Harley-Davidson 250 & 350

MOTORCYCLE

HARLEY-DAYIDSON
250 AND 350 CC SPRINT
MODEL Sprint **C" Displacement-cc 246.2 Boremm 66 Strokemm 72 Ignition Spark plugtype H-D5-6or Autolite AG901 Electrode gapmm 0.5-0.6 0.5-0.6 0.5-0.6 0.5-0.6 Inch 0.020-0.025 0.020-0.025 0.020-0.025 0.020-0.025 Pointgapmm 0.46 0.46 0.46 Inch 0.018 0.018 0.018 * Valve clearance (cold) Intakemm 0.1 0.08 0.5 0.5 Inch 0.004 0.003 0.002 0.002 Exhaust^mm 0.1 0.13 0.5 0.8 Inch 0.004 0.005 0.002 0.003 Electrical system voltage 6 6 6 12# Battery terminal grounded Negative Negative Negative Negative Tire sizefront 3.00-17 3.00-18 3.25-19t 3.25-19** Rear 3.00-17 3.50-18 3.50-18 3.50-18** Tire pressure Front^kg/cm2 1.4 1.3 1.3 1.3 Psi .. 20 18 18 18 Rear-kg/cm= 1.7 1.3 1.6|1.^* Psi .. 24 18 22t 18^* Rear chain free playmm 13 13 13 13 Inch y^ y^ ^ ^^ Number of speeds 4 4 4 5TT *Point gap should be 0.46mm (0.018 in.) for models prior to 1973 and 0.4mm (0.016 in.) for models after 1972. tTire size and pressure for Sprint "H" models 1967-1968 same as Sprint "H" models prior to 1967. #Models prior to 1973 equipped with 6 volt systems. **Tire size and pressure for Sprint "SS" models after 1968 same as Sprint "SS" models 1967-1968. ft Models prior to 1974 equipped with four speed transmission. Illustrations courtesy AMF/Harley-Davidson Motor Co. Sprint "H" Prior to 1967 246.2 66 72 Sprint "H" Sprint "SS" 1967-1968 248.4 72 61 Sprint "SS" & "SX" After 1968 344 74 81

MAINTENANCE SPARK PLUG. Recommended spark plug for normal use is HarleyDavidson No. 5-6 or Autolite AG901. Spark plug electrode gap should be 0.020-0.025 inch.

Main Jet Model Early 1961 "C" 1962 "H" Late 1961-1966 "C" 1963-1966 "H" 1967-1968 "H" & "S" 1969-1972 "SS" 1971-1972 "SX" SS" & "SX" After 1972 Jet Size 1.08mm 1.00mm 1.05mm 1.18mm 1.25mm

CARBURETOR DerOrto UB type carburetor is used on pre-1969 models. Later models are equipped with square slide DerOrto car^buretor. Idle speed is adjusted by turning stop screw (10 Fig. HD4-1 or Fig. HD4-1A). Make certain lock nut (9Fig. HD4-1) is tight- idle Jet ened after adjustment is complete. Idle mixture is adjusted at needle (8). Model Normal setting for idle mixture needle 1961-1968 All Models IS %-tum open. Clip (6) should nor- i969.Early 1971 "SS" mally be positioned m center groove m AfterEarly 1971"SS"&"SX" needle (7). Float level on pre-1969 models can be checked as shown in Fig. HD4-2. Distance between straight edge and float lever should be 13/64-15/64 Starter Jet inch. Refer to Fig. HD4-3 for float level on later models. Refer to the following Model for correct jet sizes and equivalent drill 1969-1972 "SS" & "SX" After 1973 "SS" & "SX" bit size.

Jet Size 0.5mm 0.55mm 0.45mm

l Throttle cable 4. T h i 12. Nozzle (atomizer) 15. Fiber washers

el cu

0.6mm 0.7mm

^ n.
22!

70

SERVICE

Harley-Davidson 250 & 350

} ^

Fig. HD4-3-Fioat height (H} on models after t968 should be 31132 inch.

