Harley-Davidson 250 & 350 MOTORCYCLE

HARLEY-DAVIDSON
AMF/HARLEY·DAVIDSON MOTOR CO.
Milwaukee, Wisconsin

250 AND 350 CC SPRINT

Sprmt"H" Sprint "SS"
Sprint uB" Sprint"SSIt & nsx"
MODEL Sprint "C" Priorto 1967 1967·196S After 1965
Displacemenf.-.cc . . . . . . . . . . . . . . . . • . . . 246.2 246.2 248.4 344
Bore--m m , . . . . . , . . . . . . , . . . . . . • . . . . . 66 66 72 74
Stroke-mm , . . . . . . . . . . . . . . . • • . . • • • 72 72 61 Sl
Ignition-
Spark pi u g-type ................. . H-D 5-6 or A utal ite AG901
E lectrode gap-rom ............. . 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
Point gap--mm , . . . . . . . . . . . . • . . . . . , 0.46 0.46 0.46 *

In� ........................... . 0.018 0.018 0.018 *

Valve clearance (cold)

Intak&-mm ...................... . 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
In� ............................ 0.004 0.005 0.002 0.003
Electrical system voltage . . . . . . . . . . . • . 6 6 6 12#
Battery tenninal grounded ........... . Negative Negative Negative Negative
Tire s�front ...................... 3.00·17 3.00·18 3.25-191 3.25-19*-
Rear . . . . . . . . . . . . . . . . . . . . . . . • • . . . , _ 3.00·17 3.50-1S 3.50-18 3.50-18**
Tire pressure---
Front-kg/em' . . . . . . . . . . . . ... . . . . . . 1.4 1.3 1.3 1.3
Psi . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 20 18 18 lS
Rear-kg/cm2...................... 1.7 },3 1.6t 1.3**
Psi . . . . . . . . . . . . . . . . . . . . . . . . . . • . . 24 18 22t lS--
Rear chain free play-mm . . . . . . . . . . . . 13 13 13 13
Inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I' I' I' I'
N umoor of speed s ..... . . . . . ..... . . . . . 4 4 4 Sit
·Point gap should be O.46mm (0.018 in.) for models prior to 1973 and O.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 wi th 6 volt systems.
"Tire size and pressure for Sprint "SS" models after 1968 same as Sprint "SS" models 1967·1968.
ttModels prior to 1974 equipped with four s p eed transmission.
lliustrations courtesy AMFlHarley·Davulson Motor Co.

MAINTENANCE Main Jet

SPARK PLUG. Recommended Jet
spark plug for normal use is Harley· Model Size
Davidson No. 5·6 or Autolite AG90l. Early 1961"C"
Spark plug electrode gap should be 1962"H" l.08mm
0.020-0.025 inch. Late 1961·1966"C"
1963·1966"H" l.OOmm
CARBURETOR. Del'Orlo UB type 1967·1968"H" & US" l.05mm
carburetor is used on pre-1969 models. 1969·1972"SS"
Later models are equipped with square 1971·1972"SX" l.18mm
slide Del'Orto carburetor. Idle speed is toSS" & t·SX" After 1972 l.25mm
a<ljusted by turning stop screw (10-
Fig. HD4-1 or Fig. HD4-1AJ. Make cer­
tain lock nut (9-Fig. HD4-1) is tight· Idle Jet
ened after adjustment is complete. Idle Jet
mixture is adjusted at needle (8). Model Size
Normal setting for idle mixture needle
1961·1968 All Models O.5mm
is 'l4·turn open. Clip (6) should nor­
1969-Early 1971 "SS" O.55mm US
mally be positioned in center groove in Fig. HD4-1-bploded view of D&I'Orto car·
After Early 1971 "SS" & "SX" O.45mm bureror typical of earlymodel•.
needle (7). Float level on pre-1969
models can be checked as shown in Fig. 1. Throttlecable 12. Noule (et.omiur)
2. Choke JUide 13. M.injet
HD4-2. Distance between straight edge 3. Choke rod dip 14. c.p
and float lever should be 13/64·15/64 Starter Jet IS. Fiberwashers

inch. Refer to Fig. HD4·3 for float level Jet �: �:!l: :��:g 16. Float

�: ��ve needle
17. Floatlevu
on later models. Refer to the following Model Size 18. Inlet needle
8. Idle mixture needle 19. Snap lin,
for correct jet sizes and equivalent drill 1969·1972 "SS" &"SX" O.6mm 9. Locknut 20. Pivotlhtifl.
10. IdlellGplJCJ'ew 21. Primer
bit size. After 1973 toSS" & "sx" O.7mm 11. Idlejel 22. Filter acnen
SERVICE Harley-Davidson 250 & 350

Fig. HD4-J-Flollf height (H) on model. after 1968

'---1 0
should I)e J1/32/nch.

