FX and FXE motorcycles which were assembled with substandard rear caliper piston 0-ring seals.||| 
-|<wrap hi>​**663**</​wrap>​| |4-29-1974|XLH/​XLCH|Clutch Changes| +|<wrap hi>​**663**</​wrap>​| ​{{ :​pdf:​tsb0663.pdf |Y}} |4-29-1974|L1974 XLH/​XLCH|Clutch Changes| 
-|  Notes: || Late 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.||| +|  Notes: || Late 1974clutch 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.||| 
-|664| |4-29-1974|1974 SX-175|Fuse| +|664| {{ :​pdf:​tsb0664.pdf ​|Y}} |5-29-1974|1974 SX-175|Fuse| 
-|  Notes: || |||+|  Notes: || Through a production oversight, the fuse was not installed in one of the fuse holders of SX-175 motorcycles produced at the York plant shipped before Apri1 26, 1974, and bearing VlN 50 42571 H4 through VIN 50 43100 H4. |||
 |665| |6-10-1974|1973 Z-90|Front Brake Sideplate (44143-73)| |665| |6-10-1974|1973 Z-90|Front Brake Sideplate (44143-73)|
 |  Notes: || ||| |  Notes: || |||
-|666| |7-10-1974|1974 SX-175|Ignition System|  +|666| {{ :​pdf:​tsb0666.pdf |Y}} |7-10-1974|1974 SX-175|Capacitor Discharge ​Ignition System|  
-|  Notes: || |||+|  Notes: || The breakerless capacitor discharge ignition system used on the SX-175 model consists of a charging coil inside the alternator rotor and two external triggers with a pick-up coil. Also in the system are an ignition switch, ignition module, high tension coil, and spark plug.|||
 |667| |6-21-1974|1974 SX-175|Air Cleaner Care| |667| |6-21-1974|1974 SX-175|Air Cleaner Care|
 |  Notes: || ||| |  Notes: || |||
 |668| |8-26-1974|1974 SX-175|Front Wheel Tire Bead Clamp / Rear Brake Sideplate (Recall 025)| |668| |8-26-1974|1974 SX-175|Front Wheel Tire Bead Clamp / Rear Brake Sideplate (Recall 025)|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**669**</​wrap>​| |8-16-1974|XLH/​XLCH \\ FL/FX \\ Servi-Car|Ignition Coils| +|<wrap hi>​**669**</​wrap>​| ​{{ :​pdf:​tsb0669.pdf |Y}} |8-16-1974|XLH/​XLCH \\ FL/FX \\ Servi-Car|Ignition Coils| 
-|  Notes: || Through 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.||| +|  Notes: || Through 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.||| 
-|670| |10-7-1974|SX-175|Exhaust System Cleaning| +|670| {{ :​pdf:​tsb0670.pdf |Y}} |10-7-1974|SX-175|Exhaust System Cleaning| 
-|  Notes: || ||| +|  Notes: ||A gradual reduction in power after a period of service on 2-cycle engines is most often caused by exhaust system restriction from a buildup of carbon deposits. This bulletin details instructions on how to remove these deposits to restore engine performance.||| 
-|671| |10-7-1974|SX-175|Rear Wheel Spokes| +|671| {{ :​pdf:​tsb0671.pdf |Y}} |10-7-1974|Late 1975 SX-175|Rear Wheel Spokes| 
-|  Notes: || |||+|  Notes: ||On late 1975 SX-175 motorcycles,​ positive retention of the rear wheel spokes in the right side hub flange is accomplished by using washers underneath the spoke heads. As an interim change some early 1975 motorcycles have nylon plugs installed between the spoke hooks in each slotted hole to accomplish the same purpose.|||
 |672| |10-9-1974|SX-175|Carburetor Modification| |672| |10-9-1974|SX-175|Carburetor Modification|
 |  Notes: || ||| |  Notes: || |||
-|673| |10-9-1974|FL/​FX|Oil Ring Change| +|673| {{ :​pdf:​tsb0673.pdf |Y}} |10-9-1974|FL/​FX|Oil Ring Change| 
-|  Notes: || |||+|  Notes: ||A non-chromed cast iron oil control ring is being substituted for the chrome plated type for all 1975 production 1200 cc engines and for parts order pistons, ring sets, and cylinder assemblies. ​|||
 |674| |10-14-1974|1974 X-90/​Z-90|Air Cleaner & Carburetor| |674| |10-14-1974|1974 X-90/​Z-90|Air Cleaner & Carburetor|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**675**</​wrap>​| |10-14-1974|XLH/​XLCH/​FX|Ignition Switch| +|<wrap hi>​**675**</​wrap>​| ​{{ :​pdf:​tsb0675.pdf |Y}} |10-14-1974|XLH/​XLCH/​FX|Ignition Switch| 
-|  Notes: || Due 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.|||+|  Notes: || Due to a production oversight, lubricant was omitted on the ignition key switch indexing plate which could cause the switch to bind up. This bulletin gives instructions on lubricating ​the switch.|||
 |676| |10-14-1974|FX|Jiffy Stand Support Plate| |676| |10-14-1974|FX|Jiffy Stand Support Plate|
 |  Notes: || ||| |  Notes: || |||
 |677| |10-14-1974|FX|Foot Shifter Timing| |677| |10-14-1974|FX|Foot Shifter Timing|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**678**</​wrap>​| |12-17-1974|XLH/​XLCH|Rocker Arm Covers "​M"​| +|<wrap hi>​**678**</​wrap>​| ​{{ :​pdf:​tsb0678.pdf |Y}} |12-17-1974|XLH/​XLCH|Rocker Arm Covers "​M"​| 
-|  Notes: || 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.|||+|  Notes: || A certain number of 1974 and 1975 XL & XLCH models were produced with modified rocker arms and rocker covers machined to prevent interference between the rocker arm and the inside of the rocker cover due to a thickness variation in the covers.|||
 |679| |12-17-1974|X-90|High Voltage Problem| |679| |12-17-1974|X-90|High Voltage Problem|
 |  Notes: || ||| |  Notes: || |||
Line 654: Line 656:
 |681| |1-31-1975|1973-1974 Sprint|Electric Starter Motor| |681| |1-31-1975|1973-1974 Sprint|Electric Starter Motor|
 |  Notes: || ||| |  Notes: || |||
-|682| |1-31-1975|Sprint|Spoke Maintenance| +|682| {{ :​pdf:​tsb0682.pdf |Y}} |1-31-1975|Sprint|Spoke Maintenance| 
-|  Notes: || |||+|  Notes: || Previous bulletin Nos. 441 and 535 stressed the importance of maintaining correct wheel spoke tension on SS/SX -350 models to prevent loosening and possible spoke breakage. Because we have received reports of progressive wheel spoke breakage, especially on off-road SX -350 models used severely, we are again emphasizing this important item of preventive maintenance.|||
 |683| |1-31-1975|X-90/​Z -90 \\ SX-125/​TX-125|Throttle Grip Fix (44186-74P)| |683| |1-31-1975|X-90/​Z -90 \\ SX-125/​TX-125|Throttle Grip Fix (44186-74P)|
 |  Notes: || ||| |  Notes: || |||
Line 662: Line 664:
 |685| |3-20-1975|1972 and Earlier FL/​FLH|Liberator Fairing Handlebar Mounting Bolts (Recall 026)| |685| |3-20-1975|1972 and Earlier FL/​FLH|Liberator Fairing Handlebar Mounting Bolts (Recall 026)|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**686**</​wrap>​| |4-8-1975|XLH/​XLCH|Transmission|+|<wrap hi>​**686**</​wrap>​| ​{{ :​pdf:​tsb0686.pdf |Y}} |4-8-1975|XLH/​XLCH|Transmission|
 |  Notes: || During 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.||| |  Notes: || During 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.|||
 |687| |4-8-1975|FL/​FX|Clutch Throwout Bearing Change| |687| |4-8-1975|FL/​FX|Clutch Throwout Bearing Change|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**688**</​wrap>​| |5-12-1975|XLH/​XLCH|Rear Fork Bearing Kit|+|<wrap hi>​**688**</​wrap>​| ​{{ :​pdf:​tsb0688.pdf |Y}} |5-12-1975|XLH/​XLCH|Rear Fork Bearing Kit|
 |  Notes: || Bearing 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.||| |  Notes: || Bearing 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.|||
 |689| |5-5-1975|All lightweights|Service Tools - Lightweights| |689| |5-5-1975|All lightweights|Service Tools - Lightweights|
Line 674: Line 676:
 |691| |5-12-1975|SS-250|Jiffy Stand Bracket| |691| |5-12-1975|SS-250|Jiffy Stand Bracket|
 |  Notes: || ||| |  Notes: || |||
-|692| |6-27-1975|1975 SS-250|Rear Brake Pedal Lever (Recall 027)| +|692| {{ :​pdf:​tsb0692.pdf |Y}} |6-27-1975|1975 SS-250|Rear Brake Pedal Lever (Recall 027)| 
-|  Notes: || ||| +|  Notes: || Some early 1975 SS-250 motorcycles incorporate faulty welds in the rear brake pedal lever. ​||| 
-|693| |9-9-1975|1975 SXT-125|Frame (Recall 028)| +|693| {{ :​pdf:​tsb0693.pdf |Y}} |9-9-1975|1975 SXT-125|Frame (Recall 028)| 
-|  Notes: || |||+|  Notes: || Frame defects which may cause eventual frame failure were present in 1975 SXT-125 motorcycles.|||
 |694| |7-23-1975|All Lightweights|Ignition Switches| |694| |7-23-1975|All Lightweights|Ignition Switches|
 |  Notes: || ||| |  Notes: || |||
-|694| |11-7-1975|FL/​FX|Keihin Carburetor| +|694| {{ :​pdf:​tsb0694.pdf |Y}} |11-7-1975|FL/​FX|Keihin Carburetor| 
-|  Notes: || New carb introduction information ​[[techtalk:​ih:​carb01#​keihin_butterfly_or_non-cv_carb_late_1976-1987|Read more about the Keihin Butterfly Carburetor here]] in the Ironhead Carb section of the Sportsterpedia.||| +|  Notes: || New carb model introduction information. \\ [[techtalk:​ih:​carb01#​keihin_butterfly_or_non-cv_carb_late_1976-1987|Read more about the Keihin Butterfly Carburetor here]] in the Ironhead Carb section of the Sportsterpedia.||| 
-|<wrap hi>​**695**</​wrap>​| |11-7-1975|1975 XL/XLCH \\ FX/​FXE|Wheel Spokes (Recall 029)| +|<wrap hi>​**695**</​wrap>​| ​{{ :​pdf:​tsb0695.pdf |Y}} |11-7-1975|1975 XL/XLCH \\ FX/​FXE|Wheel Spokes (Recall 029)| 
-|  Notes: || ||| +|  Notes: ||All Harley-Davidson dealers were notified by Service Letter dated August 21, 1975, that we have been experiencing an increase in warranty claim forms for wheel spoke breakage on FL's, FX's, and XL's.||| 
-|696| |11-7-1975|SS-250|High Idle| +|696| {{ :​pdf:​tsb0696.pdf |Y}} |11-7-1975|SS-250|High Idle Speed Condition
