Motorcycle, Solo (Harley-Davidson Model WLA)

United States. War Department

Motorcycle, Solo (Harley-Davidson Model WLA)

Published by Good Press, 2022

goodpress@okpublishing.info

EAN 4057664606389

Table of Contents

PART ONE—OPERATING INSTRUCTIONS

Section I INTRODUCTION

Section II DESCRIPTION AND TABULATED DATA

Section III CONTROLS AND OPERATION

Section IV FIRST ECHELON PREVENTIVE MAINTENANCE SERVICES

Section V LUBRICATION

Section VI TOOLS AND EQUIPMENT STOWAGE ON THE VEHICLE

PART TWO—VEHICLE MAINTENANCE INSTRUCTIONS

Section VII MAINTENANCE ALLOCATION

Section VIII SECOND ECHELON PREVENTIVE MAINTENANCE

Section IX ORGANIZATION TOOLS AND EQUIPMENT

Section X TROUBLE SHOOTING

Section XI ENGINE

Section XII ENGINE—REMOVAL AND INSTALLATION

Section XIII CLUTCH

Section XIV TRANSMISSION

Section XV CHAINS AND SPROCKETS

Section XVI FUEL SYSTEM

Section XVII INTAKE AND EXHAUST SYSTEM

Section XVIII IGNITION SYSTEM

Section XIX GENERATING SYSTEM

Section XX BRAKE SYSTEM

Section XXI STEERING CONTROL

Section XXII SHEET METAL AND EQUIPMENT

Section XXIII BATTERY, LIGHTING SYSTEM, HORN

Section XXIV INSTRUMENT PANEL

Section XXV TIRES, WHEELS, AND HUBS

INDEX

PART ONE—OPERATING INSTRUCTIONS

Table of Contents

Section I

INTRODUCTION

Table of Contents

1. SCOPE.

a. This technical manual2 is published for the information and guidance of the using arm personnel charged with the operation, maintenance, and minor repair of this materiel.

b. In addition to a description of the Harley‐Davidson motorcycle, this manual contains technical information required for the identification, use, and care of the materiel. The manual is divided into two parts. Part One, section I through section VI, gives vehicle operating instructions. Part Two, section VII through section XXV, gives vehicle maintenance instructions to using arm personnel charged with the responsibility of doing maintenance work within their jurisdiction.

c. In all cases where the nature of the repair, modifications, or adjustment is beyond the scope or facilities of the unit, the responsible ordnance service should be informed so that trained personnel with suitable tools and equipment may be provided, or proper instructions issued.

2. SUPERSESSION OF QUARTERMASTER MANUALS.

a. This technical manual, together with TM 9–1879, supersedes and replaces the following Quartermaster Corps publications:

(1) TM 10–1175—Maintenance manual, motorcycle, solo, Harley‐Davidson (Model 42–WLA), 11 September 1941.

(2) TM 10–1177—Maintenance manual, motorcycle, solo, Harley‐Davidson (Models 1940–41–42), 11 September 1941.

(3) TM 10–1331—Maintenance manual, motorcycle, chain drive Harley‐Davidson (Model 42 WLA, solo).

(4) TM 10–1359—Instruction folder (45–A) motorcycles, solo, Harley‐Davidson (Model 1941 WLA 45), 25 November 1941.

(5) TM 10–1361—Instruction folder (45–B) motorcycle, solo, Harley‐Davidson (Model 1941 WLA 45), 25 November 1941.

RA PD 315708

Figure 1—Top View of Motorcycle

RA PD 315709

Figure 2—Left Side View of Motorcycle

RA PD 315710

Figure 3—Right Side View of Motorcycle

2 To provide operating instructions with the materiel, this technical manual has been published in advance of complete technical review. Any errors or omissions will be corrected by changes or, if extensive, by an early revision.

Section II

DESCRIPTION AND TABULATED DATA

Table of Contents

3. DESCRIPTION (figs. 1, 2, and 3).

a. This 2‐cylinder solo motorcycle is powered by a V‐type, air‐cooled gasoline engine, operating on conventional 4‐stroke, 4‐cycle principles. Air‐cooled engines rely upon movement of air over cylinder and head radiating fins, and upon circulation of oil for dissipation of excessive heat. Motorcycle engines, therefore, under no conditions should be operated for more than 1 minute when motorcycle is not in motion.