_1112
Fig. HD4-6-Va/lffl clearance Is measured be­

14 1913
tween rocker arm and valve stem with engine
cold. Adjusting screws (t) are locked by nuts (2).

161J � or by inserting a washer under the cam

�20
retaining screw (a-Fig. HD4-4).

18 1_21
Refer to the following chart for
timing specifications in crankshaft
degrees and piston position:

Model Retarded Advanced

Fig. H04·1A-Exploded v i e w of .quare slide Year BTDC BTDC
Del'Orto carburetor used on models after 1968.
1961 21'/0.250 in. 41'/0.406 in.
1. Cable adjuster 12. "0" rinS
2. Cap 13. Starlingl" 1962-66 5' 41'/0.406 in.
3. Sprin, 14. Inletfue valve Fig. HD4-4-View of Ignition timer (I)reaker points 1967-68 5'/0.015 in. 35'/0.250 in.
4. Jet nC!iedle clip 15. Idle jet usembly). Factory timing marks are shown at
5. Throttle .lIde 16. Needlejet 1969-72 7'/0.005 in. 28'/0.219 in.
6, Jet. needle 17. "O"ring (1). 1973-74 12'/0.044 in. 34'/0.338 in.
7. Starter plunger 18. Flo.atbowl
8. Floatpin 19. Gasket 2. Cover 6. Baae p\SUl aa-eWII
9. noat 20. Mainjet 3. Cam �taininl acrew 7. Tm
i ing mar...
10. Idlespeechcrew 21. Jelholder 8. Ignition cam
VALVE SYSTEM. The valves are
4. Lodcwasher
11, Idle mixture atrew 22. Fuel inlet 6. Washer0961 11. Breaker point base actuated by a camshaft located in the
models) plal.e
crankcase via, cam followers, push rods
13/64" TO 15/W'
and rocker arms. Clearance between
5TRA1GHT EOGE degree wheel to the end of the crank­ rocker arm and valve stem should be
shaft. Using a suitable mark, position set with engine cold. Clearance for both
degree wheel to coincide with piston at valves for an Sprint "COO models should
TDC on compression. To dynamically be O.lmm (0.004 in.). For Sprint "H"
time ignition on 1971 and 1972 models, models prior to 1967, exhaust valve
remove tachometer drive cover from clearance should be 0.13mm (0.005 in.)
left side cover and attach a degree and inlet valve clearance should be
wheel to end of crankshaft. Ignition 0.08mm (0.003 in.). Clearance for both
timing may be checked on 1971 and valves of 1967 and 1968 "H" and "55"
1972 models by removing access plug models should be 0.5mm (0.002 in.).
in crankcase and directing timing light Valve clearance for "SS" and "SX"
Fig. HD4-2-Floaf leve' Is measured as ,hown. If
height /s Incorrect, float lever can be bent.
into hole. Timing mark on crankshaft models after 1968 is O.amm (0.003 in.)
and crankcase should be aligned at for the exhaust valve and 0.5mm (0.002
engine speed of 5000 rpm. If ignition in.) for the intake valve. Refer to Fig.
IGNITION AND ELECTRICAL. timing is not correct, remove tachom­ HD4-6.
Models prior to 1973 are eqwpped with eter drive cover and attach a degree
a 6 volt generator while later models wheel to crankshaft and follow the pre­ LUBRICATION. The engine and
are equipped with a 12 volt alternator. vious ignition timing procedure to set gear box are lubricated by 2 quarts of
All models are equipped with a battery ignition timing. Ignition timing on oil contained in the crankcase. Recom­
ignition with the breaker pointa lo­ models 1973 and 1974 may be checked mended oil is Harley-Davidson grade
cated under a small cover on the right with a timing light by removing plug 105 above 75 degrees F., H-D 75 be­
side cover. Breaker point gap should be in left side cover and noting alignment tween 40 degrees and 75 degrees and
0.46mm (0.018 in.) for models prior to of "R" (retard) and "AU (advance) H-D 58 oil below 40 degrees. Oil should
1973 and O.4mm (0.016 in.) for models timing marks. Pointer and "AU mark be changed and filter (Fig. HD4-7)
after 1972. Ignition timing is acljusted should be aligned at approximately cleaned every ,1000 miles. Oil level
by loosening breaker 'plate retaining 5000 rpm. should be maintained between marks
screws and rotating breaker plate. Ignition may be timed statically in on filler plug dipstick. Filler plug
Dynamic timing of ignition on retard and advance positions. Ignition should not be screwed in when
models prior to 1971 is accomplished by is normally retarded and may be checking oil leveL
removing tachometer drive on left side checked in advanced position by The oil pump used on models before
cover or left side cover and attaching a holding weights outward with a wedge 1964 is shown in Fig. HD4-8. Gears (14
Harley-Davidson 250 & 350 MOTORCYCLE