-|  Notes: || ||| +|  Notes: || This bulletin has suggested checks and adjustments to address a higher than normal idle speed under no-load conditions.||| 
-|<wrap hi>​**697**</​wrap>​| |3-29-1976|XLH/​XLCH \\ FL/​FX|Bendix Carburetor Jets|+|<wrap hi>​**697**</​wrap>​| ​{{ :​pdf:​tsb0697.pdf |Y}} |3-29-1976|XLH/​XLCH \\ FL/​FX|Bendix Carburetor Jets|
 |  Notes: || HD 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.||| |  Notes: || HD 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.|||
 |698| |3-29-1976|All Lightweights|Rear Brake Switch Kit (72200-75))| |698| |3-29-1976|All Lightweights|Rear Brake Switch Kit (72200-75))|
 |  Notes: || ||| |  Notes: || |||
-|699| |8-16-1976|1975 SX-250S & 175|Carburetor Modification| +|699| {{ :​pdf:​tsb0699.pdf |Y}} |8-16-1976|E1975 SX-250 \\ 1976 SS-175|Carburetor Modification| 
-|  Notes: || |||+|  Notes: || Suggested carburetor jet changes / recommendations.|||
  
  
Line 700: Line 702:
 |701| |5-26-1976|FL/​FX|Rear Disc Brake Service Information| |701| |5-26-1976|FL/​FX|Rear Disc Brake Service Information|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**702**</​wrap>​| |5-28-1976|1976 XL/​XLCH|Rear Brake Shoes (Recall 030)| +|<wrap hi>​**702**</​wrap>​| ​{{ :​pdf:​tsb0702.pdf |Y}} |5-28-1976|1976 XL/​XLCH|Rear Brake Shoes (Recall 030)| 
-|  Notes: || |||+|  Notes: ||The rear brake shoe linings of 1976 XL and XLCH models within the range listed in this bulletin are suspected of having a defective adhesive bond.|||
 |703A| |9-3-1976|SS / SXT-125|Oil Supply Fitting| |703A| |9-3-1976|SS / SXT-125|Oil Supply Fitting|
 |  Notes: || ||| |  Notes: || |||
 |704| |8-16-1976|1975-1976 SS/​SXT-125|Spark Plug| |704| |8-16-1976|1975-1976 SS/​SXT-125|Spark Plug|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**705**</​wrap>​| |11-11-1976|XLH/​XLCH \\ FL/​FX|Ignition Advance Unit Lubrication| +|<wrap hi>​**705**</​wrap>​| ​{{ :​pdf:​tsb0705.pdf |Y}} |11-11-1976|XLH/​XLCH \\ FL/​FX|Ignition Advance Unit Lubrication| 
-|  Notes: || There 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.||| +|  Notes: || There was a change in the ignition advance lubrication procedure ​as detailed in this bulletin.||| 
-|706| |10-15-1976|1974-1976 FL/FLH/FX/FXE|Rear Disc Brake (Recall 031)| +|706| {{ :​pdf:​tsb0706.pdf |Y}} |10-15-1976|1974-1976 FL/FX|Rear Disc Brake (Recall 031)| 
-|  Notes: || ||| +|  Notes: || Certain 1200cc motorcycles produced during the 1974, 1975 and 1976 model season may have a defective rear brake system. ​||| 
-|707| |12-1-1976|FL/​FX|Keihen Carburetor/​Adjustment/​Modification| +|707| {{ :​pdf:​tsb0707.pdf |Y}} |12-1-1976|FL/​FX|Keihen Carburetor/​Adjustment/​Modification| 
-|  Notes: || ||| +|  Notes: ||This bulletin is a supplement to bulletin 694 and outlines steps to be taken to improve carburetor performance and reliability. ​||| 
-|<wrap hi>​**708**</​wrap>​| |12-1-1976|XLH/​XLCH|Breather Valve| +|<wrap hi>​**708**</​wrap>​| ​{{ :​pdf:​tsb0708.pdf |Y}} |12-1-1976|XLH/​XLCH|Breather Valve| 
-|  Notes: || A newly designed ​breather valve was installed on engines ​produced around ​October 15, 1976. All 1000cc engine numbers (3A4A 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.||| +|  Notes: || A new design ​breather valve, part No. 24633-77, is being used in late 1977 model XL/​XLCH/​XLT ​engines ​beginning approximately ​October 15, 1976. All l000cc motorcycles VIN 3A/4A/2G-27940 H7 and above will have the new breather valve, which serves the same function as the gear driven breather valve used on 1976 and earlier engines to maintain a partial vacuum ​in the engine and prevent oil leak-age.||| 
-|<wrap hi>​**709**</​wrap>​| |3-22-1977|1975-1977 XL/XLCH/XLT \\ FX/​FXE|Front Brake Caliper Mounting Bolts (Recall 032)| +|<wrap hi>​**709**</​wrap>​| ​{{ :​pdf:​tsb0709.pdf |Y}}  ​|3-22-1977|1975-E1977 XL/XLCH/XLT \\ FX/​FXE|Front Brake Caliper Mounting Bolts (Recall 032)| 
-|  Notes: || |||+|  Notes: || An unknown number of substandard (low strength) front brake caliper assembly bolts (3453) were used in 1975 to early 1977 XL/​XLCH/​XLT/​FX and FXE motorcycles. ​|||
 |710| |5-6-1977|FL/​FX|Clutch Push Rod Thrust Washers| |710| |5-6-1977|FL/​FX|Clutch Push Rod Thrust Washers|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**711**</​wrap>​| |6-3-1977|XLH/​XLCH|Oil Pump| +|<wrap hi>​**711**</​wrap>​| ​{{ :​pdf:​tsb0711.pdf |Y}} |6-3-1977|XLH/​XLCH/XLT/XLCR|Oil Pump| 
-|  Notes: || New 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.||| +|  Notes: || New oil pump design with gerotors instead of gears, consists ​of two gerotor pumps in the same pump housing.||| 
-|<wrap hi>​**712**</​wrap>​| |6-16-1977|All|Hydraulic Brake System Maintenance|+|<wrap hi>​**712**</​wrap>​| ​{{ :​pdf:​tsb0712.pdf |Y}} |6-16-1977|All|Hydraulic Brake System Maintenance|
 |  Notes: || Brake fluid inspection intervals, changing from DOT 3 to to DOT 5 brake fluid, master cylinder inspection / operation, brake calipers, pads and discs.||| |  Notes: || Brake fluid inspection intervals, changing from DOT 3 to to DOT 5 brake fluid, master cylinder inspection / operation, brake calipers, pads and discs.|||
-|<wrap hi>​**713**</​wrap>​| |6-10-1977|XLH/​XLCH \\ FL/​FX|Keihin Carburetor|+|<wrap hi>​**713**</​wrap>​| ​{{ :​pdf:​tsb0713.pdf |Y}} |6-10-1977|XLH/​XLCH \\ FL/​FX|Keihin Carburetor|
 |  Notes: || List containing part numbers and adjustments for the variable components used on 76-77 1000 and 1200cc engines.||| |  Notes: || List containing part numbers and adjustments for the variable components used on 76-77 1000 and 1200cc engines.|||
-|<wrap hi>​**714**</​wrap>​| |8-16-1977|XLH/​XLCH \\ FL/​FX|Piston Pin Retaining Ring Changes|+|<wrap hi>​**714**</​wrap>​| ​{{ :​pdf:​tsb0714.pdf |Y}} |8-16-1977|XLH/​XLCH \\ FL/​FX|Piston Pin Retaining Ring Changes|
 |  Notes: || Starting 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).||| |  Notes: || Starting 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).|||
-|715| |8-12-1977|FL/​FX|Air Cleaner Gasket and Heat Spacer| +|715| {{ :​pdf:​tsb0715.pdf |Y}} |8-12-1977|FL/​FX|Air Cleaner Gasket and Heat Spacer| 
-|  Notes: || ||| +|  Notes: ||1200cc motorcycle carburetors having a mid-range lean condition should be checked for proper sealing between the carburetor and air cleaner backing plate. ​||| 
-|<wrap hi>​**716**</​wrap>​| |8-26-1977|1977 XL-1000|Showa Rear Shock Absorber (Recall 033)| +|<wrap hi>​**716**</​wrap>​| ​{{ :​pdf:​tsb0716.pdf |Y}} |8-26-1977|1977 XL-1000|Showa Rear Shock Absorber (Recall 033)| 
-|  Notes: || |||+|  Notes: ||A quantity of 100 electric start XL-1000 motorcycles were produced from June 24, 1977 to June 28, 1977 having the new Showa rear shock absorbers assembled with incorrect cupped washers on the motorcycle mounting studs instead of flat washers. ​|||
 |717| |9-13-1977|FL|Front Fork Change| |717| |9-13-1977|FL|Front Fork Change|
 |  Notes: || ||| |  Notes: || |||
 |718| |9-13-1977|FL/​FX|Transmission & Cam / Pinion Changes| |718| |9-13-1977|FL/​FX|Transmission & Cam / Pinion Changes|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**719**</​wrap>​| |9-13-1977|XLT 1000|Rear Fender / XLT-1000| +|<wrap hi>​**719**</​wrap>​| ​{{ :​pdf:​tsb0719.pdf |Y}} |9-13-1977|XLT 1000|Rear Fender / XLT-1000| 
-|  Notes: || Rear fender cracking at the turn signal mounting holes|||+|  Notes: || Change washers to avoid rear fender cracking at the turn signal mounting holes|||
 |720| |10-11-1977|MX-250|Front Fender Installation| |720| |10-11-1977|MX-250|Front Fender Installation|
 |  Notes: || ||| |  Notes: || |||
-|721| |10-21-1977|1978 FX/​FXE/​FXS|Rear Brake Master Cylinder O-Ring (Recall 034)| +|721| {{ :​pdf:​tsb0721.pdf |Y}} |10-21-1977|1978 FX/​FXE/​FXS|Rear Brake Master Cylinder O-Ring (Recall 034)| 
-|  Notes: || |||+|  Notes: || A quantity of 385 1978 FX, FXE, FXS-1200 motorcycles were produced from July 21, 1977 to August 18, 1977 with incorrect 0-rings assembled in the rear brake master cylinder. ​|||
 |722| |11-4-1977|1976 SS/​SX-175/​250|Auto Retard Alternator| |722| |11-4-1977|1976 SS/​SX-175/​250|Auto Retard Alternator|
 |  Notes: || ||| |  Notes: || |||
Line 746: Line 748:
 |724| |2-7-1978|FL/​FX|Electronic Ignition Timer Wires| |724| |2-7-1978|FL/​FX|Electronic Ignition Timer Wires|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**725**</​wrap>​| |2-14-1978|All|EPA Changes|+|<wrap hi>​**725**</​wrap>​| ​{{ :​pdf:​tsb0725.pdf |Y}} |2-14-1978|All|EPA Changes|
 |  Notes: || HD outlined the Clean Air Act of 1978 as it affected the company and it's customers.||| |  Notes: || HD outlined the Clean Air Act of 1978 as it affected the company and it's customers.|||
 |726| |3-30-1978|1978 FX/​FXE/​FXS|Front Brake Caliper Bolt Washer (Recall 035)| |726| |3-30-1978|1978 FX/​FXE/​FXS|Front Brake Caliper Bolt Washer (Recall 035)|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**727**</​wrap>​| |4-11-1978|1979 XLH-1000|Rear Brake Control Linkage (Recall 036)| +|<wrap hi>​**727**</​wrap>​| ​{{ :​pdf:​tsb0727.pdf |Y}} |4-11-1978|1979 XLH-1000|Rear Brake Control Linkage (Recall 036)| 
