HD Service manual - leaves a lot to be desired - are others similar?

sburns

sburns

Well-known member
Ok I know I am not a trained mechanic and just a person DYI'n my maintenance. But some stuff is pretty simple or should be. For 3 days I struggled with a clutch adjustment on my bike :( . Finally after looking at another video (thanks to Revzilla) and trying a couple of more things, it finally set!

Below are the exact instructions from the service manual which I followed.
Pages from 2011 Harley Davidson Touring Model Service Manual.jpg

What bothers me is the vagueness of what "lightly seated" means (step 5), and backing out the adjuster screw to either 1/2 or 1 full turn, what will that mean at the lever and friction zone (step 6)???

In my case I turned in and turned out the adjuster screw several times, just in case to remove any free play.
Once "seated" I then I turned it back out 1/4 turn, it worked.
Eventually with all the attempt and some more research on the net, the less you back out the further from the grip the friction zone/engagement will start.

Anywho I was curious if other vendors service manuals are similar or better, or worse possibly?
 
I believe the first gen Suzuki V-Strom manual is similar. Tighten until lightly touching is what I read it as.

"Loosen the lock-nut 3 and turn out the adjusting screw 4 two or three rotations.
From that position, slowly turn the adjuster screw 3 in until it stops.
Turn the adjuster screw 3 out 1/4 rotation, and tighten the lock-nut 4."

I think there's also another typo in at least some manuals that will cause the clutch to start slipping much more quickly than it should.
There was an adjustment nut that was left loose at two different shops, when I had the clutch done. Now I do it myself.

Edit: Notice that that have lock-nut 3 and lock-nut 4 in the text. There is only adjuster screw 3 and lock-nut 4.
 
The Service manual for my 2018 HD lacks a few things to be desired, but for the most part does the job very well.
I am sure you'll get some HD bashing but I would think any service manual has to use terms like "lightly seated" etc.
So many variables to consider when making/writing the manual..
 
Jampy00 said:
The Service manual for my 2018 HD lacks a few things to be desired, but for the most part does the job very well.
I am sure you'll get some HD bashing but I would think any service manual has to use terms like "lightly seated" etc.
So many variables to consider when making/writing the manual..
Click to expand...
For a variable reference point, it's hard to write effective instructions. I guess they could do something like tighten to 12 in-lbs but how many people have a torque wrench accurate at 12 in-lbs and compatible hex sockets for it? That's pretty low and unless you have a special low-torque wrench, you will likely be further off the desired value by measuring than you would be by feel.
 
Looks pretty clear to me. Workshop manuals generally assume a certain level of general knowledge on the part of the person using them, and it's impossible to explain every step in sufficient detail for someone that is not technically inclined without causing extreme frustration and wasted time on the part of someone who does. ("Why is this book taking 45 pages to explain how to do this simple task" type of thing)

At least there's no "use special (ed: unobtainable/outrageously expensive) tool number XXXX to do YYYY" in those steps ... although I'm sure there's some of that, elsewhere ...
 
I wonder how many HD techs are tightening that jam nut with a torque wrench...

Also - I'm not a Harley guy - does it make sense that you have to sacrifice an oil seal to adjust the clutch?
 
A handy DIYer can assess the condition of that seal to establish whether it is actually better off being replaced. I have no idea myself of what type of seal it is. If the cover can't be removed without damaging that seal (e.g. if parts of it are stuck to both sides, and it rips when pulled off) ... it needs to be replaced. If it has gone rock-hard, or it is all beat up, it needs to be replaced. A DIYer can install that cover with the existing seal and know to keep an eye on it, and replace it later if it turns out to be leaking. A workshop mechanic (which is who the factory service manual is written for) ... doesn't want you coming back complaining that oil is seeping from the clutch cover.
 
TwistedKestrel said:
I wonder how many HD techs are tightening that jam nut with a torque wrench...

Also - I'm not a Harley guy - does it make sense that you have to sacrifice an oil seal to adjust the clutch?
Click to expand...
There is a special torgque wrench which fits on top of the nut but allows an allen key to fit in as well. There is a name for it I heard it 1 time in a YouTub video, I don't think it is unquie to HD

I've never replaced that gasket, it's always in good shape, doesn't stick to anything. It's never leaked. I feel like is it's one of those recommendations which makes them a bit of money, like when you bring in your car for maintiance and they always always recommend to replace the air filter, even if it is not necessary.
 
Thanks all for the feedback, obvious the way it is written is for technicians and my lack of experience have clashed. Causing myself a bit of frustration. Hopefully next time this process will be easier, I've kept more detailed notes this go around.

Over all like @Jampy00 said it's a good manual, and surprisingly the bike isn't all that difficult to work on since it's all pretty much exposed.
 
sburns said:
There is a special torgque wrench which fits on top of the nut but allows an allen key to fit in as well. There is a name for it I heard it 1 time in a YouTub video, I don't think it is unquie to HD

I've never replaced that gasket, it's always in good shape, doesn't stick to anything. It's never leaked. I feel like is it's one of those recommendations which makes them a bit of money, like when you bring in your car for maintiance and they always always recommend to replace the air filter, even if it is not necessary.
Click to expand...
You can put a crowfoot wrench on the torque wrench to tighten that jam nut. It would be interesting to see how many do.
 
GreyGhost said:
You can put a crowfoot wrench on the torque wrench to tighten that jam nut. It would be interesting to see how many do.
Click to expand...
Most of the videos they just use a regular wrench to tighten it. I use a offset box wrench. I know when I first did the adjustment whom ever did it, didn't torque it, as it was stuck on there. I had to get a new nut.
 
GreyGhost said:
You can put a crowfoot wrench on the torque wrench to tighten that jam nut. It would be interesting to see how many do.
Click to expand...
I’m not sure I’d do that. Torque multiplies if you extend a lever so you could overtorque using a crowfoot.

Here are a couple of souvenirs from using a crowfoot on a torque wrench set for 19lbsE91A32B3-BFE3-4F8E-8C2A-1E382E5DE86F.jpeg491BECF9-C2D5-46F3-A888-C598B11F2B56.jpeg
 
Brian P said:
Looks pretty clear to me. Workshop manuals generally assume a certain level of general knowledge on the part of the person using them, and it's impossible to explain every step in sufficient detail for someone that is not technically inclined without causing extreme frustration and wasted time on the part of someone who does. ("Why is this book taking 45 pages to explain how to do this simple task" type of thing)

At least there's no "use special (ed: unobtainable/outrageously expensive) tool number XXXX to do YYYY" in those steps ... although I'm sure there's some of that, elsewhere ...
Click to expand...
100%
I had the factory manual for my Wing. Took me a while to figure out it was written for Honda techs and skipped over steps they should know.
 
I have both the HD manual and a Clymer manual, just in case I need two different perspectives. As for clutch adjustment "lightly seated" means just touching. I do mine 1/4-1/2" then do the rest on the cable.
 
Mad Mike said:
I’m not sure I’d do that. Torque multiplies if you extend a lever so you could overtorque using a crowfoot.

Here are a couple of souvenirs from using a crowfoot on a torque wrench set for 19lbsView attachment 48753View attachment 48754
Click to expand...
You want crowfoot at 90 degrees to head so effective length is unchanged. Then torque is almost correct.

tekton.com/how-to-accurately-use-a-torque-wrench-with-a-crowfoot-wrench
tekton-crowfoot-90-degree-1x.webp
 
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