REPAIR

�
CYLINDER HEAD AND VALVES.
The cylinder head can be removed
without removing engine. Valves can
be removed from cylinder head without 23
removing rocker arms on pre 1967 24 r
1 Drtun plug models. Rocker arms can be removed 25 ----e I
,
2 Gnskel
3 Inner .Kret'n
4 Outf'fl.crt!\('
after removing covers and set screws
(43-Fig. HD4-J5). Note position of , ' . 2 i 4
i
Ii F . ll!
l rSprr
rocker arm thrust washers (3l) and 21 · � I
�: �:�ne�t k spring washers (30Y. Spring washer Q
8 FillCrscreen
! 1963 and Earlier} (30) is between thrust washers (31) on 43
47 45
valve side of inlet rocker arm and push ___
rod side of exhaust rocker arm, Make
certain oil passage (H) in inlet rocker 46-./.E�-
arm cover (27) is clean. Refer to the fol­ 3D
lowing specifications and Fig.HD4-15.

22
Fig. HD4-7-011 filter screens should be cleaned
Valve Springs
Free Length@
36
35
I
. 17
I
every 1000 miles. Scavenger fflter (8) Is used on
Model Length Pressure 34

1\'1=::
models before 1964.
Model "H" 1962-63 <::> rr-16
& 16) supply pressure for lubrication Innerspring 1.64 in. 1.3 in. C$ 281bs.
and scavenger pump gears on shafts Outerspring 1.77 in. 1.42 in. @ 551bs.
(13 & 17) return oil to the crankcase. All othermodels priorto 1968 _13
. --
On 1964 and later models, the scav­ Innerspring 1.64 in. 1.28 in. @ 251bs. 8 14
11--.12
enger section is omitted as shown in
�II
Outerspring 1.77 in. 1.42 in.@'50Ibs.
1969-1972 model. 7 ,-..
".�1_
Fig. HD4-9. Gear (3-Figs. HD4-8 and -

J �:
Inner spring 1.64 in. 1.36 in.@ l8lbs.
HD4-9) is dri ven by the crankshaft 9
i g 1.77 in. 1.5 in. @ 42 Ibs.
Outer sprn
timing gear. Both types of pump can be ._

1973·1974 model.
removed after removing drive gear and Fig. HD4-U-Exploded view of typlca' Sprint front
Innerspring 1.61 in. 1.3 in.@"331bs.
pump securing bolts (6). Outerspring 1.69 in. 1.35 in. @ 57.4Ibs.
suspension assembly. Later models are
equipped wilh ball bearIngs on .teering stem.
CLUTCH CONTROLS. The clutch
Valve face and seat angle ........ 450 2. PIli,. wllher& seal 23 Steering damper
cable should be adjusted to provide the 4. Spnng koob
hand lever with free play equal to Yo-I> Valve seat width ............ 1/16-in. 5. Screw 24. Lock
6. Washer 25. Stem nut
of its total movement. Adjustment is Valve stem to guide clearance 7. Drain serew 27. Upptrbrackct
Inlet-After 1968 .. ...... 0.001 in. 8. Stal 30. Stem
provided at both ends of cable. 9. Main tube 34. Cotter pin
Prior to 1969 . .......... 0.0015 in. 10. ButTerlpring 35. Nut
II. Snap ring 36. Spring washer plate
SUSPENSION. Each front suspen­ E�aust . ......... ....... 0.002 in. 12. Dampervtllve body 37. Springwuher
sion lmit contains 4% fl. oz. of Harley­ Shafts (33) to bushings (32) 13. Washer 40. An(horplall
14. Dampervalvl! 41. Friction d isc
Davidson Sprint Fork Oil. Units can be clearance ......... 0.0005-0.0015 in. 15. Snap ring 43 Bu-rina cone
16. Damper pilnGn 44. Bearing balls (25
drained at plug (7-Fig. HD4-11) and 17. Damper tube UlltCi)
refilled at plug (2). NOTE: If front sus­ Valve guides (12 & 26-Fig.HD4-15) ��: �:rring 45. Bearing balll (26
used)
pension is disassembled and cleaned and bushings (32) can be pressed out 21. Selll 46. Btarlngtone
22. Slider 47. BearingropA
with solvent, each un.it should be ser­ after cylinder head is heated to 2500 F.
viced with 5 fl. oz. of oil. To remove Bushing (32) for left end of inlet rocker
of inlet rocker arm and on push rod side
snap ring (11), it may be necessary to arm shaft must have 0.118 inch diam­
of exhaust rocker arm. Spring washer
drill or saw fork tube (9) as shown in eter oil hole drilled. All bushings must
(30) should be between thrust washers
Fig. HD4-12. be line reamed alter installation for
(31) and at least one thrust washer
correct clearance to shafts. Valve
1812 14
should be at other end of rocke,' arm.
20 5 4 guides with 0.001, 0.002, 0.003, 0.004,