-|  Notes: || |||+|  Notes: ||Certain early 1979 XLH-1000 motorcycles were produced and shipped with deficient rear brake linkage parts during the period from February 15, 1978 to March 22, 1978. |||
 |728| |4-28-1978|1978 MX-250|Flywheel Assembly| |728| |4-28-1978|1978 MX-250|Flywheel Assembly|
 |  Notes: || ||| |  Notes: || |||
 |729| |6-13-1978|FLH-80|Carburetor Low Speed Setting| |729| |6-13-1978|FLH-80|Carburetor Low Speed Setting|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**730**</​wrap>​| |6-15-1978|1078 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 Models|+|<wrap hi>​**730**</​wrap>​| ​{{ :​pdf:​tsb0730.pdf |Y}} |6-15-1978|1078 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 Models|
 |  Notes: || Carburetor 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.||| |  Notes: || Carburetor 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.|||
-|<wrap hi>​**731**</​wrap>​| |6-20-1978|1000,​ 1200 \\ 1340 Models|[[techtalk:​ih:​wheels01#​tire_fitment_chart|Tire Fitment]]|+|<wrap hi>​**731**</​wrap>​| ​{{ :​pdf:​tsb0731.pdf |Y}} |6-20-1978|1000,​ 1200 \\ 1340 Models|Tire Fitment \\ [[techtalk:​ih:​wheels01#​tire_fitment_chart|See more here on tire fitment also]]|
 |  Notes: || List of all 16",​18"​ & 19" wheels supplied by the MoCo as standard or accessories. Correct matching of tire, tubes and wheels||| |  Notes: || List of all 16",​18"​ & 19" wheels supplied by the MoCo as standard or accessories. Correct matching of tire, tubes and wheels|||
 |732| |6-27-1978|FL/​FX|Hydraulic ​ Lifters| |732| |6-27-1978|FL/​FX|Hydraulic ​ Lifters|
Line 764: Line 766:
 |733| |7-7-1978|1978 Lightweights|Gas Caps / Mounting Screws / Rear Chain| |733| |7-7-1978|1978 Lightweights|Gas Caps / Mounting Screws / Rear Chain|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**734**</​wrap>​| |7-5-1978|All V-Twins|Wheel Bearing Spacers ​/ V-Twins+|<wrap hi>​**734**</​wrap>​| ​{{ :​pdf:​tsb0734.pdf |Y}} |7-5-1978|All V-Twins|Wheel Bearing Spacers| 
-|  Notes: || Bearing spacer lengths changed. ​For proper handling and to minimize ​bearing ​& tire wearwheel 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.||| +|  Notes: || Bearing spacer lengths changed. ​Includes checking ​bearing ​endplayspecs (.004"​-.018"​) and using the correct longer or shorter (color coded) spacer to achieve the correct specs.||| 
-|<wrap hi>​**735**</​wrap>​| |7-14-1978|FL/​FX/​XL|Flywheel Assembly| +|<wrap hi>​**735**</​wrap>​| ​{{ :​pdf:​tsb0735.pdf |Y}} |7-14-1978|FL/​FX/​XL|Flywheel Assembly| 
-|  Notes: || Use of lockplates and screws ​no longer ​used in production||| +|  Notes: || The lockplates and screws used to secure the nuts on V-Twin flywheel assemblies were discontinued ​in production ​for improved serviceability.||| 
-|<wrap hi>​**736**</​wrap>​| |7-31-1978|1978-79 XLH/XLCH \\ FL/FX|Front Brake (Recall 037)| +|<wrap hi>​**736**</​wrap>​| ​{{ :​pdf:​tsb0736.pdf |Y}} |7-31-1978|1978-79 XLH/XLCH \\ FL/FX|Front Brake (Recall 037)| 
-|  Notes: || ||| +|  Notes: ||Certain 1978 and 1979 model FLH, FLH-80, FX, FXE, FXS, XLH and XLCH motorcycles were produced and shipped with deficient front brake master cylinders during the period from June 7, 1978 to June 14, 1978. A complete list of these vehicles is included with this bulletin. ​||| 
-|<wrap hi>​**737**</​wrap>​| |8-3-1978|FL/​FX/​XL|Disc Brake Changes| +|<wrap hi>​**737**</​wrap>​| ​{{ :​pdf:​tsb0737.pdf |Y}} |8-3-1978|FL/​FX/​XL|Disc Brake Changes| 
-|  Notes: || Harder ​stainless steel discs, brake pad replacement & (caliper parts - only 1200 & 1340 models)||| +|  Notes: || Several changes have been made to the calipers, discs and pads used on the front and rear hydraulic brakes includes harder ​stainless steel discs, brake pad replacement & (caliper parts - only 1200 & 1340 models)||| 
-|<wrap hi>​**738**</​wrap>​| |10-17-1978|All models w/ 16" wheels|Lacing 16" Wheels (New Hub)|+|<wrap hi>​**738**</​wrap>​| ​{{ :​pdf:​tsb0738.pdf |Y}} |10-17-1978|All models w/ 16" wheels|Lacing 16" Wheels (New Hub)|
 |  Notes: || 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.||| |  Notes: || 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.|||
-|<wrap hi>​**739**</​wrap>​| |11-3-1978|All 1200/​1340/​1000|Carburetion and Ignition|+|<wrap hi>​**739**</​wrap>​| ​{{ :​pdf:​tsb0739.pdf |Y}} |11-3-1978|All 1200/​1340/​1000|Carburetion and Ignition|
 |  Notes: || Countering 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.||| |  Notes: || Countering 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.|||
 |740| |11-30-1978|FL/​FX|Primary ​ Chain Tensioner (black)| |740| |11-30-1978|FL/​FX|Primary ​ Chain Tensioner (black)|
Line 782: Line 784:
 |742| |1-31-1979|1979 FLH/​FLH-80|Classic ​ King Tour  Pak| |742| |1-31-1979|1979 FLH/​FLH-80|Classic ​ King Tour  Pak|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**743**</​wrap>​| |4-3-1979|1200/​1340/​1000|Cam Gear Selection| +|<wrap hi>​**743**</​wrap>​| ​{{ :​pdf:​tsb0743.pdf |Y}} |4-3-1979|1200/​1340/​1000|Cam Gear Selection ​for Quieter Operation
-|  Notes: || Cam gear selection method ​for quieter operation||| +|  Notes: ||Measuring and specs for the different cam gear color codes (included) ​||| 
-|<wrap hi>​**744**</​wrap>​| |4-3-1979|E1979 1000cc engines|Transmission Changes| +|<wrap hi>​**744**</​wrap>​| ​{{ :​pdf:​tsb0744.pdf |Y}} |4-3-1979|E1979 1000cc engines|Transmission Changes| 
-|  Notes: || Changes to improve the engagement of the clutch teeth between the mainshaft 2nd gear and the clutch gear|||+|  Notes: || Changes to improve the engagement of the clutch teeth between the mainshaft 2nd gear and the clutch gear. Includes clutch gear, washer and drive sprocket changes.|||
 |745| |4-24-1979|FL/​FX|Improving Oil Mileage| |745| |4-24-1979|FL/​FX|Improving Oil Mileage|
 |  Notes: || ||| |  Notes: || |||
 |746| |5-11-1979|FL/​FX|Push Rod Covers (loss of vacuum)| |746| |5-11-1979|FL/​FX|Push Rod Covers (loss of vacuum)|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**747**</​wrap>​| |5-1-1979|1979 1200/​1340/​1000cc engines|Front Brake Master Cylinder (Recall 039)| +|<wrap hi>​**747**</​wrap>​| ​{{ :​pdf:​tsb0747.pdf |Y}} |5-1-1979|1979 1200/​1340/​1000cc engines|Front Brake Master Cylinder (Recall 039)| 
-|  Notes: || |||+|  Notes: ||A quantity of 370 motorcycles were produced and shipped from 3/22/79 to 3/30/79 with a possible defect in the front brake master cylinder. Some of the (included list of) motorcycles may have brake fluid leakage through a tear or crack in the metal between the master cylinder outlet and the fluid reservoir.|||
 |748| |5-18-1979|1979 models|Miscellaneous Information| |748| |5-18-1979|1979 models|Miscellaneous Information|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**749**</​wrap>​| |6-12-1979|1977-78 XLCR -1000|Rear Brake Master Cylinder Pushrod (Recall 040)| +|<wrap hi>​**749**</​wrap>​| ​{{ :​pdf:​tsb0749.pdf |Y}} |6-12-1979|1977-78 XLCR -1000|Rear Brake Master Cylinder Pushrod (Recall 040)| 
-|  Notes: || |||+|  Notes: ||All XLCR-1000 motorcycles produced during the 1977 and 1978 model season were shipped with the rear brake master cylinder push rods having insufficient contact area with the rear brake master cylinder plastic piston. ​|||
  
  
Line 802: Line 804:
 |750| |6-15-1979|FL/​FX|Tappet Guide Blocks| |750| |6-15-1979|FL/​FX|Tappet Guide Blocks|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**751**</​wrap>​| |6-29-79|1979 XLH/​XLS|Rear Brake Pedal Stop Bolt Jam-nut (Recall 041)| +|<wrap hi>​**751**</​wrap>​| ​{{ :​pdf:​tsb0751.pdf |Y}} |6-29-79|1979 XLH/​XLS|Rear Brake Pedal \\ Stop Bolt Jam-nut ​\\ (Recall 041)| 
-|  Notes: || |||+|  Notes: || A quantity of 1979 XLH and XLS motorcycles were produced and shipped between March 30, 1979 and April 19,1979 with a possible defect in the assembly of the brake pedal stop bolt jam-nut. This bulletin gives the VINs affected and instructions to repair.|||
 |752| |7-6-1979|1979 FLH/​FLH-80|Frame Mounted Seat (Recall 042)| |752| |7-6-1979|1979 FLH/​FLH-80|Frame Mounted Seat (Recall 042)|
 |  Notes: || ||| |  Notes: || |||
 |753| |8-14-1979|FL/​FX|Rear Brake Master Cylinder Change| |753| |8-14-1979|FL/​FX|Rear Brake Master Cylinder Change|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**754A**</​wrap>​| |3-21-1980|1979 XLH/XLCH/XLS \\ FL/FX|Rear Brake Master Cylinder Piston (Recall 044)| +<wrap hi>​**754**</​wrap>​ \\ <wrap hi>​**754A**</​wrap>​ | {{ :​pdf:​tsb0754.pdf ​|Y}} |8-17-1979 \\ 3-21-1980|1979 XLH/XLS/FL \\ 1979 XLCH/FL/FX|Rear Brake Master Cylinder Piston (Recall 044)| 
-|  Notes: || ||| +|  Notes: ||A quantity of 1979 model 1200/1340 and 1000cc motorcycles were assembled and shipped with master cylinder pistons made from an incorrect material as received from the supplier.||| 
-|<wrap hi>​**755**</​wrap>​| |9-7-1979|1978-1979 \\ XLH/​XLCH/​XLS|Rear Brake Pedal (Recall 043)|+|<wrap hi>​**755**</​wrap>​| ​ |9-7-1979|1978-1979 \\ XLH/​XLCH/​XLS|Rear Brake Pedal (Recall 043)|
 |  Notes: || ||| |  Notes: || |||
