SHEET METAL AND EQUIPMENT
Paragraph
Chain guards 102
Carriers 103
Mudguards 104
Battery box 105
Tool box 106
Tanks 107
Stands 108
Saddle post 109
Safety guards 110
Skid plate 111
102. CHAIN GUARDS.
=a. Remove Outer Front Chain Guard= (figs. 68 and 69).
(1) Remove nut and washer which secures center of chain guard and skid
plate left‐side support bracket.
(2) Loosen skid plate support bracket lower bolt and nut and remove
bracket from stud.
(3) Loosen the nut which secures footboard rear stud to sidebar, then
remove nut which secures footboard front stud to sidebar. Pull front
end of footboard away from sidebar so that stud will clear end of
safety guard.
(4) Remove extended nut which secures sidebar to frame front support
rod.
(5) Disconnect clutch control cable end at clutch foot pedal by
removing cotter pin and plain washer from stud.
(6) Left side footboard, sidebar, and clutch foot pedal assembly can
now be removed. If rear end of sidebar is lowered, the front end will
clear end of safety guard.
(7) Remove cotter pin, nut, spring, washer, and bolt from chain guard
rear mounting. Outer front chain guard can now be removed, exposing
engine sprocket, front drive chain, and clutch assembly.
=b. Install Outer Front Chain Guard.=
(1) Locate outer front chain guard on center support stud (frame rear
support rod end). Line up rear mounting bracket with frame bracket.
(2) Install bolt, washer, spring, nut, and cotter pin to secure rear
mounting.
(3) Install footboard, sidebar, and clutch foot pedal assembly on frame
support rod ends.
[Illustration: RA PD 310264
_Figure 68—Left Footboard Assembly Removed_]
[Illustration: RA PD 315729
_Figure 69—Outer Front Chain Guard Removed_]
(4) Attach front end of sidebar. Install extended nut and lock washer
to secure front sidebar and support rod mounting.
(5) Install skid plate support bracket on support rod (in center of
chain guard), tightening nut on bolt. Install nut and lock washer which
secure skid plate bracket and chain guard on rear support rod. Tighten
nut.
(6) Pull front end of footboard away from sidebar so that hole in end
of safety guard lines up with hole in sidebar, then pass footboard stud
through both pieces, installing washer and securing stud nut. Tighten
footboard rear stud nut.
(7) Attach brake control cable end to foot pedal stud.
=c. Remove Rear Chain Guard.=
(1) Remove cap screw which secures rear chain oil pipe clamp, and
provides mounting for front end of chain guard on transmission sprocket
cover. Remove chain guard.
(2) Remove chain guard from rear mounting by pushing the guard back so
that stud (with washers and spring) slips out of mounting clip notch.
=d. Install Rear Chain Guard.=
(1) Locate rear chain guard in position for mounting. Spread the large
washer on the rear stud to engage clip notch. Push guard forward until
front end hole lines up with chain oiler pipe clamp, then install cap
screw and washer, securing guard and clip to sprocket cover.
103. CARRIERS.
=a. Remove Ammunition Box Carrier.=
(1) Remove nut and screw which secures carrier bracket to front
mudguard.
(2) Remove nut and lock washer from rocker plate rear stud. This frees
lower end of carrier.
(3) Remove nut, washer, cable clip, and plain washer from rigid fork
stud. Remove carrier and box.
=b. Install Ammunition Box Carrier.=
(1) Locate hole in lower end of bracket on rocker plate rear stud.
Attach upper end of bracket to rigid fork stud. Replace lock washers
and nuts. Tighten nuts.
(2) Attach carrier bracket to front mudguard with screw, washer, and
nut. Tighten nut.
=c. Remove and Install Scabbard Carrier.= The procedure for removing
and installing scabbard carrier is the same as outlined for ammunition
box carrier, except that scabbard carrier is on left side of vehicle.
Follow procedure outlined under steps =a= and =b= above.
=d. Remove Luggage Carrier.=
(1) Loosen straps of both saddlebags, and remove saddlebags from
keyhole notches in luggage carrier side plates. Remove nuts from right
and left side mounting studs, which secure luggage carrier to frame
clips. Deflate rear wheel tire so that a piece of wood or suitable
object can be used to depress top part of tire under mudguard, to
provide clearance, and access to the three nuts which secure screws for
luggage carrier mudguard mounting. NOTE: _If rear wheel is removed,
mounting screws are accessible._
(2) Remove the three luggage carrier center mounting screws. Remove
luggage carrier from vehicle.