4. DATA.

Section III

CONTROLS AND OPERATION

Table of Contents

RA PD 310201

Figure 4—Controls

5. CONTROLS (fig. 4).

a. Controls are peculiar to the motorcycle. The rider must become thoroughly familiar with the location and use of all control devices before attempting to operate vehicle.

b. Gasoline Valve (figs. 5 and 6). Gasoline valve is located in left tank, forward. Valve is closed by turning to the right, finger tight. Turning to left opens valve. Valve is in normal operating position when turned to left, with valve head down. Lifting valve head releases emergency supply of fuel (3 quarts).

RA PD 310202

Figure 5—Fuel Supply Valve

RA PD 310293

Figure 6—Fuel Supply Valve Positions

c. Throttle. The throttle is controlled by right handle bar grip. Turning grip inward opens throttle, turning it outward closes throttle.

d. Spark. Spark is controlled by left handle bar grip. Turning grip inward advances spark, turning it outward retards spark.

e. Clutch (fig. 7). Clutch is operated by left foot (rocker‐type) pedal, connecting with steel cable, which actuates clutch release lever. Pedal is located on left side of motorcycle above footboard. Forward downward (toe) position of pedal engages clutch. Rear downward (heel) position of pedal disengages clutch. Foot pedal provided with friction device to retain it in either engaged or disengaged position.

RA PD 310204

Figure 7—Clutch Pedal Positions

RA PD 310205

Figure 8—Gear Shifter Lever Positions

f. Service Brake (Rear Wheel). Foot pedal is located on right side of motorcycle at forward end of footboard.

g. Auxiliary Brake (Front Wheel). Auxiliary brake is operated by hand lever located on left handle bar. It is used in conjunction with service brake, as an emergency brake, or for holding vehicle while starting engine on grade. CAUTION: Brake is to be applied lightly and cautiously on wet and slippery roads.

h. Gear Shifter (fig. 8). Shifter lever is located on left tank, forward position, and operates within a guide. Shifter lever guide is notched for positive location of gears and each position is identified, front to rear: 1—low gear; N—neutral; 2—second gear; 3—direct high gear.

RA PD 310206

Figure 9—Carburetor Choke Lever Positions

i. Steering Damper. Steering damper is an adjustable friction device to damper turning action of forks, steady front wheel, and prevent wobble in rough terrain or at high speeds, and is located on top of steering head in center of handle bars. Move handle to right to apply desired friction.

j. Foot Starter Crank (fig. 1). The foot starter crank is located on right side of motorcycle. Gear shifter lever must be in neutral position, and clutch foot pedal in forward engaged position, before using foot starter crank. Starter crank normally is in upward position. Straddle motorcycle, place right foot on starter crank, and shift weight of body for forceful downward crank operation to start engine.

k. Ignition and Light Switch. Earlier models are provided with switch lock, later models are nonlocking. Switch is off in straight‐forward position. First position to right is for engine ignition only. Second position to right is for ignition and blackout lights. To use vehicle service lights, depress button to turn switch to third right position.

l. Instrument Panel Signal Lights. Instead of an ammeter and oil pressure gage, signal lights indicate generator charging, and engine oil pressure.

(1) Green light is located on left side of instrument panel. When engine is running, and light is out, it indicates generator is charging.

(2) Red light is located on right side of instrument panel. When engine is running, and light is out, it indicates engine oil is circulating.

m. Carburetor Choke (fig. 9). Choke lever is in full prime position when all the way up, and in normal running position when all the way down.

6. ENGINE PRESTARTING INSTRUCTIONS.

a. Before the engine is started, perform the Before‐operation Service outlined in paragraph 15. Special care must be taken during starting and warming‐up period to avoid unnecessary engine wear.

b. The rider must acquire correct motorcycle engine starting habits, and learn to do the job the quickest, easiest, and most dependable way. The following pointers will be helpful to the beginner as well as to a seasoned rider:

(1) Mount (straddle) motorcycle to obtain firm grip on handle bars.

(2) Leave side stand (jiffy stand) outward to support vehicle while operating foot starter crank with right foot.

(3) Engine starting will be benefited by use of front wheel, hand‐operated brake, to prevent vehicle from rolling or shifting during starting kicks. This is especially helpful if vehicle is parked on an incline or on soft, uneven surface.

c. The procedure outlined below is preparatory to starting either cold, warm, or hot engine:

(1) Place gear shifter lever in N (neutral) position (fig. 8).

(2) See that gasoline shut‐off valve is open (fig. 5).

(3) Engage clutch (fig. 7).

(4) Spark control (left) grip must be turned inward to fully advanced position, or nearly so.

(5) Foot starter crank may travel ½ way downward before starting engine. See that a full vigorous starter stroke is used. A vigorous kick, using a full swing (not a jab) of right leg and hip, is correct engine starting practice.