 |756| |10-16-1979|FL|Frame Mounted Seat Reinforcement Kit| |756| |10-16-1979|FL|Frame Mounted Seat Reinforcement Kit|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**757**</​wrap>​| |10-19-1979|Early 1980 XLH/XLS|Cam Timing| +|<wrap hi>​**757**</​wrap>​| ​{{ :​pdf:​tsb0757.pdf |Y}} |10-19-1979|Early 1980 XLH/XLS|Cam Timing| 
-|  Notes: || Some 1980 Sportster were built with incorrect front exhaust cam gear timing.||| +|  Notes: ||A small quantity of early 1980 Sportster ​engines ​were produced ​with incorrect front exhaust cam gear timing.||| 
-|<wrap hi>​**758**</​wrap>​| |10-23-1979|1978-1979 1200/​1340/​1000cc models|Rear Brake Pedal (Recall 043) \\ Rear brake master cylinder (Recall 044)|  +|<wrap hi>​**758**</​wrap>​| ​{{ :​pdf:​tsb0758.pdf |Y}} |10-23-1979|1978-1979 1200/​1340/​1000cc models|Rear Brake Pedal (Recall 043) \\ Rear brake master cylinder (Recall 044)|  
-|  Notes: || ||| +|  Notes: ||Return of unused parts from dealer stock: 42410-75A brake pedals with (ID) month code and master cylinder kit 42374-77 with plastic (no ID) pistons. ​||| 
-|<wrap hi>​**759**</​wrap>​| |10-16-1979|1980 XLH/​XLS|Battery Position| +|<wrap hi>​**759**</​wrap>​| ​{{ :​pdf:​tsb0759.pdf |Y}} |10-16-1979|1980 XLH/​XLS|Battery Position| 
-|  Notes: || On 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.||| +|  Notes: || Check that battery to make sure the battery ​isn'​t ​mis-positioned ​in the battery ​box.||| 
-|<wrap hi>​**760**</​wrap>​| |11-16-1979|All 1980 HD Models|Resistor ​Plugs & Ignition Rotor Bolt+|<wrap hi>​**760**</​wrap>​| ​{{ :​pdf:​tsb0760.pdf |Y}} |11-16-1979| ​"​R"​ Type Spark Plugs| 
-|  Notes: || "​R"​ (resistor) ​type spark plugs are now used on all 1980 models to provide radio ignition noise suppressionimprove 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.|||+|  Notes: || Resistor ​type spark plugs are being introduced in 1980 models to provide radio ignition noise suppression ​and improve the reliability of the transistorized Magnavox ignition system.|||
 |761| |11-30-1979|Early 1980 FL/​FX|Piston Replacement| |761| |11-30-1979|Early 1980 FL/​FX|Piston Replacement|
 |  Notes: || ||| |  Notes: || |||
 |762A| |4-1-1980|FL/​FX|Front Chain Housing| |762A| |4-1-1980|FL/​FX|Front Chain Housing|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**763**</​wrap>​| |12-21-1979|1074-1979 \\ 1200/​1340/​1000cc|Starter Relay|+|<wrap hi>​**763**</​wrap>​| ​{{ :​pdf:​tsb0763.pdf |Y}} |12-21-1979|1974-1979 \\ 1200/​1340/​1000cc|Starter Relay|
 |  Notes: || In some cases, the [[techtalk:​ih:​elec02#​starter_relay|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.||| |  Notes: || In some cases, the [[techtalk:​ih:​elec02#​starter_relay|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.|||
 |763A| |3-21-1980|1975-1980 FL|Front Fender Mounting (Recall 045)| |763A| |3-21-1980|1975-1980 FL|Front Fender Mounting (Recall 045)|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**764**</​wrap>​| |12-21-1979|1000cc models|Shock Absorber Rubber Bushings| +|<wrap hi>​**764**</​wrap>​| ​{{ :​pdf:​tsb0764.pdf |Y}} |12-21-1979|1000cc models|Shock Absorber Rubber Bushings| 
-|  Notes: || The condition of the rear shock absorber upper and lower [[techtalk:​ih:​susp02#​mounting_bushings|mounting bushings]] should be checked at least every 5,000 miles since excessive looseness of the bushings ​could affect proper shock absorber function.|||+|  Notes: || The condition of the rear shock absorber upper and lower [[techtalk:​ih:​susp02#​mounting_bushings|mounting bushings]] should be checked at least every 5,000 miles for excessive looseness of the bushings.|||
 |765| |3-14-1980|1980 FLT|Rear Brake Caliper (Recall 046)| |765| |3-14-1980|1980 FLT|Rear Brake Caliper (Recall 046)|
 |Letter| |3-7-1980|1980 FLT|Sprocket Mounting Screws (Recall 047)| |Letter| |3-7-1980|1980 FLT|Sprocket Mounting Screws (Recall 047)|
 |  Notes: || ||| |  Notes: || |||
-|766| |2-29-1980|FL/​FX \\ Servi-Car|Brake Fluid / Sidecar|+|766| {{ :​pdf:​tsb0766.pdf |Y}} |2-29-1980|FL/​FX \\ Servi-Car|Brake Fluid / Sidecar|
 |  Notes: || Reaffirming 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).||| |  Notes: || Reaffirming 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).|||
 |767| |3-4-1980|FL/​FX|Square Seal Brake Caliper| |767| |3-4-1980|FL/​FX|Square Seal Brake Caliper|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**768**</​wrap>​| |3-18-1980|1954-1979 XL \\ 1958-1978 XL|Crank Pin \\ Chain Adjuster| +|<wrap hi>​**768**</​wrap>​| ​{{ :​pdf:​tsb0768.pdf |Y}} |3-18-1980|1954-1979 XL \\ 1958-1978 XL|Crank Pin \\ Chain Adjuster| 
-|  Notes: || 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|||+|  Notes: || 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.|||
 |<wrap hi>​**769**</​wrap>​| |4-18-1980|All|Service Information - 1980| |<wrap hi>​**769**</​wrap>​| |4-18-1980|All|Service Information - 1980|
 |  Notes: || ||| |  Notes: || |||
Line 849: Line 851:
 |772| |4-22-1980|FL/​FX/​FLT|1340cc Low Compression Pistons| |772| |4-22-1980|FL/​FX/​FLT|1340cc Low Compression Pistons|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**773**</​wrap>​| |4-25-1980|1980 XL|Shock Absorbers| +|<wrap hi>​**773**</​wrap>​| ​{{ :​pdf:​tsb0773.pdf |Y}} |4-25-1980|1980 XL|Shock Absorbers| 
-|  Notes: || Some 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|||+|  Notes: || Some XLs had 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.|||
 |774| |4-25-1980|FL/​FX|Gear Shaft 1958-1972| |774| |4-25-1980|FL/​FX|Gear Shaft 1958-1972|
 |  Notes: || ||| |  Notes: || |||
 |775| |5-6-1980|FXB|Belt Adjustment and Alignment Procedure| |775| |5-6-1980|FXB|Belt Adjustment and Alignment Procedure|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**776**</​wrap>​| |5-9-1980|1977-1980 XL|Solenoid Cover|+|<wrap hi>​**776**</​wrap>​| ​{{ :​pdf:​tsb0776.pdf |Y}} |5-9-1980|1977-1980 XL|Solenoid Cover|
 |  Notes: || Some [[techtalk:​ih:​engctl02#​check_solenoid_cover_for_conductivity|solenoid covers]] used since 1977 have the ability to conduct electricity. ||| |  Notes: || Some [[techtalk:​ih:​engctl02#​check_solenoid_cover_for_conductivity|solenoid covers]] used since 1977 have the ability to conduct electricity. |||
-|<wrap hi>​**777**</​wrap>​| |5-13-1980|1980 XL|Cylinder Head Gaskets| +|<wrap hi>​**777**</​wrap>​| ​{{ :​pdf:​tsb0777.pdf |Y}} |5-13-1980|1980 XL|Cylinder Head Gaskets| 
-|  Notes: || Starting 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.||| +|  Notes: || Starting 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 installedThe part number (16769-73) didn't change for the new gasket.||| 
-|<wrap hi>​**778**</​wrap>​| |5-13-1980|XL/​XLH/​XLCH/​XLS|Crankcase Cover Gasket| +|<wrap hi>​**778**</​wrap>​| ​{{ :​pdf:​tsb0778.pdf |Y}} |5-13-1980|XL/​XLH/​XLCH/​XLS|Crankcase Cover Gasket| 
-|  Notes: || There 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. ||| +|  Notes: || There 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. ||| 
-|<wrap hi>​**779**</​wrap>​| |5-23-1980|1980 XL/XLS|Rear Brake Clevis Rod End| +|<wrap hi>​**779**</​wrap>​| ​{{ :​pdf:​tsb0779.pdf |Y}} |5-23-1980|1980 XL/XLS|Rear Brake Clevis Rod End| 
-|  Notes: || Inspect ​[[techtalk:​ih:​wheels02#​rear_brake_clevis_rod|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.||| +|  Notes: || Inspect ​the brake stop bracket for correct bend. The bracket ​is welded to the muffler and should form a 90° angle out from muffler. ||| 
-|<wrap hi>​**780**</​wrap>​| |5-23-1980|1000/​1340cc engines|Revised Ignition Timing| +|<wrap hi>​**780**</​wrap>​| ​{{ :​pdf:​tsb0780.pdf |Y}} |5-23-1980|1000/​1340cc engines|Revised Ignition Timing| 
-|  Notes: || Some 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||| +|  Notes: || Some 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||| 
-|<wrap hi>​**781**</​wrap>​| |5-23-1980|1980 1000/1340cc models|Ignition Timing Marks| +|<wrap hi>​**781**</​wrap>​| ​{{ :​pdf:​tsb0781.pdf |Y}} |5-23-1980|1980 1000/1340cc models|Ignition Timing Marks| 
-|  Notes: || [[techtalk:​ih:​engctl01f|Timing marks have been revised]] to enable to be electronically set at the factory and reduce setup time for dealers||| +|  Notes: || [[techtalk:​ih:​engctl01#​timing_marks|Timing marks have been revised]] ​ to enable to be electronically set at the factory and reduce setup time for dealers||| 
-|782A| |6-20-1980|FL/​FX/​FLT|Three Angle Valve Seats| +|<wrap hi>​782</​wrap>​ \\ <wrap hi>782A</​wrap>​| {{ :​pdf:​tsb0782.pdf ​|Y}} |6-3-1980 \\ 6-20-1980|FL/​FX/​FLT/XL|Three Angle Valve Seats| 
-|  Notes: || |||+|  Notes: || All production models incorporate three angle valve seats on both the intake and exhaust of the cylinder head ports. This bulletin outlines the procedure for cutting the seats. ​|||
 |783| |5-23-1980|FLT|Accessory Gauge Kit Installation| |783| |5-23-1980|FLT|Accessory Gauge Kit Installation|
 |  Notes: || ||| |  Notes: || |||
 |784| |5-23-1980|FLT|Service Procedure| |784| |5-23-1980|FLT|Service Procedure|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**785**</​wrap>​| |6-10-1980|1979 XL/​FL/​FX|Rear Brake Master Cylinder Piston (Recall 044 - addendum)| +|<wrap hi>​**785**</​wrap>​| ​{{ :​pdf:​tsb0785.pdf |Y}} |6-10-1980|1979 XL/​FL/​FX|Rear Brake Master Cylinder Piston (Recall 044 - addendum)| 
