Harley-Davidson Aermacchi Sprint (OHV single) — Example photo: Asurnipal, CC BY-SA 4.0, Wikimedia Commons

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Harley-Davidson · Pushrod four-stroke single, wet sump, gearbox shares engine oil, chain drive

Aermacchi Sprint (OHV single)

Library entry covers 1961-1974

15 factory 49 guideline

Published source

Aermacchi Ala Bianca, Ala Rossa, Ala Azzurra, Ala Verde, Wisconsin Uso e Manutenzione (Aeronautica Macchi), Manutenzione periodica pp.22-23

Factory owner's handbook. Covers Aermacchi factory owner's manual for the Ala Bianca, Ala Rossa, Ala Azzurra, Ala Verde and Wisconsin (the 175/250 horizontal OHV single sold in the US as the Harley-Davidson Sprint); Italian text, chart in km.

Open the source

64 items for a 1962 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Mesh screens / strainers only
Valve gear: Overhead valve, pushrods, adjustable tappets
Ignition: Battery and coil with contact points
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Drum (or band / stirrup)
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1962 Harley-Davidson Aermacchi Sprint (OHV single)

On the road: every 300 mi

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 310 mi

1 item

Check engine oil level

Pre-ride / on the road

Factory

Manual: Check and top up engine oil level. Factory: Manutenzione periodica pp.22-23: every 500 km

On the road: every 1,000 mi

1 item

Check road kit: plugs, points file, master link, tube patches, wire, tape

Pre-ride / on the road

Guideline

On the road: every 1,250 mi

2 items

Check chain slack and rear wheel alignment

Pre-ride / on the road

Factory

Manual: Check and adjust chain tension. Factory: Manutenzione periodica pp.22-23: every 2000 km
Walk-around: check nuts and bolts for vibration loosening

Pre-ride / on the road

Factory

Manual: Check tightness of all nuts and bolts. Factory: Manutenzione periodica pp.22-23: every 2000 km

Every 1,000 mi or 6 months

4 items

Adjust front drum brake

Brakes

Guideline
Adjust rear drum brake and rod / cable linkage

Brakes

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline
Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 1,250 mi

5 items

Change engine oil

Engine

Factory

Manual: Change the engine oil. Factory: Manutenzione periodica pp.22-23: every 2000 km
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Check spark plug electrode gap. Factory: Manutenzione periodica pp.22-23: every 2000 km
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Factory

Manual: Wipe the chain and brush on thick engine oil. Factory: Manutenzione periodica pp.22-23: every 2000 km; remove, wash and lubricate the chain every 4000 km
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Grease the swinging arm pivot with a grease gun. Factory: Manutenzione periodica pp.22-23: every 2000 km (grease nipple on the left side)
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Oil brake control joints, exposed cable ends and all other pivots. Factory: Manutenzione periodica pp.22-23: every 2000 km, a few drops of engine oil

Every 1,500 mi or 6 months

2 items

Clean oil strainers / mesh screens

Engine

Guideline

Often done with every oil change on old machines.
Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.

Every 1,500 mi or 12 months

1 item

Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 2,500 mi or 12 months

1 item

Check and adjust valve clearances

Engine

Guideline

Every 2,500 mi

1 item

Clean and gap contact breaker points, oil cam felt

Ignition and electrics

Factory

Manual: Check contact breaker gap and grease the breaker felt. Factory: Manutenzione periodica pp.22-23: every 4000 km

Every 3,000 mi or 12 months

13 items

Check engine mounting bolts and plates

Engine

Guideline
Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Check / set ignition timing

Ignition and electrics

Guideline
Adjust clutch pushrod / clutch adjuster

Primary and gearbox

Guideline
Check chain guard, chain oiler (if fitted), rear chain case

Final drive

Guideline
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering damper (friction or hydraulic)

Front end

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 4,000 mi or 12 months

1 item

Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 5,000 mi or 2 years

1 item

Check cylinder head bolt torque

Engine

Guideline

Air-cooled iron and alloy engines can lose head bolt tension; follow your manual's sequence and whether it is done hot or cold.

Every 6,000 mi or 12 months

4 items

Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 6,000 mi or 2 years

3 items

Check engine breather and oil return

Engine

Guideline
Lubricate and check automatic advance unit

Ignition and electrics

Guideline
Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 7,500 mi

5 items

Decarbonize head, grind / lap valves (top-end decoke)

Engine

Factory

Manual: Decarbonize combustion chamber, grind valves if necessary, clean exhaust pipe and muffler. Factory: Manutenzione periodica pp.22-23: every 12,000-15,000 km or at overhauls (at a service station)
Replace spark plugs

Engine

Factory

Manual: Replace the spark plug. Factory: Manutenzione periodica pp.22-23: every 12,000-15,000 km
Clean carburetor float bowl(s), check float level and jets

Fuel and air

Factory

Manual: Remove and clean the carburetor. Factory: Manutenzione periodica pp.22-23: every 12,000-15,000 km
Repack / replace steering head bearings

Front end

Factory

Manual: Remove, clean and lubricate steering head bearings. Factory: Manutenzione periodica pp.22-23: every 12,000-15,000 km
Repack / replace wheel bearings

Wheels and tires

Factory

Manual: Remove, clean and lubricate wheel bearings. Factory: Manutenzione periodica pp.22-23: every 12,000-15,000 km

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 10,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 12,000 mi or 3 years

1 item

Replace points and condenser

Ignition and electrics

Guideline

Every 15,000 mi or 5 years

1 item

Inspect clutch plates and springs

Primary and gearbox

Guideline

Every 15,000 mi

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 1 month

1 item

Check battery electrolyte, top up with distilled water

Ignition and electrics

Factory

Manual: Add distilled water to the battery. Factory: Manutenzione periodica pp.22-23: monthly; every two weeks in hot countries and in summer

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

3 items

Inspect fuel tank for rust, sealer failure, leaks

Fuel and air

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 4 years

1 item

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.