Jd/ 1¥.\- I!Jl�9

Additional thrust washer can be in-
0.006 and 0.008 inch oversize outside
�!' e--l0
diameter are available for service.

)�
Valve seats (11 & 25) are NOT inter­
11 7 63 2 1 changeable. Valve seats can be re·
191615 •

moved and installed with cylinder head

iii �v heated to 5400 F.

9
191713
When reassembling, make certain
that spring washer (30) is on valve side 12
Fig. HD4-8-Exploded view of all pump used at, 12
11
_ I
1963 and earlier Sprint models. Scavenge gears
17\

.�, •
are on shafts /13& 17} and pressure geaf$ Bre at Drill 3/32" hole
(14& 16). ooove snap ,ing.
00 NOT DRill THRU
1. NUL II. Outer(ovt't" • • Notch with hadesaw.
TUBE. Remove
2. Lock plate 12 Inner c:over "
� Must remove aU burrs
3. Drive gear 13. Driveahaft on inside .,d outside snap ring.
4 <Anne(torfilting 14. Pressure gear
;;;;;;;:.., of lube. Remove all burrs.
05
6.
Copper wlI.ht�
Retainingaaew8 ( 4
115. Drive key 13/
:� rJI::'��:!tear Fig. HD4-12-Snap ring (11) must be removed
used) . Fig. HD4-9-Exploded view of 011 pump used on before damper lIallle body (12) can be withdrawn
7. Lock platetl (4 used) 18. 0 rin g
9 Seavange Line 19. Dowel pinl 1964 and lat.r Sprint models. No scavenger from tube (9). Make certain all burrs are re-
10 Gasket 20. Pump bod)' pump Is used. Refer to Fig. HD4·8 for legend. moved.
SERVICE Harley-Davidson 250 & 350

H�
lJ���" 28
15 � �
14'-Jt!jW : Il- @ @

13�
35 32 � 26"1
3
fJ :b I ,-
Wi Pod �
IN•
.IIlDEl H

1.DZ3IH.
1.6251H.
1.348 IN.
Fig. HD4-f6-When distance from end of valve
stem tovalve guide shoulderItxceeds 1.650 Inch
w ith new vslve Installed, valve aeat must be re-
newed.

� ?L.
24'"
.{ �
12 13
1415 �
,," � 43 31 32

��;(?
37A ,A2 38
4 5 /\19 18
3 :& 41 � �
It;;;Wai . !l� ......
39./"""'& ,,-, 19
1:
20
40.-0 � 42 Fig. H04·n-CondlUon of the connectingrod and
lower end(crankpln) bearing canbe checkedby
measuring connecting rod shake 8S shown. If
Fig. HD4·'5�xp'oded Iflew of early model cylinder hoad assembly. Cam follower bushings (5) and side play at connecting rod small (piston pin)
camshalf bushing (3lA) used on1963 and earliermodels mustbe reamed afterInslellsHan. On 1964 end e.ceeds1/16 Inch, crankp/n, connecting rod
and latermodels, needlebearing (378) Is used. andbearing shouldbe renewed.