=e. Install Luggage Carrier.=
(1) Mount luggage carrier on frame clip studs. Install washers and
nuts. With rear tire deflated and depressed for clearance under
mudguard, install the three screws, lock washers, and nuts for
carrier‐mudguard mounting. NOTE: _If rear wheel is removed, mounting
screws are accessible._
(2) Tighten frame stud nuts to secure both sides of carrier.
(3) Attach saddlebags and securely strap to frame stays.
(4) Inflate tire to 20 pounds.
104. MUDGUARDS.
=a. Remove Front Mudguard.=
(1) Remove front wheel (par. 125).
(2) Remove instrument panel cover (par. 119), disconnect front mudguard
blackout marker light wire at switch. Pull wire out, free from tanks.
(3) Remove the two screws and nuts from rigid fork and mudguard
mounting. Remove the two screws and nuts securing lamp bracket to
mudguard.
(4) Remove bolt and nut which secure ammunition box carrier to mudguard.
(5) Remove bolt and nut which secure gun scabbard carrier to mudguard.
(6) Remove nuts from fork left rocker plate stud. These nuts secure
ammunition box lower bracket, and mudguard stay clip. Remove nuts from
fork right rocker plate stud. These nuts secure gun scabbard carrier
lower bracket, and mudguard stay clip.
(7) Pull carrier brackets off rocker plate studs. Remove mudguard brace
clip locks from slots in clips so that mudguard can be dropped. When
removing mudguard from vehicle, take care not to break and/or damage
blackout light wire.
=b. Install Front Mudguard.=
(1) Locate mudguard in mounting position. Engage slots in stay clips
on rocker plate studs, installing the special locks in the clip slots.
NOTE: _Brace clip locks are made for right and left side installation.
Secure both clip locks with stud nuts._
(2) Attach ends of ammunition and scabbard carriers to rocker plate
studs. Secure with lock washers and nuts.
(3) Mount mudguard to rigid fork bracket. Tighten the two screws,
washers, and nuts.
(4) Attach lower end of headlight bracket to mudguard with two bolts,
washers, and nuts.
(5) Attach ammunition box carrier bracket to mudguard. Tighten bolt,
washer, and nut.
(6) Attach gun scabbard carrier bracket to mudguard. Tighten bolt,
washer, and nut.
(7) Reinstall front wheel and brake assembly (par. 125).
(8) Connect mudguard blackout light wire to switch terminal. Refer to
wiring diagram, figure 73.
(9) Install instrument panel cover (par. 119).
=c. Remove Rear Mudguard.=
(1) Support vehicle on rear stand. Remove rear wheel (par. 127).
(2) Remove luggage carrier (par. 103).
(3) Remove rear chain guard (par. 102).
(4) Remove the two U‐bolt nuts which mount safety guard at upper frame
bracket. Then pull safety guard away from studs and remove studs from
frame bracket, freeing mudguard at this point. NOTE: _These two studs
screw into a “plate” nut._
(5) Remove bolt and nut which secure battery box left‐side bracket to
mudguard.
(6) Remove bolt and nut which secure battery box right‐side bracket.
This bolt also secures lower tool box bracket and speedometer cable
clip to mudguard.
(7) Remove nut and washers from bolt which secures lower end of
mudguard to frame (behind transmission).
(8) Remove taillight connector plugs from sockets and remove cable from
mudguard spring clips.
(9) Remove nuts from studs which secure right‐ and left‐side mudguard
brace clips to frame axle clips. Mudguard can now be removed from
vehicle.
=d. Install Rear Mudguard.=
(1) Locate mudguard in position for mounting. Install the two studs,
washers, and nuts which secure right‐ and left‐side brace clips to
frame axle clips. NOTE: _If brake side cover interferes with locating
nut on right side, loosen the brake sleeve nut and push brake side
cover assembly inward for clearance. Be sure to retighten brake sleeve
nut._
(2) Attach front lower end of mudguard. Install flat washer, lock
washer, and nut on bolt to secure lower end of mudguard to frame (in
back of transmission).
(3) Install the two studs which mount mudguard and upper battery box
bracket on frame bracket. These two studs screw into a plate nut
located underneath the battery box bracket. Removing the battery box
cover will give more access to plate nut in this step. Install battery
box cover if it is removed for this job.
(4) Attach rear safety guard to the two frame bracket studs. Install
washers and nuts. Securely tighten nuts and tighten U‐bolt nuts, which
secure ends of safety guard to frame stays.