-|  Notes: || |||+|  Notes: || Addendun referenced to TSB 754A with further instruction. ​|||
 |786| |8-29-1980|1972-E1980 FL/​FX|Interchangeable Front Brake Piston| |786| |8-29-1980|1972-E1980 FL/​FX|Interchangeable Front Brake Piston|
 |  Notes: || ||| |  Notes: || |||
Line 889: Line 891:
 |792| |7-3-1980|FLT|Electrical Charging System Diagnostic Procedure| |792| |7-3-1980|FLT|Electrical Charging System Diagnostic Procedure|
 |  Notes: || ||| |  Notes: || |||
-|<wrap hi>​**793**</​wrap>​| |7-3-1980|All 1980 models|Ignition Coils| +|<wrap hi>​**793**</​wrap>​| ​{{ :​pdf:​tsb0793.pdf |Y}} |7-3-1980|All 1980 models|Ignition Coils| 
-|  Notes: || A number of ignition coils have failed at low mileage due to an internal breakdown in the windings|||+|  Notes: || A number of ignition coils have failed at low mileage due to an internal breakdown in the windings|||
 |794| |7-14-1980|1980 FXWG|Rear Brake Control Mounting Bolts (Recall 050)| |794| |7-14-1980|1980 FXWG|Rear Brake Control Mounting Bolts (Recall 050)|
 |  Notes: || ||| |  Notes: || |||
Line 907: Line 909:
 ====== TSB 800-849 ====== ====== TSB 800-849 ======
 |TSB_#​|PDF?​|Date|Model(s)|Title - Short Notes (Add'l Notes on Next Line)| |TSB_#​|PDF?​|Date|Model(s)|Title - Short Notes (Add'l Notes on Next Line)|
-|<wrap hi>​**800**</​wrap>​| |10-10-1980|All 1981 models|17 Digit VIN System|+|<wrap hi>​**800**</​wrap>​| ​{{ :​pdf:​tsb0800.pdf |Y}} |10-10-1980|All 1981 models|17 Digit VIN System|
 |  Notes: || The 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.||| |  Notes: || The 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.|||
-|<wrap hi>​**801**</​wrap>​| |11-14-1980|Models covered under \\ Service Bulletins|Service Bulletin Index|+|<wrap hi>​**801**</​wrap>​| ​{{ :​pdf:​tsb0801.pdf |Y}} |11-14-1980|Models covered under \\ Service Bulletins|Service Bulletin Index|
 |  Notes: || Index 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).||| |  Notes: || Index 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).|||
-|<wrap hi>​**804**</​wrap>​| |11-4-1980|All|Throttle Cable Adjustment| +|<wrap hi>​**804**</​wrap>​| ​{{ :​pdf:​tsb0804.pdf |Y}} |11-4-1980|All ​81 Models|Throttle Cable Adjustment| 
-|  Notes: || All 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 return spring which closes the throttle when grip is released (as on previous models).||| +|  Notes: || All 1981 model motorcycles are equipped with a dual cable throttle assembly ​commonly referred to as a "​Pull-Pull Throttle." ​||| 
-|<wrap hi>**804**</​wrap>​| ​|11-21-1980|All models affected|Safety Recall Campaign Index| +|<wrap hi>**806**</​wrap>​| ​{{ :pdf:tsb0806.pdf |Y}} |12-5-1980|1971 and up FX \\ All HD model seats containing buttons| Seat Repair| 
-|  Notes|| Simple list of safety recalls from the beginning of the recall campaign up to 7-14-1980 (recall numbers 001-050).||| +|  Notes: ||Two 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.||| 
-|<wrap hi>​**806**</​wrap>​| ​|12-5-1980|1971 and up FX but pertains to all HD model seats containing buttons| Seat Repair| +|<wrap hi>​**807**</​wrap>​ \\ <wrap hi>​**807A**</​wrap>​ | {{ :​pdf:​tsb0807.pdf ​|Y}} \\ {{ :​pdf:​tsb0807a.pdf |Y}}|11-21-1980 \\ 10-14-1984|All models affected ​\\ More models added|Safety Recall Campaign Index|
-|  Notes: ||Two 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).||| +
-|<wrap hi>​**807A**</​wrap>​| |10-14-1984|All models affected|Safety Recall Campaign Index|+
 |  Notes: || Simple list of safety recalls, arranged per model affected, from the beginning of the recall campaign up to 5-2-1984 (recall numbers 001-058).||| |  Notes: || Simple list of safety recalls, arranged per model affected, from the beginning of the recall campaign up to 5-2-1984 (recall numbers 001-058).|||
-|<wrap hi>​**813**</​wrap>​| |1-30-1981|XLH/​XLS|Service Information| +|<wrap hi>​**813**</​wrap>​| ​{{ :​pdf:​tsb0813.pdf |Y}} |1-30-1981|XLH/​XLS|Service Information| 
-|  Notes: || 1972-1981 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.||| +|  Notes: || 1972-1981 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. \\ The MoCo also issued a warning regarding brake line routinge ​on 80 and 81 XLH/XLS models. \\ The torque value in the FSM for rocker arm acorn nuts is incorrect. \\ 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 ​also suggested for E1981 models as well.||| 
-|<wrap hi>​**814**</​wrap>​| |2-6-1981|All|1981 Service Update: Ignition Module| +|<wrap hi>​**814**</​wrap>​| ​{{ :​pdf:​tsb0814.pdf |Y}} |2-6-1981|All|1981 Service Update: Ignition Module| 
-|  Notes: || The ignition modules, with the part number suffix -80 (Sportster part number 32410-80), ((1979-1980 HD Sportster Parts Catalog pg 23)) 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 secondsthe module will only start fir­ing on the second or third stroke, which may present a problem ​with kick-start motorcycles. This causes ​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, ((1979-1982 HD Sportster Parts Catalog pg 31)) ) have a 6 second delay, will fire on the first compression stroke will work in 1980 and E1981 applications without modification.||| +|  Notes: || New electronic ​ignition modules (-80A) have a 6 second delay as opposed ​to the previous ignitions ​(-80) with a second delay. ​Check sidecar wheel lubricationFXWG, FXBFXS-80 got a new exhaust. ​See Parts and accessories ​Bulletin ​Number ​129 for FLH Heritage ​special parts.|||
-|:::||FL Sidecar|Sidecar Wheel Lubrication|FL model sidecar wheel bearings should be checked for wear and repacked with grease every 10,000 milesWe recommend using the new wheel bearing grease (99855-80)for all wheel bearings.| +
-|:::||1981 FXWG/FXB/FXS-8O|Exhaust System|The 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 assemblyAdditional 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 Heritage|Seat Bar Lubrication|Parts 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.|+
 |815| | -date- |FL/FX|Rear Brake Anti-Vibration Kit| |815| | -date- |FL/FX|Rear Brake Anti-Vibration Kit|
 |  Notes: || ||| |  Notes: || |||
 |815A| |12-18-1981|1973-1980 FL/FX|Rear Brake Anti-Vibration Kit| |815A| |12-18-1981|1973-1980 FL/FX|Rear Brake Anti-Vibration Kit|
 |  Notes: || The 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.||| |  Notes: || The 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.|||
-|<wrap hi>​**824**</​wrap>​| |4-17-1981|1200/​1340/​1000 models|Crankshaft Bearing Race Tool| +|<wrap hi>​**824**</​wrap>​| ​{{ :​pdf:​tsb0824.pdf |Y}} |4-17-1981|1200/​1340/​1000 models|Crankshaft Bearing Race Tool| 
-|  Notes: || A 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.|||+|  Notes: || A new crankshaft bearing race press tool (94547-80) is now available ​through Kent-Moore ​Tool Division.|||
 |825| |4-21-1981|FLT|FLT Wheel Alignment Tool| |825| |4-21-1981|FLT|FLT Wheel Alignment Tool|
 |  Notes: || The 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.||| |  Notes: || The 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.|||
-|<wrap hi>​**827**</​wrap>​| |4-24-1981|1981 XL|Three Angle Valve Seats| +|<wrap hi>​**827**</​wrap>​| ​{{ :​pdf:​tsb0827.pdf |Y}} |4-24-1981|1981 XL|Three Angle Valve Seats| 
-|  Notes: || The 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).||| +|  Notes: || The 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 81 XL Models starting with crankcase ​(781012001).||| 
-|<wrap hi>​**828**</​wrap>​| |4-21-1981|All|VIN Character Identification| +|<wrap hi>​**828**</​wrap>​| ​{{ :​pdf:​tsb0828.pdf |Y}} |4-21-1981|All|VIN Character Identification| 
-|  Notes: || The "​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.||| +|  Notes: || The "​6"​ and "​9"​ characters used in the factory ​stamping of engine and crankcase numbers could be interchanged ​and 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.||| 
-|<wrap hi>​**829**</​wrap>​| |5-19-1981|1200/​1340/​1000|Commonized Flywheels| +|<wrap hi>**829**</​wrap>​ \\ <wrap hi>​**829A**</​wrap>​|{{ :​pdf:​tsb0829.pdf |Y}} \\ {{ :​pdf:​tsb0829a.pdf |Y}} |5-19-1981 \\ 6-12-1981|1200/​1340/​1000 ​cc Engines|Commonized Flywheels| 
-|  Notes: || [[techtalk:​ih:​engmech01#​commonized_flywheels|Commonized flywheel]] taper design on 1200/1340 and 1000cc engines. All tapers have were communized at 6° and all keyways were standardized.||| +|  Notes: || [[techtalk:​ih:​engmech01#​commonized_flywheels|Commonized flywheel]] taper design on 1200/1340 and 1000cc engines. All tapers have were communized at 6° and all keyways were standardized. TSB #829 includes ​part numbers||| 
-|<wrap hi>​**829A**</​wrap>​| |5-19-1981|1200/​1340/​1000|Commonized Flywheels| +|<wrap hi>​**830**</​wrap> ​\\ <wrap hi>​**830A**</​wrap>​| ​\\ {{ :​pdf:​tsb0830a.pdf ​|Y}} | \\ 6-30-1981|1200/​1340/​1000cc Engines|Color Coded Cam Gear Selection| 
-|  Notes: || Update to TSB$#829 to include ​part numbers||| +|  Notes: || Color coded cam gears are sold in matched sets for 1000/​1200/​1340cc models to provide the proper gear lash (tooth clearance) for quiet operation. Update bulletin replaces ​parts and part numbers from Bulletin #830 for 1000cc engines.  ​||| 