I. CanllIhlll1.gl!Df' 13. Spring leat 24. Inlet valve 3<1, Flange (2 uledl Piston pin to piston-
Clearance . .. light press fit@ 70· F.
2. Wooch-utTkey 14. Inner .pring.. lUi, Inl.tv.lv.... .t 35. Oll..r nan• • ('l undl
3. Camahaft 15. Outulpring. 26. Inlet Vlll Vil guide 36. Carburetor nange
4. Exhawt cam rollower 16. Vlllvceapa 27 Inlet valve c:over 37A. Bushing
Piston to cylinder clearance--
5. Bushing. 17. Keepera 28. Rocker lirm oil tube 370. Net:dle bearing and
6. Exhawt pUlih rod 18. EzhaUllt valve cover 29. Adju�ill.K lCrew outer race 1969 models ............. 0.004 in.
7. AdjulI'ting.crew 19. Oringa 88. Thrust w8.ll her
8. Lock nut 39. Ball beann'\,
oo_u
All other models ... : ..... 0.002 in.
9. ExhsWit rocker arm ��. ?r:l:ee:�:toiro�er �?: ��::�:� 40, Crailihlln u.ahlng
Connecting rod side play (shake)
10. ExhaWit valve 22. Inlet pUlh rod 42. CntruhnnluPporl.
11. Exhaust valve lIeat 23. Inlet rocker arm ��: ��I!����rana 43. Rocker IlTm llet should be measured as shown in Fig.
12. Valve-guide screws
HD4-17. If total side play at piston pin
end exceeds 1I16·inch, crankpin. con·
stalled at either end to center rocker as outlined in previous paragraph. necting rod and bearings should be
arm over valve stem and partially Refer to the following specifications for renewed. Oversize pistons and rings
compress spring washer (30). The in­ piston, rings, cylinder and piston pin. are available.
side cam follower (21) is for the inlet Standard cylinder bore diameter-
valve. Make certain that rocker arm Early 250cc ...... 2.5984 in. (66mm) CAMSHAFT A N D TIMING
screws (43) are tightened into holes in Late 250cc .... . ... 2.835 in. (72mm) GEARS. To remove timing gear cover
rocker arm shafts. Cylinder head re­ 350cc .. . . . .. . .... 2.913 in. (74mm) (right side cover), drain crankcase oil
taining nuts should be torqued to 25 AlI piston rings- or lay motorcycle on left side so oil will
Ft.-lbs. Refer to previous paragraph in End gap .... .. . ... ..0.010-0.016 in. not drain out when cover is removed.
MAINTENANCE section for setting Side clearance in groove 0.001-0.002 The clutch on models after 1968 must
valve clearance. in. be removed before the cover can be
Piston pin to bushing (in connecting removed. Ignition breaker point cam
PISTON, RINGS AND CYL­ rod)- retaining screw (3-Fig. HD4-3) must
INDER. The cylinder can be removed Clearance .........0.006-0.0012 in. be unscrewed on all models. Clutch re­
after first removing the cylinder head wear limit . ............ 0.002 in. lease lever on models prior to 1969
Harley-Davidson 250 & 350 MOTORCYCLE
must be rotated forward when re­
r1Ji;;;;;; 1 9 I0 \I 12 13 15 14
moving 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) 3
Ij '��JJ� ed-d
;;; 9'��;l