Fig. HD4-6-Vaive clearance Is measured between rocker arm and valve stem with engine cold. Adiusting screws (i) are iocked by nuts (2).

1 8
Fig. HD4-1 A-Expioded view of square silde Del'Orto carburetor used on models after 19S8. 1. Cahle adjuster 12. "O"ring 2. Cap 13. Starting jet 3. Spring U. Inlet fuel valve 4. Jet needle clip 15. Idle jet 5. Throttle slide 16. Needle jet 6. Jet needle 17. "O"ring 7. Starter plunger 18. Float bowl 8. Float pin 19 Gasket 9. Float 20. Main jet 10. Idle speed screw 21. Jet holder 11. Idle mixture screw 22. Fuelinlet

or by inserting a washer under the cam retaining screw (3Fig. HD4-4). Refer to the following chart for timing specifications in crankshaft degrees and piston position: Model Year 1961 1962-66 1967-68 1969-72 1973-74 Retarded BTDC 2170.250 in. 5 570.015 in. 770.005 in. 1270.044 in. Advanced BTDC 4170.406 in. 4170.406 in. 3570.250 in. 2870.219 in. 3470.338 in.

Fig. HD4'4'View of ignition timer (breaker points assembly). Factory timing marks are shown at (7). 2. 3. 4. 5. Cover Cam retaining screw Lockwasher Washer (1961 models) 6. 7. 8. 11. Base plate screws Timing marks Ignition cam Brea] point base iker plate

13/64" TO 15/W"
STRAIGHT EDGE

Fig. HD4-2'Float level Is measured as shown. If height Is Incorrect, float lever can be bent.

IGNITION AND ELECTRICAL. Models prior to 1973 are equipped with a 6 volt generator while later models are equipped with a 12 volt alternator. All models are equipped with a battery ignition with the breaker points located under a small cover on the right side cover. Breaker point gap should be 0.46mm (0.018 in.) for models prior to 1973 and 0.4mm (0.016 in.) for models after 1972. Ignition timing is adjusted by loosening breaker plate retaining screws and rotating breaker plate. Dynamic timing of ignition on models prior to 1971 is accomplished by removing tachometer drive on left side cover or left side cover and attaching a

degree wheel to the end of the crankshaft. Using a suitable mark, position degree wheel to coincide with piston at TDC on compression. To dynamically time ignition on 1971 and 1972 models, remove tachometer drive cover from left side cover and attach a degree wheel to end of crankshaft. Ignition timing may be checked on 1971 and 1972 models by removing access plug in crankcase and directing timing light into hole. Timing mark on crankshaft and crankcase should be aligned at engine speed of 5000 rpm. If ignition timing is not correct, remove tachometer drive cover and attach a degree wheel to crankshaft and follow the previous ignition timing procedure to set ignition timing. Ignition timing on models 1973 and 1974 may be checked with a timing light by removing plug in left side cover and noting alignment of '*R** (retard) and "A" (advance) timing marks. Pointer and **A" mark should be aligned at approximately 5000 rpm. Ignition may be timed statically in retard and advance positions. Ignition is normally retarded and may be checked in advanced position by holding weights outward with a wedge

VALVE SYSTEM. The valves are actuated by a camshaft located in the crankcase via, cam followers, push rods and rocker arms. Clearance between rocker arm and valve stem should be set with engine cold. Clearance for both valves for all Sprint "C" models should be 0.1mm (0.004 in.). For Sprint "H" models prior to 1967, exhaust valve clearance should be 0.13mm (0.005 in.) and inlet valve clearance should be 0.08mm (0.003 in.). Clearance for both valves of 1967 and 1968 "H" and "SS" models should be 0.5mm (0.002 in.). Valve clearance for "SS" and "SX" models after 1968 is 0.8mm (0.003 in.) for the exhaust valve and 0.5mm (0.002 in.) for the intake valve. Refer to Fig. HD4-6. LUBRICATION. The engine and gear box are lubricated by 2 quarts of oil contained in the crankcase. Recommended oil is Harley-Davidson grade 105 above 75 degrees F., H-D 75 between 40 degrees and 75 degrees and H-D 58 oil below 40 degrees. Oil should be changed and filter (Fig. HD4-7) cleaned every 1000 miles. Oil level should be maintained between marks on filler plug dipstick. Filler plug should not be screwed in when checking oil level. The oil pump used on models before 1964 is shown in Fig, HD4-8. Gears (14