-|<wrap hi>​**830**</​wrap>​| |6-30-1981|1200/​1340/​1000|[[techtalk:​ih:​engmech02#​cam_gear_selection_for_quiet_operation|Color Coded Cam Gear Selection]]| +|<wrap hi>​**831**</​wrap>​| ​{{ :​pdf:​tsb0831.pdf |Y}} |6-12-1981|1980-1981 FLT \\ 1981 FXE/​FXEF/​FXS/​XLH/​XLS|1981 Service Information|
-|  Notes: || Parts and part number changes for cam gears and components||| +
-|<wrap hi>​**830A**</​wrap>​| |6-30-1981|1200/​1340/​1000|Color Coded Cam Gear Selection| +
-|  Notes: || Replacing ​parts and part numbers from Bulletin #830 for 1000cc engines||| +
-|<wrap hi>​**831**</​wrap>​| |6-12-1981|1980-1981 FLT \\ 1981 FXE/​FXEF/​FXS/​XLH/​XLS|1981 Service Information|+
 |  Notes: || 80-81 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.||| |  Notes: || 80-81 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.|||
-|<wrap hi>​**832**</​wrap>​| |6-12-1981|XL/​FX/​FLT|Front Brakes| +|<wrap hi>​**832**</​wrap>​| ​{{ :​pdf:​tsb0832.pdf |Y}} |6-12-1981|XL/​FX/​FLT|Front Brakes| 
-|  Notes: || A 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.||| +|  Notes: || A special foam tape was made available for XL/​FX/​FLT ​model front brake calipers. Applied to the front of the outer caliper half, it helps to prevent caliper rattle.||| 
-|<wrap hi>​**837**</​wrap>​| |10-2-1981|XL|1982 Model Service Information| +|<wrap hi>​**837**</​wrap>​| ​{{ :​pdf:​tsb0837.pdf |Y}} |10-2-1981|All models|1982 Model Service Information| 
-|  Notes: || 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.||| +|  Notes: || New handlevers ​and switches, new front brake lever is design, low maintenance ​battery, ​a .015" ​thick spacer ​added inside the 0-ring under the right end screw of the rocker arm shaft (on E1982 models, the rocker arm shafts ​were changed to eliminate ​the need for these spacersXL modelsNew 13 amp generator and rear brake caliper. ​FXR: New rear brake caliper ​and master cylinder (same as on XL). FLT: New saddlebag locks, rear sprocket housingand wheel bearings. FL, FX, FL T, FXR all got new valve springs.||| 
-|:::||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.|| +|<wrap hi>​**838**</​wrap>​| ​{{ :​pdf:​tsb0494.pdf |Y}} |10-2-1981|All|1980-1982 Motorcycle Tire Fitment|
-|:::​||1000/​1200/​1340cc|Rocker arm shafts now have 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 shaftE1982 models, ​with the new 45° shafts ​do not need the washerNever use more than 1 washer on the shaft|| +
-|:::||FXR|The rear caliper ​is identical to one on XL models except it is located on the right side of the motorcycle.|| +
-|:::​||FL/​FX/​FLT/FXR|New 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|| +
-|<wrap hi>​**838**</​wrap>​| |10-2-1981|All|1980-1982 Motorcycle Tire Fitment|+
 |  Notes: || New tire and wheel combinations||| |  Notes: || New tire and wheel combinations|||
-|<wrap hi>​**839**</​wrap>​| |10-2-1981|1982 XL|Battery Cable Routing| +|<wrap hi>​**839**</​wrap>​| ​{{ :​pdf:​tsb0839.pdf |Y}} |10-2-1981|1982 XL|Battery Cable Routing| 
-|  Notes: || On 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.||| +|  Notes: || On VINs prior to (1HD1CAH15CY111159)the positive battery cable on some 1982 vehicles ​may contact the leading edge of the oil tank. This surface could cut the insulation, causing a short circuit.||| 
-|<wrap hi>​**840**</​wrap>​| |10-2-1981|1982 XL|1982 Service Information| +|<wrap hi>​**840**</​wrap>​| ​{{ :​pdf:​tsb0840.pdf |Y}} |10-2-1981|1982 XL|1982 Service Information| 
-|  Notes: || * 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.||| +|  Notes: || The 13 amp generator ​that is being used in 1982 production ​can be retrofitted to 1965. See the bulletin for guidelines for retrofitting. ​A limited number of early production 1982 engines were assembled without ​the commonized flywheel taper design. New lower torque ​recommendation ​for the oil separator washer nut on VINs prior to (1HD1CAH1XCY111183) ​to keep from bowing the washer ​and subsequent ​generator noise (whistling sound).||| 
-|<wrap hi>​**844**</​wrap>​| |10-30-1981|All|[[techtalk:​ih:​engmech03#​standard_piston_grading|Standard Piston Grading]]| +|<wrap hi>**841**</​wrap>​| {{ :​pdf:​tsb0841.pdf |Y}} |10-16-1981|L1981-E1982 XL|XL Gearcase covers and gaskets| 
-|  Notes: || All 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.||| +|  Notes: || Late 1981 and early 1982 engines ​may have one of two different types of gear case cover and crankcase set combinations. This bulletin identifies ​the differences in covers and gaskets.||| 
-|<wrap hi>​**845**</​wrap>​| |11-17-1981|1982 ​XL|Information Update| +|<wrap hi>​**844**</​wrap>​| ​{{ :​pdf:​tsb0844.pdf |Y}} |10-30-1981|All|[[techtalk:​ih:​engmech03#​standard_piston_grading|Standard Piston Grading]]| 
-|  Notes: || Sportster 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.||| +|  Notes: || All standard sized pistons are graded ​(stamped) ​for size in .00025” increments for production purposes on­ly and does not apply to oversized (.010“-.070”) pistons.||| 
-|:::||1982 FLT| * Incorrect ​(3/​4"​) ​windshield mounting screws ​were factory installed ​on some early modelsReplace the incorrect screws with 10-32x1"​ screws ​to 4 in/lbs\\ * The model designation number has changed in VIN|| +|<wrap hi>​**845**</​wrap>​| ​{{ :​pdf:​tsb0845.pdf |Y}} |11-17-1981|All 1982 Models|Information Update| 
-|<wrap hi>​**848**</​wrap>​| |4-9-1982|XL|[[techtalk:​ih:​oil01#​crankcase_ventilation_or_foo_foo_valve|Crankcase Breather Valve]]| +|  Notes: || Incorrect windshield mounting screws on 1982 FLTSportster fuel requirements were lowered ​to 89 pump octane due to lower compression ratioFLT VIN changes.||| 
-|  Notes: || Late 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.|||+|<wrap hi>​**848**</​wrap>​| ​{{ :​pdf:​tsb0848.pdf |Y}} |4-9-1982|Late 1982 XL|[[techtalk:​ih:​oil01#​crankcase_ventilation_or_foo_foo_valve|Crankcase Breather Valve]]| 
 +|  Notes: || A new style rubber crankcase breather valve has been put into production beginning with crankcase number 782-078-050 replacing ​the 79 reed valve. New kit part # (26909-79A). The late '​82 ​crankcase breather valve was installed ​along with a larger diameter (1-3/​4"​ O.D.) oil separator washer on the generator armature.|||
 |849| |2-16-1982|1200/​1340cc|Valve Guide Replacements| |849| |2-16-1982|1200/​1340cc|Valve Guide Replacements|
 |  Notes: || Introduction of new valve guides with seals to help improve oil consumption||| |  Notes: || Introduction of new valve guides with seals to help improve oil consumption|||
 +
 +
  
  
 ====== TSB 850-899 ====== ====== TSB 850-899 ======
 |TSB_#​|PDF?​|Date|Model(s)|Title - Short Notes (Add'l Notes on Next Line)| |TSB_#​|PDF?​|Date|Model(s)|Title - Short Notes (Add'l Notes on Next Line)|
-|<wrap hi>​**851A**</​wrap>​| |3-23-1982|XL|Information Update| +|<wrap hi>​**851A**</​wrap>​| ​{{ :​pdf:​tsb0851a.pdf |Y}} |3-23-1982|All models|Information Update| 
-|  Notes: || The 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.||| +|  Notes: || The 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. ​Parts and Accessories has obsoleted the one-piece (welded) exhaust system used on XL models.||| 
-|:::||All|The 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.|| +|<wrap hi>​**853**</​wrap>​| ​{{ :​pdf:​tsb0853.pdf |Y}} |3-19-1982|All ​Models|Front Brake Stoplight Switch| 
-|<wrap hi>​**853**</​wrap>​| |3-19-1982|All|Front Brake Stoplight Switch| +|  Notes: || On all 1982 models, the front brake master cylinder is constructed ​so there is no free play in the brake hand lever when the hand control switch assemblies are positioned ​correctly.||| 
-|  Notes: || The front brake master cylinder is made so there is no free play in the brake hand lever when the hand control switch assemblies are posi­tioned ​correctly. Also, improper positioning of the 1982 hand control switch assemblies may cause the brake light to stay on. The switch is spring loaded to the on position. The push rod switch tab must contact and depress the stoplight switch for the brake light to go off. If the brake light stays on, do not modify the push rod switch tab. The switch tab must be perpendicular to the push rod. Disassemble the component assembly, inspect it and repair as necessary.||| +|<wrap hi>​**855**</​wrap>​| ​{{ :​pdf:​tsb0855.pdf |Y}} |7-19-1982|1982 XL|Footrest Chain Protector| 
-|<wrap hi>​**855**</​wrap>​| |7-19-1982|1982 XL|Footrest Chain Protector| +|  Notes: || A 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.||| 
-|  Notes: || A 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.||| +|<wrap hi>​**856**</​wrap>​| ​{{ :​pdf:​tsb0856.pdf |Y}} |8-6-1982|1983 XL|Service Information| 
-|<wrap hi>​**856**</​wrap>​| |8-6-1982|1983 XL|Service Information| +|  Notes: || New pistons / ringsThe crown surface ​(.040" higher) along with a new two stage ignition system, provides increased performance while allowing use of leaded regular grade gasoline. ​Ignition, VOES operation, ​timing, ​oil tank drain method ​and indicator ​lamps also discussed in this bulletin.||| 