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 key­
ways in crankshaft and gear. If key is
improperly installed, camshaft timing
may be incorrect. To remove the crank·
shaft primary drive gear, it is neces·
sary to remove the oil pump gear, cam·
shaft, 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 i s adjusted by varying
washers (3S-Fig. HD4-15).
When reassembling, observe the fol·
lowing. Thoroughly clean all oil and
dirt from end of crankshaft, especially
tapered section, and inside of gear (8 or
8A-Fig. HD4-19). On early 1961 mod­
els, the take-up gear (6) should be ro­
tated 3 t.eeth 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, crank­
shaft must be set at Top Dead Center
and woodruff key installed in crank­
shaft keyslot pointing toward camshaft
mount (B-Fig. 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
a1igned as in Fig. HD4-18 with crank­
shaft at TDC. Nut (I-Fig. HD4-19)
should be tightened to 35 Ft.-Ibs. of
torque.
Fig. HD4-19-Vlew 0' crankshaft gears. Take up
gear (6), thrust washer (5), spring (7) and nar­
rower gear (8) are used on early 1951 models
only. L8te 1961 end all other models use only
gear(SA).
1. Nut 4. WoodrufTkey
2. Lnck p late 9. Sn[lpnng
S. Cranka
ha n timing 10. Crankehaflrightend
gear
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, cyl­
inder and piston are removed. The
crankshaft and connecting rod as­
sembly can be removed as follows after
the complete engine assembly is re­
moved from the frame. Remove the cyl­
inder head, cylinder, and piston. Re­
move the crankcase left side cover. the
complete generator assembly, starter
ratchet assembly (9, 10, II, 12, 13, 14
& 15-Fig. HD4-22) and drive sprocket
from left Elide 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.
���;�.��i
, 6 5
Fig. HD4-22-Exploded view of klcht.rter 85-
sembly. Klc/(starter ratchet assembly (9 thru 15)
Is located on left end of transmission ma/nshal'
(19-Flg. HD4-2S,.
3 Kickstarur pedlll 10. Spring leat
4. Acorn nut lind 11. Ratchet.pring
washer 12. Ratchet.
5. Stop bumper 13. Rat.chetgC'ar
'
6. Stopstud 14. Snaprin,
7. Ge8r 15. Ratchel gear bushi ng
8. 'Return spring 21. Pedal_hafl buehin,
9. Snap ring 22. SDri nlc40wei bin
Remove snap ring (9-Fig. HD4-19)
from right end. Remove the seven cap
screws and three socket head screws
which attach crankcase halves to­
gether 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 pro­
cedure is self-evjdent.
Refer to Fig. HD4-24 for exploded
view of crankshaft assembly. A press of
approximately 10 ton capacity is re­
qulred to press crankpin (5 or 5A) out
of flywheels. Oil hole in crankpin must
be aligned with hole in flywheel (1).
Conn.ecting rod side clearance between
flywheels should be 0.0005-0. 0010
inch. The crankshaft should be disas­
sembled ONLY if tools required to
check and align reassembled crank­
shaft are available. Crankshaft eccen­
tricity should not exceed 0.001 inch
when measured at main bearing jour­
nals as close as possible to flywheels
with crankshaft supported at ends in
lathe centers.

Fig. HD4-ZO-V/ew of proper

pos/Hon 'or cam gear wood­
ruff hy for 1954 rhru 1968
models tA) and ,," other
models (B). Crankshaft Is at
TOC on both versIons.

Fig. HD4-18-Vlew with right side cover removed

and timing marks aligned.
SERVICE Harley-Davidson 250 & 350

Orifice plug (12-Fig. HD4-24) Fig. HD4·24-Exploder1 view

01 crankshaft assembly.
should be installed on all Sprint "H"
Crankpin bearing (4A. 48 &
models and Sprint "e" models after SA) Is type used on I.te
1962. Orifice plug and oil passage to models.
crankpin must be open to properly lu­ I. RightllidenywheeJ
2. Thrwt wuhera (2 used)
3. Connecting rod

�
bricate connecting rod bearing. Diam­
eter of orifice opening is 0.0595 inch 4. Roller bearing (early models)
.tA. Retainer
(Drill size 53). 48. Rollers (24 uled)
5. Cnmkpin (early models)

���N!n
CLUTCH. The cl utch assembly used
in 1965 and earlier models (Fig. HD4-
26) can be removed after crankcase
right side cover is removed. Use appro­
priate tool to compress clutch spring
5�:

8. Oil5e8r

10. Snaprinl(
11. Ballbeann,
wheel
7. PiSlon intu8hinl:

9. Ball beanng

12. Orifice plug (Iale models)

48
�, 4A 5A

(12) and remove snap ring (1). Clutch

discs and plates assembly (4) can be
removed. Clutch spring (12) should Fig. HD4-26-Exploded view
of clutch assembly used in
have a free length of 1 29/32 inch and
1961 thru 196B models.
should be renewed if less than 1 13116 Spacer (19)'s used on 1961
inch. On 1963 and earlier models, models only and keys (ISA)
spring (12) should exert 223 lbs. when are used on 1962 thru 1968
models.
compressed to 1.12 inch. On 1964 and
later models, spring pressure should be
2651bs. when compressed to 1.12 inch. I. Snap ring 24
2. Relene belU'ing cap
Clutch assembly used in 1969 and 3. Ball releue bearing 23
5. Nuts (4ued) 22
later models is shown in Fig. HD4-27. 6. Lock pillet 14 Uledi
1. Releas!! disc
8. Oul.erd�
21::::;
1
Primary gear (20) can be removed after
20
9. Friclion diSQI (4 uliedl
10. Drive plnlea(4 used) 15S. Shims
disassembling and removing clutch
22. Release eam
assembly and right side cover. Clutch 11. Preuure plate 16. Clutch drum 23. Snap ring
12. Cluu:hspnng 17. Drum bearing (2 Wled) 24.. Oilles!
13. Nut 18. Snap rinp(2uHd) 25. RIlleasBlever
��: �CU{l961
is dry type and seal in side cover should
14. Lockplate only) 26. Spacer CUse only on early
Hi Hub
be inspected for damage. Inspect fric­
models with narrow gear on
tion discs for uneven wear or fractures. 15A. Hub keya(I962 and IDter) 2L Lock washer drum 16)