71

Harley-Davidson 250 & 350 REPAIR

CYLINDER HEAD AND VALVES.
The cylinder head can be removed without removing engine. Valves can be removed from cylinder head without removing rocker arms on pre 1967 models. Rocker arms can be removed after removing covers and set screws (43_Fig. HD4-15). Note position of rocker arm thrust washers (31) and spring washers (30). Spring washer (30) is between thrust washers (31) on valve side of inlet rocker arm and push rod side of exhaust rocker arm. Make certain oil passage (H) in inlet rocker arm cover (27) is clean. Refer to the following speciflcations and Fig. HD4-15. Valve Springs Model Free Length Length @ Pressure
Model "H" 1962-63 Inner spring 1.64 in. 1.3 in. (ct 28 lbs. Outer spring 1.77 in. 1.42 in. @ 55 lbs. All other models prior to 1968 Inner spring 1.64 in. 1.28 in. @ 25 lbs. Outer spring 1.77 in. 1.42 in. @ 50 lbs. 1969-1972 models Inner spring 1.64 in. 1.36 in. @ 18 lbs. Outer spring 1.77 in. 1.5 in. @ 42 lbs. 1973-1974 models Inner spring 1.61 in. 1.3 in. @ 33 lbs. Outer spring 1.69 in. 1.35 in. @ 57.4 lbs.

MOTORCYCLE

1. 2. 3. 4. 5. 6. 7. 8.

Drain plug Gasket Inner screen Outer screen Filter spring Magnetic plug Gasket Filter screen (1963 and Earlier)

Fig. HD4'7-Oil filter screens shouid be cleaned every 1000 miles. Scavenger filter (8) is used on modeis before 1964.

& 16) supply pressure for lubrication and scavenger pump gears on shafts (13 & 17) return oil to the crankcase. On 1964 and later models, the scavenger section is omitted as shown in Fig. HD4-9. Gear (3Figs. HD4-8 and HD4-9) is driven by the crankshaft timing gear. Both types of pump can be removed after removing drive gear and pump securing bolts (6). CLUTCH CONTROLS. The clutch cable should be adjusted to provide the hand lever with free play equal to VB-V^ of its total movement. Adjustment is provided at both ends of cable. SUSPENSION. Each front suspension unit contains 4^A fl. oz. of HarleyDavidson Sprint Fork Oil. Units can be drained at plug (7Fig. HD4-11) and refilled at plug (2). NOTE: If front suspension is disassembled and cleaned with solvent, each unit should be serviced with 5 fl. oz. of oil. To remove snap ring (11), it may be necessary to drill or saw fork tube (9) as shown in Fig.HD4-12.
1812 14 20 5 4

Fig. HD4-11-Exploded view of typical Sprint front suspension assembiy. Later modeis are equipped with bail bearings on steering stem. 2, 4. 5. 6. 7. 6, 9, 10. 11. 12. 13. 14. 15. 16. 17. 19, 20, 21, 22, Plug, washer & seal Spring Screw Washer Drain screw Seal Main tube Buffer spring Snap ring Damper valve body Washer Damper valve Snap ring Damper piston Damper tube Snap ring Seal Seal Slider 23. Steering dam pier knob 24. Lock 25. Stem nut 27. Upper bracket 30. Stem 34. Cotter pin 35. Nut 36. Spring washer plate 37. Spring washer 40, Anchor plate 41, Friction disc 43. Bearing cone 44. Bearing balls (25 used) 45. Bearing balls (25 used) 46. Bearing cone 47. Bearing cups