(5) Attach battery box bracket to mudguard bracket. Install bolt,
washer, and nut which secure battery box right‐side bracket, tool box
bracket lower end, and speedometer cable clip to mudguard bracket. Bolt
is inserted from front side, head toward engine. NOTE: _Speedometer
cable clip is under head of bolt._
(6) Attach left‐side mudguard bracket and battery box bracket. Install
bolt, washer, and nut which secure battery box left‐side bracket to
mudguard bracket. Bolt is inserted from front side, head toward engine.
(7) Install rear chain guard (par. 102).
(8) Locate and retain taillight cable in mudguard spring clips. Attach
connector plugs to taillights (wiring diagram, fig. 73).
(9) Install luggage carrier (par. 103).
(10) Install rear wheel (par. 127).
(11) Securely tighten all bolts and nuts.
105. BATTERY BOX.
=a. Remove Battery Box.=
(1) Remove battery (par. 113).
(2) To remove rear brake rod, disconnect clevis from brake lever, and
free front end of rod at brake shaft bell crank.
(3) Remove rear chain guard (par. 102).
(4) Remove tool box and bracket in one piece (par. 106).
(5) Remove nut and bolt securing left side lower battery box mounting
to mudguard bracket. Remove nut and bolt securing battery front
mounting to frame saddle post tube bracket.
(6) Remove the two nuts securing rear safety guard center connection
to mounting studs. Unscrew mounting studs to free the plate nut which
clamps the battery box bracket to frame cross member.
(7) Remove battery box from right side of vehicle.
=b. Install Battery Box.= Locate battery box in vehicle
from left side and secure upper rear mounting bracket with the two
frame cross member studs and the plate nut. Install washers and nuts
which secure safety guard to these same two studs.
(1) Install bolt to secure battery box front mounting to frame tube.
Make sure that bolt passes through frame tube bracket from left side,
and that large plain washer bears against battery box front bracket
(bracket has open end). Tighten nut to secure box bracket to frame tube
bracket.
(2) Install tool box and bracket (par. 106).
(3) Install bolt, washer, and nut which secure battery box left‐side
mounting to mudguard. Insert bolt from the front.
(4) Install rear chain guard (par. 102).
(5) Connect rear brake rod end to bell crank fitting. Attach clevis to
brake operating lever, installing plain washer, clevis pin, and cotter
pin.
(6) Install battery (par. 113).
106. TOOL BOX.
=a. General.= When tool box only is to be removed and/or installed,
it is a simple matter to open box and remove and/or install the three
large screws. Gear‐toothed lock washers and large recessed washers fit
under screw heads.
=b. Remove Box and Bracket Assembly.= Remove bolt and nut which
secure tool box upper mounting bracket to frame clip. Lower end of
mounting bracket, battery box bracket, and speedometer cable are all
secured to the mudguard bracket by the same bolt and nut. Remove
speedometer cable from clip and remove bolt and nut, freeing tool box
and bracket assembly for removal. NOTE: _Removal of rear brake rod will
make bracket lower mounting bolt and nut more accessible._
=c. Install Box and Bracket Assembly.= Locate box and bracket
assembly on vehicle and install bolt, washer, and nut at the upper
frame clip mounting. To attach bracket lower end to mudguard bracket,
place bolt through speedometer cable clip, then through box mounting
bracket, battery box bracket, and mudguard bracket, securing assembly
with lock washer and nut.
[Illustration: RA PD 310245
_Figure 70—Fuel and Oil Tanks Removed_]
=107. TANKS= (fig. 70).
=a. General.= Fuel and oil tanks are separate, fitting together,
saddle‐type, in upper frame tubes, and are retained in position with
three mounting bolts. Either tank can be removed and/or installed
without disturbing line connections of the other tank.
=b. Fuel Tank.= Fuel tank is located on left side of vehicle and
holds slightly over 3 U.S. gallons. It provides mounting for shifter
lever and shifter lever guide. Drain is located in forward position on
under side of tank.
=c. Oil Tank.= Oil tank is located on right side of vehicle and holds
1 U.S. gallon. Oil feed pipe, scavenger (return) pipe, and breather
pipe connections are on under side of tank. Drain is located in forward
position on under side of tank.
=d. Remove Fuel Tank.=
(1) Disconnect battery negative ground wire at frame connection.
(2) Loosen the two cap screws which secure caution plate and tank top
strip.
(3) Remove instrument panel cover (par. 119).
(4) Disconnect gear shifter lever and shifter rod by removing bolt.
(5) Shut off fuel supply. Disconnect fuel pipe at tank union nipple.
(6) Remove nuts, lock washers, and flat washers from the two front (one
upper and one lower) mounting bolts, and nut, lock washer, and flat
washer from the rear mounting bolt. Leave bolts in place so that oil
tank will stay in position after fuel tank is removed. Remove fuel tank
from vehicle.