7. STARTING THE ENGINE.

a. Procedure for starting cold, warm, or hot motorcycle engines differs. Therefore, following instructions are used with paragraph 6 c to cover correct procedure in all three cases.

b. Starting Cold Engine. When vehicle has not been operated for some time, and engine is normally cold, follow progressive procedure for easiest starting.

(1) Set carburetor choke lever in full upward (closed) position.

(2) Open throttle wide by turning right grip inward as far as it will go.

(3) Prime cylinders by operating foot starter crank one or two strokes.

(4) Set carburetor choke lever in ¼ to ½ closed position for mild weather starting: ¾ closed (or leave fully choked) for extremely cold weather starting. CAUTION: It is only in extremely cold weather that engine may start best with choke fully closed, and even then it will have to be moved from this position immediately after engine is started.

(5) Set throttle (right) grip to slightly open position.

(6) Turn ignition switch on, first right position.

(7) Start engine with vigorous strokes of foot starter crank.

(8) When engine starts, set throttle for moderate idling speed for warming up, or until ready to set vehicle in motion. Do not race engine unnecessarily.

(9) After engine warms up, and misfires due to an overrich mixture, gradually move choke lever downward. After engine has thoroughly warmed up, move choke lever to fully open (downward) position.

c. Starting Warm Engine. Following instructions apply to engine when halfway between hot and cold. With engine in this condition, carburetor choking must be handled cautiously.

(1) Lift choke lever to first upward position from normal (¼ closed).

(2) Set throttle (right) grip to fully closed (outward) position.

(3) Operate foot starter crank one or two strokes.

(4) Set throttle grip to between ¼ and ¹⁄3 open position.

(5) Turn ignition switch on.

(6) Start engine with vigorous strokes of foot starter crank.

(7) Soon after engine starts, choke lever must be moved to fully open (downward) position.

(8) Turn throttle grip to control idling speed of engine.

d. Starting Hot Engine. If engine has been shut off for only a brief period and is near normal operating temperature, it is not necessary to use carburetor choke lever. With some engines, depending upon carburetor condition and adjustment, hot starting is easier and more dependable if foot starter crank is operated one stroke before turning ignition switch on.

(1) Close throttle grip by turning fully outward.

(2) Turn ignition switch on.

(3) Operate foot starter crank to start engine.

(4) When hot engine does not start readily after two or three strokes of the foot starter crank, it is usually due to an overrich (flooded) condition, and the proper procedure then is to open throttle wide so that more air can enter: close throttle quickly after engine starts. CAUTION: After engine has warmed up to a normal operating temperature, do not allow engine to stand idling for longer than a 1 minute interval.

e. Starting Engine with Dead Battery. See paragraph 12.

f. Behavior of Instrument Panel Signal Lights. Function of generator (green) signal light depends upon action of cut‐out relay; engine oil pressure (red) signal light depends upon action of oil feed pump. Rider must, therefore, thoroughly understand operating characteristics of both signal lights to judge condition of generator‐battery circuit and pressure in engine oil circulating system.

(1) When ignition light switch is turned to first (right) position, preparatory to starting engine, both green and red signal lights should go on. CAUTION: When switch is turned on, immediately after engine has been primed by cranking, red (oil pressure) signal light may not light at once, but will light after a few seconds, due to oil pressure built up by cranking, and is most likely to be noticed in cold weather.

(2) With engine started and running at medium idling speed, both signal lights should go off. CAUTION: Should oil pressure (red) signal light fail to go off at speeds above idling, conditions must be brought to attention of unit mechanic.

(3) At slow idle speed, or under approximately 20 miles per hour road speed (in high gear), generator (green) signal light will normally flash on and off, because at that speed generator voltage output is very low and unsteady. CAUTION: Should generator (green) signal light fail to go off at speed above approximately 20 miles per hour, generator is either not charging at all, or its current output is not up to normal, and generator should be given attention at once.

8. STOPPING THE ENGINE.

a. Stop engine only by turning ignition and light switch to off (straight‐ahead) position, to prevent discharge of battery through spark coil primary circuit.

9. OPERATION OF VEHICLE.

a. Starting on Level Ground. The engine having been warmed up and checked for satisfactory operation, the vehicle (with operator in riding position) is put in motion as follows:

(1) Transfer body weight to right leg.

(2) Fold back side stand (jiffy stand).

(3) Disengage clutch by depressing clutch foot pedal with heel of left foot.

(4) Shift gear shifter lever into 1 (low)