Valve face and seat angle 45 Valve seat width 1/16-in. Valve stem to guide clearance Inle^-After 1968 0.001 in. Priorto 1969 0.0015in. Exhaust 0.002 in. Shafts (33) to bushings (32) clearance 0.0005-0.0015 in. Valve guides (12 & 26Fig. HD4-15) and bushings (32) can be pressed out after cylinder head is heated to 250*" F. Bushing (32) for left end of inlet rocker arm shaft must have 0.118 inch diameter oil hole drilled. All bushings must be line reamed after installation for correct clearance to shafts. Valve guides with 0.001, 0.002, 0.003, 0.004, 0.006 and 0.008 inch oversize outside diameter are available for service. Valve seats (11 & 25) are NOT interchangeable. Valve seats can be removed and installed with cylinder head heated to 540 F. When reassembling, make certain that spring washer (30) is on valve side

J
191615

of inlet rocker arm and on push rod side of exhaust rocker arm. Spring washer (30) should be between thrust washers (31) and at least one thrust washer should be at other end of rocker arm. Additional thrust washer can be in-

19 1713

Fig. HD4-8-Expioded view of oii pump used or. 1963 and eariier Sprint models. Scavenge gears are on shafts (13 A 17) and pressure gears are at (14S.16). Nut Lockplate Drive gear Connector fitting Copper washers Retaining screws (4 used) 7. Lock plates (4 used) 9. Scavenge line 10. Gasket 1. 2. 3. 4. 5. 6. U. 12. 13. 14. 15. 16. 17. 18. 19. 20. Outer cover Inner cover Drive shaft Pressure gear Drive key Pressure gear Idler shaft OrinB Dowel pins Pump body Notch with hacksaw. Must remove ali burrs on inside and outside of tube.

Drill 3 / 3 2 " hole above snap ring. DO NOT DRILL THRU TUBE. Remove snap ring. Remove all burrs.

Fig. HD4-9-Expioded view of oil pump used on 1964 and later Sprint modeis. No scavenger pump is used. Refer to Fig, HD4-8 for legend.

Fig. HD4-12~Snap ring (11) must be removed before damper valve body (12) can be withdrawn from tube (9). Make certain all burrs are removed.

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SERVICE

Harley-Davidson 250 & 350

INTAKE AND EXHAUST L600 MINIMUM . 1.650 MAXIMUM

28

35 32
\

31 30 31

SEAT WIDTH APPROX. 1/16 IN. MODEL C IN. 1.259 in. EX. l.Q23in. IN. 1.545 in. EX. 1.348 in. MODEL H 1.339 IN. 1.023 IN. 1.S25 IN. 1.348 IN.

Fig. HD4'16-When distance from end of valve stem to valve guide shoulder exceeds f .650 Inch wtth new vatve Installed, valve seat must be renewed.

Fig. HD4-17~Condltlon of the connecting rod and tower end (crankpin) bearing can be checked by measuring connecting rod shake as shown. If Fig. HD4-1 S-Expioded view of earty modei cyttnder head assembty. Cam fotiower bushings (S) and stde play at connecting rod smait (ptston pin) camshaft bushing (37A) used on 1963 and eariier modeis must be reamed after tnstattatton. On 1964 end exceeds 1116 Inch, crankpin, connecting rod and bearing shouid be renewed. and iater modeis, needie bearing (37B) is used. Camshaft gear Woodruff key Camshaft Exhaust cam follower Bushings Exhaust push rod Adjusting screw Lock nut Exhaust rocker arm Exhaust valve Exhaust valve seat Valve guide 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Spring seat Inner springs Outer springs Valve caps Keepers Exhaust valve cover O rings Oil return pipe Inlet cam follower Inlet push rod Inlet rocker arm
24. 25. 26. 27. 28. 29.

40

30. 31. 32. 33.