=e. Install Fuel Tank.=
(1) Position fuel tank on vehicle. Pass the three mounting bolts
through tank brackets from right side of vehicle. It will be necessary
to pry up on tank top strip in order to slip top edge of tank under
strip. Install large flat washers, lock washers, and nuts on mounting
bolts and securely tighten the nuts.
(2) Tighten the two cap screws, securing caution plate and tank top
strip.
(3) Connect fuel pipe at tank nipple union. Open supply valve.
(4) Install instrument panel cover (par. 119).
(5) Connect gear shifter lever and shifter rod by installing bolt, lock
washer, and nut.
(6) Connect battery negative ground wire to frame connection.
(7) After fuel tank has been filled, check pipe connection and drain
plug for leaks.
=f. Remove Oil Tank.=
(1) Disconnect battery negative ground wire at frame connection.
(2) Loosen the two cap screws which secure caution plate and tank top
strip.
(3) Remove instrument panel cover (par. 119).
(4) Drain oil from tank by removing drain plug. Use a trough (of
cardboard or tin) to keep oil from draining on engine. NOTE: _If oil
feed pipe nipple cap (manufacturer’s (H-D) No. 3583-15) is available,
it can be screwed on to tank nipple, thus eliminating draining of oil._
(5) Disconnect oil feed pipe at rear nipple union.
(6) Disconnect scavenger (return) pipe at nipple union.
(7) Disconnect breather pipe banjo‐type connection by taking out bolt.
(8) Remove nuts, lock washers, and flat washers from the two front
(one upper and one lower) mounting bolts, and nut, lock washer, and
flat washer from rear mounting bolt. NOTE: _To prevent fuel tank
from falling out of frame, remove upper front mounting bolt and rear
mounting bolt and pass both back through fuel tank mounting brackets
from the left side of vehicle. Oil tank can then be removed, and fuel
tank will stay in place._
=g. Install Oil Tank.=
(1) Position oil tank on vehicle. Make sure that composition buffer is
in place before installing mounting bolts from right side of vehicle.
Pry up on tank top strip in order to slip top edge of tank under strip.
(2) Install large flat washers, lock washers, and nuts on mounting
bolts. Securely tighten the nuts.
(3) Tighten the two cap screws securing caution plate and tank top
strip.
(4) Connect oil feed pipe to tank nipple. Tank nipple is located at
lower rear end of tank.
(5) Connect scavenger (return) pipe to tank nipple. Nipple is located
underneath tank, near center.
(6) Connect breather pipe with banjo‐type fitting to tank. Use hollow
bolt, making sure flat washers are in place on both sides of banjo
fitting and that mounting bolt is tight.
(7) Install instrument panel cover (par. 119).
(8) See that oil tank drain plug and washer are in place, and that the
plug is tight.
(9) Connect battery negative ground wire to frame connection.
(10) After filling oil tank, check all pipe fittings for leaks.
108. STANDS.
=a. Remove Rear Stand.= Remove nuts which secure rear stand mounting
bolts. Drift bolts out of frame clip holes, freeing stand.
=b. Install Rear Stand.= Locate stand in position so that bracket
stop is downward and will bear against frame axle clips to support
vehicle when stand is in use. See that cupped spring washers are on
mounting bolts before attaching stand to frame. Drift mounting bolts
into frame axle clips and secure with lock washers and nuts.
=c. Remove Jiffy Stand.=
(1) Support vehicle on rear stand.
(2) Loosen footboard rear support stud nut. Remove footboard front
support rod nut and pull footboard outward to release end of safety
guard. Remove extended nut from footboard sidebar front mounting.
Remove nut securing upper end of skid plate hanger and sidebar rear
mounting (located in center of chain guard cover). Loosen nut and bolt
which secure skid plate hanger bracket to skid plate: drop bracket.
Disconnect clutch control cable from foot pedal stud to prevent damage
to cable end piece. Remove left footboard, clutch foot pedal, and
sidebar assembly from support rod ends.
[Illustration: RA PD 310269
_Figure 71—Saddle and Suspension_]
(3) Remove the two nuts from U‐bolt which secure safety guard bracket
to frame tube, remove bracket from U‐bolt, and slide safety guard
assembly out of support rod.
=d. Install Jiffy Stand.=
(1) Install safety guard assembly on support rod and secure mounting
bracket to frame tube with U‐bolt, washers, and nuts.