Springs (2) should be renewed if less

than 1 Ii! inches long.
When reassembling, observe the fol­
lowing. On early models equipped with
take-up gear (6-Fig. HD4-19), gear (6)
should be rotated counter-clockwise
three teeth to pre-load spring (7) when
meshing clutch drum gear with crank­
shaft gear. Vary the th;ckness of sh;ms
U5B-Fig. 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,
install fiber backed steel plate (7-Fig.
HD4-27) first with steel side against
bottom of drum (IS). Install sufficient
shlms (22) behind primary gear (20) to
obtain 0.004-0.00S inch clutch as­
sembly end play. Remainder of as­
sembly procedure is self-evident. Ad­
just clutch cable as outlined i n
paragraph i n MAINTENANCE sec­
tion.
TRANSMISSION. Models prior to
1973 aTe 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 para­
graph CRANKSHAFT AND CON­
NECTING ROD. Gears (16 or 16A, 17,
22, and 23-Fig. HD4-2S or IS-Fig.
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 (lSA, 20A and 24A-Fig.
HD4-2S and 2S-Fig. HD4-29) must be
reamed after installation in gears to
provide 0.001-0.002 inch clearance on
shafts. When assembling transmis­
sions prior to 1973. second gear (24-
Fig. HD4-2S) must be' installed with

Fig. H04-27-Exploded view

ot crutch assembly used In

�moo�
later models.
I. Spring nul
2. Spring
3. Spnng holder
te
:. �I��I��
6. Steel plate
7. Fiber &..wel plClte
8. Lock nul
9. Cluteh IItlJuster
1 2 3 [__________ ____ __ _____ .J 10. SillI

rU-�-�-�-I--J It. Push rod

12. Nut
13. Tab was:her
14. Hub

n�f)vr\
15. "O"rmg
16. Nut
17. Tab washer
18. ClUlCh drum
19. Washer
20 Primary drinn gear
21 RolJerbearings
Fig. HD4-23-One sockel head screw attaching
crankcase halves togelher /5 located on lelf side 22. Shims
.s shown. 12 13 14 15 16 17 18 19 20 21 22 23 23. Wll.Iher
Harley-uavloson :.!5U III �50 MOTORCYCLE

Fig. H04-28�xploded view

21---A
29--V�
reces s on gear away from splines.
Teeth on third gear (23) should be to­
of four speed transmission
assembly used on Harley­
30�
30A""'--- '
ward second gear (24)_ Teeth on fourth
gear (22) should be away from thlrd
Calf/dsan 250 cc Sprint
m o d e l s . L.ate (350 ee)
21 gear (23)_ Install first gear (20) with
model' are equipped with recess away from shift clutch (21) and
needle bearings Instead of third gear (18) wiih recess away from
bushings (26A).
rnainshaft splines. Teeth on second

�1518A18, 1
gear (17) should be toward third gear
32� (I8). First gear (16 or 16M must be in­
1 Sh.l'tercamapacer(limall)
Z. (;QUntcrahafl thruat ....ll5her
. 2 stalled with bearing side out. Install
3. Cotler pm 12 wsecil
22�ilII!I
�
:: ��:�:� ���; r2���U:MJ
sufficient shims (16C) on late 1962-
23 ---- 1972 models to obtain zero mainshaft

�j6
8. Plug
9, WRlihcr
241� 31
_
end play.

leA.6e ��
10 Sprmg
II Cnm IItop plunger
24 \.. When assembling transmission on

1 fJP'
12 Snap rillt!