Inlet valve Inlet valve seat Inlet valve guide Inlet valve cover Rocker arm oil tube Adjusting screw cover Spring washers Thrust washers Shaft bushings Rocker arm shafts

37A. Bushing 37B. Needle bearing and outer race 38. Thrust washer 39. Ball bearing 40. Crankshaft Dushing 42. Camshaft support 43. Rocker arm set screws

34. Flange (2 used) 35. Oiler flange (2 used) 36. Carburetor flange

stalled at either end to center rocker arm over valve stem and partially compress spring washer (30). The inside cam follower (21) is for the inlet valve. Make certain that rocker arm screws (43) are tightened into holes in rocker arm shafts. Cylinder head retaining nuts should be torqued to 25 Ft.-lbs. Refer to previous paragraph in MAINTENANCE section for setting valve clearance. PISTON, RINGS AND CYLINDER. The cylinder can be removed after first removing the cylinder head

as outlined in previous paragraph. Refer to the following specifications for piston, rings, cylinder and piston pin. Standard cylinder bore diameter Early 250cc 2.5984 in. (66mm) Late 250cc 2.835 in. (72mm) 350cc 2.913 in. (74mm) All piston rings End gap 0.010-0.016 in. Side clearance in groove 0.001-0.002 in. Piston pin to bushing (in connecting rod) Clearance 0.006-0,0012 in. wear limit 0.002 in.

Piston pin to piston Clearance . . , light press fit @ 70 F. Piston to cylinder clearance 1969 models 0.004 in. All other models . . . ! 0.002 in. Connecting rod side play (shake) should be measured as shown in Fig. HD4-17. If total side play at piston pin end exceeds 1/16-inch, crankpin, connecting rod and bearings should be renewed. Oversize pistons and rings are available.

CAMSHAFT AND TIMING

GEARS. To remove timing gear cover (right side cover), drain crankcase oil or lay motorcycle on left side so oil will not drain out when cover is removed. The clutch on models after 1968 must be removed before the cover can be removed. Ignition breaker point cam retaining screw (3Fig. HD4-3) must be unscrewed on all models. Clutch release lever on models prior to 1969 73

Harley-Davidson 250 & 350

must be rotated forward when removing cover. Be careful not to damage sealing surfaces of cover or crankcase. With piston at top dead center on compression stroke, camshaft support (found on 1968 and earlier models only) and camshaft can be removed. Before the crankshaft timing gear is removed, the position of the woodruff key (4 Fig. HD4-19) in crankshaft (10), and crankshaft gear (8 or 8A) should be marked. NOTE: There are three keyways in crankshaft and gear. If key is improperly installed, camshaft timing may be incorrect. To remove the crankshaft primary drive gear, it is necessary to remove the oil pump gear, camshaft, crankshaft timing gear and pull the drive gear from the crankshaft taper. Camshaft end play should be 0.001-0.004 inch on models prior to 1973 and 0.004-0.008 on models after 1972 and is adjusted by varying washers (38Fig. HD4-15). When reassembling, observe the following. Thoroughly clean all oil and dirt from end of crankshaft, especially tapered section, and inside of gear (8 or 8AFig. HD4-19). On early 1961 models, the take-up gear (6) should be rotated 3 teeth counter-clockwise before meshing teeth with clutch gear. This will properly preload gear (6) by spring (7). Make certain that woodruff key (4) is installed in previously marked keyway and install gear with correct keyway in gear on woodruff key. NOTE: If marks were not previously affixed to crankshaft and gear, crankshaft must be set at Top Dead Center and woodruff key installed in crankshaft keyslot pointing toward camshaft mount (BFig. HD4-20) on all models except 1964 thru 1968. These models should have key installed in lower key slot (A) with crankshaft at TDC. In any case, camshaft drive gear on crank should be installed with timing mark aligned as in Fig. HD4-18 with crankshaft at TDC. Nut (1Fig. HD4-19) should be tightened to 35 Ft.-lbs. of torque.

MOTORCYCLE

10 4

15 14

Fig, HD4-22'Exploded view of kickstarter assembly, Kickstarter ratchet assembly (9 thru 15) Is located on left end of transmission malnshaft (19-Fig.HD4-28).