-|  Notes: || * Oil tank drain method: Using hose clamp pliers (HD-84 04), loosen and slide the clamp from the oil drain hose to the plug bracketDisconnect 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 (8.8-1achieved 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 ringa 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 [[techtalk:​ih:​engctl01#​voes_-_vacuum-operated_electric_switch|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 sideone 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.||| +|<wrap hi>​**857**</​wrap>​| ​{{ :​pdf:​tsb0857.pdf |Y}} |10-5-1982|L1982 & E1983 XL|Tumbling Stone Contamination| 
-|<wrap hi>​**857**</​wrap>​| |10-5-1982|L1982 & E1983 XL|Tumbling Stone Contamination| +|  Notes: || Reports were received ​indicate ​tumbling stone contamination may exist from polishing tappet bodies ​in engines with crankcase ​VIN'​s ​782025001 ​through ​783200001.||| 
-|  Notes: || Reports 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.||| +|<wrap hi>​**858**</​wrap>​| ​{{ :​pdf:​tsb0858.pdf |Y}} |10-7-1982|1983 and later XL|Service Information|
-|<wrap hi>​**858**</​wrap>​| |10-7-1982|XL|Service Information|+
 |  Notes: || [[techtalk:​ih:​engctl01#​voes_-_vacuum-operated_electric_switch|Checking VOES operation]] on 1983 and later models and the number of  [[techtalk:​ih:​transfinal03#​transmission_mainshaft_shims|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).||| |  Notes: || [[techtalk:​ih:​engctl01#​voes_-_vacuum-operated_electric_switch|Checking VOES operation]] on 1983 and later models and the number of  [[techtalk:​ih:​transfinal03#​transmission_mainshaft_shims|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).|||
-|<wrap hi>​**859**</​wrap>​| |10-29-1982|XL/​FXR/​FLT/​FLHT|Screw Type Fuel Cap| +|<wrap hi>​**859**</​wrap>​| ​{{ :​pdf:​tsb0859.pdf |Y}} |10-29-1982|XL/​FXR/​FLT/​FLHT|Screw Type Fuel Cap| 
-|  Notes: || All 1983 XL/FXR models produced after VIN (1HD1CCH17DY113282and FL/FX models ​pro­duced ​after VIN (1HD1AKK16DY011657) ​use a [[techtalk:​ih:​body01#​fuel_cap|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.||| +|  Notes: || The vent relief pressure has been reduced on the screw type fuel caps by utilizing a softer spring. ​All 1983 XL/FXR models produced after VIN 1HD1CCH17DY113282 and 1983 FLIFX models ​produced ​after VIN 1 HD1AKK16DY011657,​ except FLT/FLHT models, will use the new low pressure cap.||| 
-|<wrap hi>​**860**</​wrap>​| |11-12-1982|XL|Service Information| +|<wrap hi>​**860**</​wrap>​| ​{{ :​pdf:​tsb0860.pdf |Y}} |11-12-1982|XL|Service Information| 
-|  Notes: || * [[techtalk:​ih:​engmech02#​camshaft_shims|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 [[techtalk:​ih:​oil03a#​late_1983_oil_pump_assembly_design_modification|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.||| +|  Notes: || * [[techtalk:​ih:​engmech02#​camshaft_shims|Camshaft shims]] (6769 & 6770), used to control maximum camshaft end play have been discontinued in production engines. New finish to cylinder and head gaskets ​while 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 [[techtalk:​ih:​oil03a#​late_1983_oil_pump_assembly_design_modification|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.||| 
-|<wrap hi>​**867**</​wrap>​| |3-11-1983|All|Tire Fitment|+|<wrap hi>​**867**</​wrap>​| ​{{ :​pdf:​tsb0867.pdf |Y}} |3-11-1983|All|Tire Fitment|
 |  Notes: || Correct matching of tire, tubes and wheels||| |  Notes: || Correct matching of tire, tubes and wheels|||
-|<wrap hi>​**870**</​wrap>​| |4-15-1983|XL|New Valve Guides / Transmission Mainshaft Shims / Ignition Module / Sensor Connections| +|<wrap hi>**870**</​wrap>​ \\ <wrap hi>​**870A**</​wrap>​ | {{ :​pdf:​tsb0870.pdf |Y}} \\ {{ :​pdf:​tsb0870a.pdf |Y}} |4-15-1983 \\ 5-10-1983|XL|New Valve Guides / Transmission Mainshaft Shims / Ignition Module / Sensor Connections| 
-|  Notes: || **Valve Guides**: ​[[techtalk:​ih:​engmech03f#​valve_guide_changes|New valve components]] including: \\ * New shoulder-less ​intake and exhaust valve guides ​for 1000cc engines (beginning ​with crankcase number 783). New (flatlower 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).||| +|  Notes: || [[techtalk:​ih:​engmech03f#​valve_guide_changes|New valve components]] including ​new style '​shoulderless' ​intake and exhaust valve guides with new flat lower spring collars and longer inner and outer springs ​(beginning with crankcase number 783). Spring data and installation instructions also included with this bulletin. A new style transmission mainshaft ​thrust washer ​(in 4 different thicknesses) ​is used on Late 83 XL engines to control transmission mainshaft endplay ​and has no antirotation ​tang. The roll pin in the crankcase has also been eliminated. Late 83 XL ignition modules (32410-84) and sensor assemblies (32400-84) are being made with rubber rather than plastic components and will fit Early 83 engines as a set or individually ​(changing one or the other connector halves). ​Update bulletin sent to add further information to M-870||| 
-|<wrap hi>​**870A**</​wrap>​| |5-10-1983|XL|New Valve Guides / Transmission Mainshaft Shims / Ignition Module / Sensor Connections| +|<wrap hi>​**871**</​wrap>​| ​{{ :​pdf:​tsb0871.pdf |Y}} |6-7-1983|1982 and later FXR/XL \\ 1983 FXSB/​FXWG/​FLHS \\ Late 1983 FXE|Girling Rear Brake Service| 
-|  Notes: || Resending ​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.||| +|  Notes: || * The stainless steel abutment shim (41665-82) used on the 5/8" piston ​Girling rear brake calipers is now available for parts order along with detailed installation ​and bleeding ​instructions.||| 
-|<wrap hi>​**871**</​wrap>​| |6-7-1983|1982 and later FXR/XL \\ 1983 FXSB/​FXWG/​FLHS \\ Late 1983 FXE|Girling Rear Brake Service| +|<wrap hi>​**872**</​wrap>​| ​{{ :​pdf:​tsb0872.pdf |Y}} |8-18-1983|XL|Service Information| 
-|  Notes: || * 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.||| +|  Notes: || A production change beginning ​with crankcase ​number ​784174011, incorporates a new crankcase set (24527-82Aon the 1000cc series engines.||| 
-|<wrap hi>​**872**</​wrap>​| |8-18-1983|XL|Service Information| +|<wrap hi>​**873**</​wrap>​| ​{{ :​pdf:​tsb0873.pdf |Y}} |12-9-1983|All except FLH|Battery Vent Hose Clamp| 
-|  Notes: || Beginning ​with crankcase ​(#784174011)a production change ​incorporates a new crankcase set (35105-83and 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.||| +|  Notes: || Due 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 [[techtalk:​ref:​elec03a#​hose_clamp|battery hose clamp]] (10067). Also, as P&A batteries are received from the vendor, a clamp will be included with the hose.||| 
-|<wrap hi>​**873**</​wrap>​| |12-9-1983|All except FLH|Battery Vent Hose Clamp| +|<wrap hi>​**875**</​wrap>​| ​{{ :​pdf:​tsb0875.pdf |Y}} |10-11-1983|All 1982 and later motorcycles|Brake Pad Inspection| 
-|  Notes: || Due 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 [[techtalk:​ref:​elec03a#​hose_clamp|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||| +|  Notes: || A reminder that more frequent inspections should be made if the vehicle ​is ridden under more adverse conditions ​such as steep hills, heavy traffic, etc.||| 
-|<wrap hi>​**875**</​wrap>​| |10-11-1983|All 1982 and later motorcycles|Brake Pad Inspection| +|<wrap hi>​**876**</​wrap>​ \\ <wrap hi>​**876A**</​wrap>​| ​{{ :​pdf:​tsb0876.pdf ​|Y}} \\ {{ :​pdf:​tsb0876a.pdf |Y}}|1-13-1984 \\ 2-7-1984|XL/​XR-1000|Transmission Information| 
-|  Notes: || The 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.||| +|  Notes: || Revised transmission gear and shifter fork changes. Bulletin updated ​to fix a typo on TSB M-876 regarding the part number for the +.020" fork to (34292-72) instead of -84.||| 
-|<wrap hi>​**876**</​wrap>​| |1-13-1984|XL/​XR-1000|Transmission Information| +|<wrap hi>​**881**</​wrap>​| ​{{ :​pdf:​tsb0881.pdf |Y}} |3-9-1984|(FL (except FLT)/​FX/​XL|Wheel Weights| 
-|  Notes: || Gear 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||| +|  Notes: || A number of 1984 16-inch laced wheel rims were manufactured without a radius on the outer rim flange. ​As a result, the automotive type wheel weights used for factory balancing of the 16-inch laced wheels may not stay on the rim at normal operating speed.||| 
-|<wrap hi>​**876A**</​wrap>​| |2-7-1984|XL/​XR-1000|Transmission Information| +|<wrap hi>​**883**</​wrap>​| ​{{ :​pdf:​tsb0883.pdf |Y}} |3-13-1984|All 1984 models|Tire Fitment|
-|  Notes: || Resending ​to fix a typo on TSB M-876 regarding the part number for the +.020" fork to (34292-72) instead of -84.||| +
-|<wrap hi>​**881**</​wrap>​| |3-9-1984|(FL (except FLT)/​FX/​XL|Wheel Weights| +
-|  Notes: || A 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.||| +
-|<wrap hi>​**883**</​wrap>​| |3-13-1984|All 1984 models|Tire Fitment|+
 |  Notes: || Correct matching of tire, tubes and wheels||| |  Notes: || Correct matching of tire, tubes and wheels|||