�·V
13. Sh.fler cam "pacer tlorgcl models after 1972, install third gear
14 Shlfterrnm
15. Shifterdul�h
16. Mamshaft finl 81.'IIrl17 l�th)
25/'l\ (12-Fig. HD4-29) with lugs out and
install fourth gear (10) with shift fork
.if'311
16A. Mninahnl'l. (in! gear (late
21�..8
20j:....�
19(2) groove towards lugs on third gear. In­
168. Snap ring Ollte 1962) __ 16B stall fourth gear (20) with lugs to in­
16C.ShimrLatel9621
17. Mainahllfi.erondgear\23
r side and fifth gear (18) with nat side
tl!ethl
18. Mainsha/\ third gtar 127 2OI/t out. Third gear (22) must be installed
teelhl
18A. BU!hing
19. Mainahan
33 with shift fork groove towards fourth
gear (20). Install shift clutch (26) with
20 Count('rahaft lirat gellr 133
teeth) nat side next to second gear (24).
20A Bushing
21 Shirtercluteh
22. CountenhaA. fourth gellr (16
Countershaft end play should be
teeth) 0.004-0.008 inch. To measure end play,
23. Countu,haIt thIrd gf!tlr\23
teeth) install countershaft assembly in crank­
24. CoullleMihllft sec ond gear 127 27. Spacer 31A. Right mallllihan bearing
teeth)
cases with original washer (29-Fig.
28. Sprocket .p8�r rctaine-(l.IIle 1962)
24A. Bu.hmg 29. OIlseal 32. Bcaring HD4-29 or a 1.0mm washer placed on
25. Counlershal"t 30. Bearing 33. Bearing
26. Sprocket genr (24 teeth) :lOA Snap rillg (1..at e 19631 34 Shiftu cambu,hing
the end of the countershaft. Do not in­
26A. Buahlllg(2usedl 31. Bearing 35 Shiner cam bushinK stall a washer on models prior to 1971.
Gasket must be installed between
crankcase halves. Measure end play
and install necessary shims (2-Fig.
HD4-28 or 17-Fig. HD4-29) to obtain
desired end play.

Free length of cam plunger spring

Fig. HD4-29�:tploded view (lO-Fig. HD4-28 or 42-Fig. HD4-29)
of five speed transmission
should be 1.535 inch. Shift cam bush­
used on models after 1972.
ings must be reamed to provide clear­
5 ance of 0.0005-0.0015 inch between
1. Spacer bushings and shift cam. Shift f o r k
2. OUleal
3. Ball beanng clearance o n shift cam should b e 0.001-
4 Shim
5. Sp rocket gear
0.0015 inch. Install necessary shims
6. Wu-e ring (l3-Fig. HD4-28 or 37-Fig. HD4-29)
1. Bushing
8. Sp acer to obtain equal clearance with trans­
9 N.edle bnri n8 mission in neutral between lugs of shift
10. Mainahaft fourth gear
11. Lock rin&, clutch (21-Fig. HD4-28) and gears (20
12. Mainahaft thirdgear
13 Mainahafl and 24) on models prior to 1973, or to
14. Shim
It;. Bcarlngretamer
obtain equal clearance between lugs of

�J.
3t 31
16. Ball benrlng third gear (22) and gears (20 and 24) on
11. Shim
18. Counterahaft flRh gear models after 1972.
19. Lock ring
20. Countl!r ahaR rourth gear
21. Countenhan
Shift cam end play should be 0.004-

3 3 22. CountCIt$hllf\ third gear

2J Lock ring
24 Countuahaf\ .econd gear
0.008 a n d is adjusted by varying
number andlor size of shims (I-Fig.

31 Siiz;"L 31
25. W..h.r
HD4-28 or 31-Fig. HD4-29).
f� 34 35
26. Slide- dutch
27. Count....h.nfirltpar
. Sprocket gear bushing (26A-Fig.
28. Bushill(

lill£/36
29. Shim HD4-28) on models prior to 1969 must
•• 30. BUlhing

d<i
I 31. Shim
be reamed after inst.allation in gear to

rfj 38
32 Pin provide 0.0005-0.0015 inch clearance
33. Second & four th ,hin fork
- 34. Third at fifth Ihift fork on mainshaft (19). Install sufficient
39 3S. Fil'lt .hlft fork
shims (27-Fig. HD4-28 or 4-Fig.

�
36. Snap ring
31. Shim HD4-29) to obtain sprocket gear end
38. BUlhing
play of 0.008-0.010 inch.
4
39. Shll"team

40 41 42
40. Plug End play of all shafts should be
41. Wuhl'r

'c,'@.L.�
42. Sp ring checked after transmission has been
43. Shiftcam lklp plunger
completely assembled.