Fig. HD4-19-View of crankshaft gears. Take up gear (6), thrust washer (5), spring (7) and narrower gear (8) are used on early 1961 models only. Late 1961 and all other models use only gear (8 A).
1. Nut 2. Lockplate 3. Crankshaft timing gear 4. Woodruff key 9. Snap ring 10. Crankshaft right end

3. Kickstarter pedal 4. Acorn nut and washer 5. Stop bumper 6. Stop stud 7. Gear 8.'Return spring 9. Snap ring

10. 11. 12. 13. 14. 15. 21. 22.

Spring seat Ratchet spring Ratchet Ratchet gear Snap ring Ratchet gear bushing Pedal shaft bushing SDrine dowel pin

CRANKSHAFT

AND CON-

NECTING ROD. The condition of the connecting rod lower end (crankpin) bearing can be checked as shown in Fig. HD4-17 after cylinder head, cylinder and piston are removed. The crankshaft and connecting rod assembly can be removed as follows after the complete engine assembly is removed from the frame. Remove the cylinder head, cylinder, and piston. Remove the crankcase left side cover, the complete generator assembly, starter ratchet assembly (9, 10, 11, 12, 13, 14 & 15Fig. HD4-22) and drive sprocket from left side of crankcase. Remove the right side cover, camshaft, oil pump and crankshaft gears. NOTE: Observe the precautions outlined in previous paragraph before removing crankshaft gears. Remove clutch assembly on early models, and gear shifter pawl.

Remove snap ring (9Fig. HD4-19) from right end. Remove the seven cap screws and three socket head screws which attach crankcase halves together and separate halves. NOTE: One socket head screw is located under breather on left side as shown in Fig. HD4-23. Do not damage crankcase sealing surfaces when separating halves. The remainder of removal procedure is self-evident. Refer to Fig. HD4-24 for exploded view of crankshaft assembly. A press of approximately 10 ton capacity is required to press crankpin (5 or 5A) out of flywheels. Oil hole in crankpin must be aligned with hole in flywheel (1). Connecting rod side clearance between flywheels should be 0.0005-0.0010 inch. The crankshaft should be disassembled ONLY if tools required to check and align reassembled crankshaft are available. Crankshaft eccentricity should not exceed 0.001 inch when measured at main bearing journals as close as possible to flywheels with crankshaft supported at ends in lathe centers.

Fig. HD4-2thiew of proper position for cam gear woodrun key for 1964 thru 1968 models (A) and ali other models (B). Cranknhaft is at TDC on both versions.

Fig. HD4-18^iew with right side cover removed and timing marks aiigned.

74

SERVICE
Orifice plug (12 Fig. HD4-24) should be installed on all Sprint "H" models and Sprint "C " models after 1962. Orifice plug and oil passage to crankpin must be open to properly lubricate connecting rod bearing. Diameter of orifice opening is 0.0595 inch (Drill size 53). CLUTCH. The clutch assembly used in 1968 and earlier models (Fig. HD426) can be removed after crankcase right side cover is removed. Use appropriate tool to compress clutch spring (12) and remove snap ring (1). Clutch discs and plates assembly (4) can be removed. Clutch spring (12) should have a free length of 1 29/32 inch and should be renewed if less than 1 13/16 inch. On 1963 and earlier models, spring (12) should exert 223 lbs. when compressed to 1.12 inch. On 1964 and later models, spring pressure should be 265 lbs. when compressed to 1.12 inch. Clutch assembly used in 1969 and later models is shown in Fig. HD4-27. Primary gear (20) can be removed after disassembling and removing clutch assembly and right side cover. Clutch is dry type and seal in side cover should be inspected for damage. Inspect friction discs for uneven wear or fractures. Springs (2) should be renewed if less than iy2 inches long. When reassembling, observe the following. On early models equipped with take-up gear (6Fig. HD4-19), gear (6) should be rotated counter-clockwise three teeth to pre-load spring (7) when meshing clutch drum gear with crankshaft gear. Vary the thickness of shims (15BFig. HD4-26) so that clutch drum (16) has just slight end play on shaft. Install hub (15) with small hole hub facing out. On late model clutch.
Fig. HD4'24-Expioded view of crankshaft assembly. Crankpin bearing (4A, 4B & 54; Is type used on late modets. 1. Right side flywheel 2. Thrust washers (2 used) 3. Connecting rod 4. Roller bearing (early models) 4A. Retainer 4B. Rollers (24 used) 5. Crankpin (early models* 5A. Crankpin 6. Left side ny wheel 7. Piston pin bushing 8. Oil seal 9. Ballbearing 10. Snap ring 11. Ball bearing 12. Orifice plug (late models)