-|<wrap hi>​**885**</​wrap>​| |4-10-1984|All 1984 models ​\\ (except FLH and \\ 1983 XR-1000)|Information Update| +|<wrap hi>​**885**</​wrap>​| ​{{ :​pdf:​tsb0885.pdf |Y}} |4-10-1984|All 1984 models|Information Update| 
-|  Notes: || * Front caliper mounting bolts: ​The torque ​specs for the front caiper ​mounting bolts have changed from 40-45 ft lbsto 25-30 ft lbs.||| +|  Notes: || The torque ​spec for the front caliper ​mounting bolts has been reduced on all accept FLH and 1983 XR1000. The rear axle nut torque ​specification has been increased on all 1984 models. To aid the stamping operation, the locations of the crankcase numbers were changed.||| 
-|:::||* All| * The rear axle nut torque ​specs have been changed from 45-50 ft lbsto 65-70 ft lbs. Wheel bearing endplay, however, remains the same. Bearing endplay must be checked after tightening the axle nut.|| +|<wrap hi>​**886**</​wrap>​| ​{{ :​pdf:​tsb0886.pdf |Y}} |4-6-1984|XL/​XR|Sprocket 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)|| +|  Notes: || A L84 service ​replacement mainshaft sprocket nut (35049-71) has been developed to prevent transmission oil leakage ​from the sprocket splines on 1971-E1984 models. This bulletin also includes ​instructions ​for fitment or modifying 71-E84 sprocket covers to accept the new sprocket nut.||| 
-|<wrap hi>​**886**</​wrap>​| |4-6-1984|XL/​XR|Sprocket Nut| +|<wrap hi>**891**</​wrap>​| ​{{ :​pdf:​tsb0891.pdf |Y}} |5-18-1984|All|Battery Electrolyte| 
-|  Notes: || A 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.||| +|  Notes: || Recommendation on activating new batteries ​including charging rates.||| 
-|<wrap hi>**886**</​wrap>​| |5-18-1984|All|Battery Electrolyte| +|<wrap hi>​**892**</​wrap>​| ​{{ :​pdf:​tsb0892.pdf |Y}} |6-22-1984|XL|1000cc Engines| 
-|  Notes: || Many 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.||| +|  Notes: || * Announcing the retirement of the 77-E83 oil pump assembly ​replaced by the new L83 style pump along with service instructions for retrofitting the new pump/ parts to 77-E83 pumps. (See also [[techtalk:​ih:​oil03a#​late_1983_oil_pump_assembly_design_modification|Late 1983 oil pump assembly design modification]] ). An alignment toolSNAP-ON 1650MAC LF-12or equivalent is recommended to draw the transmission trap door from the dowel pins. ||| 
-|<wrap hi>​**892**</​wrap>​| |6-22-1984|XL|1000cc Engines| +|<wrap hi>​**894**</​wrap>​| ​{{ :​pdf:​tsb0894.pdf |Y}} |9-7-1984|XL|Production Changes on XL \\ Transmission Cover \\ Alternator Stator Mounting|
-|  Notes: || * 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 [[techtalk:​ih:​oil03a#​late_1983_oil_pump_assembly_design_modification|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-12or 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.||| +
-|<wrap hi>​**894**</​wrap>​| |9-7-1984|XL|Production Changes on XL \\ Transmission Cover \\ Alternator Stator Mounting|+
 |  Notes: || 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 [[techtalk:​ih:​transfinal03#​l1984_trapdoor_34847-84|L84 cover]] is also available for parts order.||| |  Notes: || 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 [[techtalk:​ih:​transfinal03#​l1984_trapdoor_34847-84|L84 cover]] is also available for parts order.|||
-|<wrap hi>​**899**</​wrap>​| |11-30-1984|XL|Midyear Production Changes to \\ XL Pistons and Oiling System| +|<wrap hi>​**899**</​wrap>​| ​{{ :​pdf:​tsb0899.pdf |Y}} |11-30-1984|XL|Midyear Production Changes to \\ XL Pistons and Oiling System| 
-|  Notes: || 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.|||+|  Notes: || Beginning with crankcase (785 306029) manufactured after November 1, 1984, pistons have a new style cam ground, barrel shape. 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) requires a modification to be done on the piston pin retaining ring installer (HD-34623) to work on the new style pistons. 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 end oil passage to the gear mesh between first / second gears and third / fourth gears.|||
  
  
Line 1035: Line 1019:
 |901| |2-22-1985|L84 and later BTs|Diaphragm Clutch Adjustment| |901| |2-22-1985|L84 and later BTs|Diaphragm Clutch Adjustment|
 |  Notes: || Details adjusting procedure for 4 and 5 speed models.||| |  Notes: || Details adjusting procedure for 4 and 5 speed models.|||
-|<wrap hi>​**902**</​wrap>​| |6-4-1985|All|[[:​techtalk:​ref:​genmsr10#​application_from_the_moco|Locking/​Sealing Compounds]] \\  and Tire Fitment| +|<wrap hi>​**902**</​wrap> ​\\ <wrap hi>​**902A**</​wrap>​| {{ :​pdf:​tsb0902.pdf |Y}} \\ {{ :​pdf:​tsb0902a.pdf ​|Y}}|6-4-1985 \\ 12-20-1985|All|[[:​techtalk:​ref:​genmsr10#​application_from_the_moco|Locking/​Sealing Compounds]] \\  and Tire Fitment| 
-|  Notes: || List of recommended threadlocker and sealant compounds for various applications ​\\ * Correct ​matching of tire, tubes and wheels||| +|  Notes: || List of recommended threadlocker and sealant compounds for various applications.  Also includes correct ​matching of tire, tubes and wheels. The update ​bulletin ​includes ​warning ​advisories with the use of Loctite on thermoplastic parts and precautions,​ handling, exposure and treatment guidelines for working with Hylomar ​due to EPS investigations.||| 
-|<wrap hi>​**902A**</​wrap>​| |12-20-1985|All|[[:​techtalk:​ref:​genmsr10#​application_from_the_moco|Locking/​Sealing Compounds]] \\  and Tire Fitment| +|<wrap hi>​**904**</​wrap>​| ​{{ :​pdf:​tsb0904.pdf |Y}} |5-31-1985|1986 XLH 883|Pre-Delivery Setup| 
-|  Notes: || 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.||| +|  Notes: || Addition 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, checking throttle cable routing, instrument indicator lights operation and ignition timing.||| 
-|<wrap hi>​**904**</​wrap>​| |5-31-1985|1986 XLH 883|Pre-Delivery Setup| +|<wrap hi>​**905**</​wrap>​| ​{{ :​pdf:​tsb0905.pdf |Y}} |8-26-1985|All with California \\ Emissions Control|Fuel Supply Closure| 
-|  Notes: || Addition 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.||| +|  Notes: || Diagrams the 3 position petcock (main, reserve and off) and suggests ​the importance of the '​off'​ position when used with a California Emissions Control kit.||| 
-|<wrap hi>​**905**</​wrap>​| |8-26-1985|All with California \\ Emissions Control|Fuel Supply Closure| +|<wrap hi>​**907**</​wrap>​| {{ :​pdf:​tsb0907.pdf |Y}} |10-29-1985|All Models| Batteries | 
-|  Notes: || Diagrams 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.|||+|  Notes: || This service bulletin contains ​the latest recommendations for battery activation, charging, installation,​ maintenance,​ storage ​and testing. ||| 
 +|<wrap hi>​**909**</​wrap>​| {{ :​pdf:​tsb0909.pdf |Y}} |9-16-1985|All Models| Ignition Components \\ Resistance Tests | 
 +|  Notes: || Supplement ignition tests that are not contained in the service manual.||| 
 +|<wrap hi>​**910**</​wrap>​| {{ :​pdf:​tsb0910.pdf |Y}} |9-17-1985|Evo 1100cc Sportsters| Vacuum Operated \\ Electric Switch \\ (VOES) | 
 +|  Notes: || On 1986 1100cc Sportsters, a mid-year production change has rerouted ​the VOES ground wire to a different mounting location.||| 
 +|<wrap hi>​**911**</​wrap>​| {{ :​pdf:​tsb0911.pdf |Y}} |10-8-1985|XLH| Jiffy Stand Catches | 
 +|  Notes: || Some 1986 XLH models may have been assembled with "​soft"​ jiffy stand catches which may allow the square on the jiffy stand to rotate in the catch and allow the motorcycle to tip.|||
  
 ====== TSB 950-999 ====== ====== TSB 950-999 ======
 |TSB_#​|PDF?​|Date|Model(s)|Title - Short Notes (Add'l Notes on Next Line)| |TSB_#​|PDF?​|Date|Model(s)|Title - Short Notes (Add'l Notes on Next Line)|
-|<wrap hi>​**961**</​wrap>​| |4-8-1988|All|Screaming Eagle Carb Kit - Accelerator Pump Length| +|<wrap hi>​**961**</​wrap>​| ​{{ :​pdf:​tsb0961.pdf |Y}} |4-8-1988|All|Screaming Eagle Carb Kit - Accelerator Pump Length| 
-|  Notes: || A number of Screaming Eagle carb kits (91731-85A),​ packaged during March of 1988 (3/88 date code), contained carburetors with [[:​techtalk:​ref:​carb01#​accelerator_pump|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".|||+|  Notes: || A number of Screaming Eagle carb kits (91731-85A),​ packaged during March of 1988 (3/88 date code), contained carburetors with [[:​techtalk:​ref:​carb01#​accelerator_pump|accelerator pump rods]] that were too short. The incorrect pump rods completely disabled the accelerator pump and caused the engine to stumble upon fast acceleration.||| 
 + 
 +====== TSB 1000-1049 ====== 
 + 
 +\\ 
 + 
 +====== Parts and Accessories Bulletins (PAB) ======
  
 +|PAB_#​|PDF?​|Date|Subject|
 +|XX| {{ :​pdf:​pab_11-24-75.pdf |Y}} |11-24-1975|Engine Crankcase Policy|
 +| |  Notes: ​ |Procedure for ordering and replacement.||
 +|XX| {{ :​pdf:​pab_1-16-76.pdf |Y}} |1-16-1976|Sportster Rear Shock Absorbers|
 +| |  Notes: ​ |1967 thru 1974 Part #(54535-67) is replaced by part #(54547-75) and the new shock mounting conversion kit, part #​(54529-76).||
 +|21| {{ :​pdf:​pab_12-12-77.pdf |Y}} |12-12-1977|Tires and Wheels|
 +| |  Notes: ​ |Tires, Tubes, Rim Strips and Wheel Asemblies.||
  
 \\ \\