(2) Install footboard, clutch foot pedal, and sidebar assembly. Attach
skid plate hanger bracket and secure to support rod. Attach clutch
control cable end to foot pedal stud, installing plain washer and
cotter pin. Install washer and extended nut on end of front support
rod. Securely tighten nut. Attach front end of sidebar to end of
safety guard by pulling front of footboard outward, alining hole in
safety guard end with hole in sidebar, and passing footboard front
support stud through both parts, securing with washer and nut. Tighten
footboard rear support stud nut.
(3) Return vehicle to operating position.
=109. SADDLE POST= (fig. 71).
=a.= Saddle is mounted on saddle bar by means of three mounting bolts
and can be shifted forward or backward to provide three positions
on saddle bar. Spacer collars can be added and or removed from the
two rear mountings to raise or lower rear of saddle to alter riding
position. Saddle bar hinges on frame bracket and is clevis‐connected
to saddle spring post. Saddle and saddle bar can be lifted upward and
forward after releasing spring latch (on left side) from groove in
clevis pin end and removing clevis pin from saddle bar.
=b. Remove Saddle Spring Post.= Support vehicle on rear stand.
Raise saddle and saddle bar after removing saddle post clevis pin.
Remove bolt and nut from left‐side skid plate bracket and remove nut
to free right‐side skid plate bracket at muffler pipe clamp and frame
connection. Drop skid plate. Remove saddle spring post clamp nut, which
is located underneath frame at bottom end of saddle post frame tube.
Saddle spring post assembly can be pulled upward out of frame tube.
=c. Install Saddle Spring Post.= When saddle spring post assembly is
inserted in frame tube, see that flat side machined on post rod end nut
registers in flat side of hole in bottom of frame tube. Install and
securely tighten saddle spring post clamp nut at bottom end of frame
tube. Lift skid plate and secure in position with left‐side bracket
bolt, washer, and nut and with right bracket bolt, washer, and nut
(this also secures muffler pipe clamp to frame clip). Lower saddle and
saddle bar into position. Insert clevis pin from right side and secure
with spring latch, making sure that spring is in pin groove.
110. SAFETY GUARDS.
=a. Remove Front Safely Guard.=
(1) Loosen nuts which secure right and left footboard rear support
studs to sidebars. Remove nuts which secure right and left footboard
front support studs (and mount ends of safety guard) to sidebars. Pull
front end of each footboard outward so that support stud will free end
of safety guard. Remove four nuts from the two U‐bolts which mount
safety guard upper bracket to frame tube. Remove safety guard.
=b. Install Front Safety Guard.= Locate safety guard and mount upper
bracket to frame tube with the two U‐bolts, washers, and nuts, but do
not tighten nuts as yet. Pull front end of right footboard outward,
line up hole in safety guard end with hole in sidebar, and pass
footboard front support stud through both parts, securing with washer
and nut. Follow same procedure to mount left end of safety guard.
Tighten U‐bolt nuts securely.
=c. Remove Rear Safety Guard.= Remove nuts from U‐bolts which mount
ends of safety guard to lower frame stays. Remove the two nuts from
upper safety guard mounting. After removing U‐bolts, safety guard can
be removed from vehicle.
=d. Install Rear Safety Guard.= Position safety guard on vehicle.
Install U‐bolts, washers, and nuts for lower end mounting on frame
stays. Do not tighten nuts. Engage upper mounting holes on studs and
replace washers and nuts. Tighten all mounting nuts.
[Illustration: RA PD 310234
_Figure 72—Showing Skid Plate Dropped_]
111. SKID PLATE.
=a.= Rear end of skid plate must be dropped when removing and or
replacing muffler assembly, saddle spring post, transmission, and
engine.
=b. Drop Skid Plate= (fig. 72).
(1) Remove nut from bolt which secures skid plate side mounting bracket
to frame clip. This bolt also mounts muffler tube clamp to frame clip.
(2) Remove left side mounting. Remove nut and bolt which secures lower
end of hanger bracket to skid plate on left side of vehicle. Drop rear
end of skid plate.
=c. Install Dropped Skid Plate.=
(1) Lift rear end of skid plate into position. Attach right‐side
bracket at frame clip bolt. Secure mounting with washer and nut.
(2) Attach lower end of left‐side hanger bracket to skid plate. Install
bolt, washer, and nut. Tighten nut.
=d. Remove and/or Install Skid Plate.=
(1) To remove skid plate from vehicle, follow instructions in step b
above; then remove nut and bolt from U‐clamp which secures skid plate
to frame bracket, and remove nut and belt from clamp which secures
right front end to support rod.
(2) To install skid plate, mount right front end to support rod clamp,
and install bolt and nut to secure U‐clamp under frame bracket. Then
follow instructions in step =c= above.