Harley-Davidson 250 & 350

4B 4A

5A

Fig. HD4'26-Exploded view of dutch assembty used in 1961 thru 1968 modets. Spacer (19) is used on 1961 models onty and keys (ISA) are used on 1962 thru 1968 modeis. 1. 2. 3. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 15A. Snap ring Release bearing cap Ball release bearing Nuts (4 used) Lock plates (4 used) Release disc Outer disc Friction discs (4 used) Drive plates (4 used) Pressure plate Clutch spring Nut Lock plate Hub Hub keys (1962 and later)

1819 19 26 1 12 25

15B 1

15B. 16. 17. 18. 19. 20. 21.

Shims Clutch drum Drum bearing (2 used) Snap rings (2 used) Spacer (1961 only) Nut Lock washer

22. 23. 24. 25. 26.

Release cam Snap ring Oil seal Release lever Spacer (Use only on early models with narrow gear on drum 16)

install fiber backed steel plate (7Fig. HD4-27) first with steel side against bottom of drum (18). Install sufficient shims (22) behind primary gear (20) to obtain 0.004-0.008 inch clutch assembly end play. Remainder of assembly procedure is self-evident. Adjust clutch cable as outlined in paragraph in MAINTENANCE section. TRANSMISSION. Models prior to 1973 are equipped with a four speed transmission while all models after 1972 are equipped with a five speed transmission.

Transmission gears and shafts are accessible after separating crankcase halves as outlined in previous paragraph CRANKSHAFT AND CONNECTING ROD. Gears (16 or 16A, 17, 22, and 23-~Fig. HD4-28 or 18Fig. HD4-29) must be pressed from their respective shafts. NOTE: Gears are tight press fit on shafts and should be pressed from shafts one at a time. Bushings (18A, 20A and 24AFig. HD4-28 and 28Fig. HD4-29) must be reamed after installation in gears to provide 0.001-0.002 inch clearance on shafts. When assembling transmissions prior to 1973, second gear (24 Fig. HD4-28) must be installed with
Fig. HD4-27-Exploded view of dutch assembty used In later models. 1. Spring nut 2. Spring 3. Spring holder 4. Pressure plate 5. Friction disc 6. Steel plate 7. Fiber & steel plate 8. Lock nut 9. Clutch adjuster 10. Ball 11. Push rod 12. Nut 13. Tab washer 14. Hub 15. "O"ring 16. Nut 17. Tab washer 18. Clutch drum 19. Washer 20. Primary driven gear 21. Roller bearings 22. Shims 23. Washer

Fiy .^.j-One socket head screw attaching crankcase halves together is iocated on ieft side as shown.

12 13 14 15 16 17 18 19 20 21 22 23

75

Harley-Davidson 250 & 350

Fig. HD4-2B-Expioded view of four speed transmission assembly used on HarieyDavidson 250 cc Sprint models. Late (350 cc) models are equipped with needie bearings instead of bushings (2eA).

MOTORCYCLE
recess on gear away from splines. Teeth on third gear (23) should be toward second gear (24). Teeth on fourth gear (22) should be away from third gear (23). Install first gear (20) with recess away from shift clutch (21) and third gear (18) with recess away from mainshaft splines. Teeth on second gear (17) should be toward third gear (18). First gear (16 or 16A) must be installed with bearing side out. Install sufficient shims (16C) on late 19621972 models to obtain zero mainshaft end play. When assembling transmission on models after 1972, install third gear (12Fig. HD4-29) with lugs out and install fourth gear (10) with shift fork groove towards lugs on third gear. Install fourth gear (20) with lugs to inside and fifth gear (18) with flat side out. Third gear (22) must be installed with shift fork groove towards fourth gear (20). Install shift clutch (26) with flat side next to second gear (24). Countershaft end play should be 0.004-0.008 inch. To measure end play, install countershaft assembly in crankcases with original washer (29Fig. HD4-29 or a 1.0mm washer placed on the end of the countershaft. Do not install a washer on models prior to 1971. Gasket must be installed between crankcase halves. Measure end play and install necessary shims (2Fig. HD4-28 or 17Fig. HD4-29) to obtain desired end play. Free length of cam plunger spring (10Fig. HD4-28 or 42Fig. HD4-29) should be 1.535 inch. Shift cam bushings must be reamed to provide clearance of 0.0005-0.0015 inch between bushings and shift cam. Shift fork clearance on shift cam should be 0.0010.0015 inch. Install necessary shims (13_Fig. HD4-28 or 37Fig. HD4-29) to obtain equal clearance with transmission in neutral between lugs of shift clutch (21Fig. HD4-28) and gears (20 and 24) on models prior to 1973, or to obtain equal clearance between lugs of third gear (22) and gears (20 and 24) on models after 1972. Shift cam end play should be 0.0040.008 and is adjusted by varying number and/or size of shims (1Fig. HD4-28 or 31Fig. HD4-29). Sprocket gear bushing (26AFig. HD4-28) on models prior to 1969 must be reamed after installation in gear to provide 0.0005-0.0015 inch clearance on mainshaft (19), Install sufficient shims (27Fig. HD4-28 or 4Fig. HD4-29) to obtain sprocket gear end play of 0.008-0.010 inch. End play of all shafts should be checked after transmission has been completely assembled.

Shifter cam spacer (small) Countershaft thrust washer Cotter pin (2 used) Shifter fork pin (2 used* Shifter fork (2 used) H. Plug 9. Washer 10. Spring II. Cam stop plunger 12. Snap ring l.H. ShifttT cam spacer (largeI 14. Shifter cam 15. Shifter clutch 16. Muinshafl first gear (17 teeth) 16A. Mainshaa first gear (late 1962) I6B. Snap ring (late I962i 16C. Shim (Late 1962) 17. Mainshadt second gear (23 teeth I Mainshafl third gear (27 teeth) 18A. Bushing 19. Main.shaft 20. Countershaft first gear (33 teeth) 20A. Bushing 21. Shifter clutch 22. Countershaft fourth gear (16 teeth I 23. (Countershaft third gear (23 teeth I 24 Cfiuntershaft second gear (27 teeth I 24 A. Bushing 25. Counter.Hhaft Spriickct gi'ar(24 teeth i Bu.shin^,'(2used)
1. 2. 3. 4. 6.

32

27. 28. 29. 30. 30A. 31.

Spacer Sprocket spacer Oil seal Bearing Snap ringf Late 1963) Bearing

31 A. Right mainshaft bearing retainer (Late 1962) 32. Bearing 33. Bearing 34. Shifter cam bushing 35. Shifter cam bushing

Fig. ,HD4'29-Exploded view of five speed transmission used on models after i 972.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

23.

24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41.

Spacer Oil seal Ball bearing Shim Sprocket gear Wire ring Bushing Spacer ^(eedle bearing Mainshaft fourth gear Lock ring Mainshaft third gear Mainshaft Shim Bearing retainer Ball bearing Shim Countershaft fifth gear Lock ring Countershaft fourth gear Countershaft Countershaft third gear Lock ring Countershaft second gear Washer Slider clutch Countershaft first gear Bushing Shim Bushing Shim
Pin

Second & fourth shift fork Third &fifthshift fork First shift fork Snap ring Shim Bushing Shift cam Plug Washer 42. Spring 43. Shift cam stop plunger

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