🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLH

Generation:

Shovelhead

Applicable Years:

1981, 1982, 1983, 1984

Engine Code Designation:

Shovelhead

Model Code Designation:

FLH (Touring model variant)

👋 Introduction

Target Audience:

Harley-Davidson FLH owners, independent mechanics, restoration specialists, and motorcycle enthusiasts performing their own maintenance and repairs.

Manual Value:

Provides essential, detailed technical information that often exceeds the scope of basic owner's manuals, crucial for maintaining and repairing these classic motorcycles.

Comprehensiveness:

Covers all major systems and components of the FLH models for the specified years, offering a complete resource for mechanical and electrical work.

Clarity Of Instructions:

Step-by-step procedures, exploded views, and detailed schematics facilitate accurate repairs.

📋 Manual Details

Primary Coverage:

Complete Service, Repair, Maintenance, and Troubleshooting

Included Components:

Engine, Transmission, Drivetrain, Chassis, Electrical System, Bodywork, Suspension, Brakes, Fuel System, Exhaust System

Estimated Pages:

Over 500 pages (typical for a comprehensive workshop manual)

Type:

Workshop Service Repair Manual

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Engine:

Shovelhead V-Twin, disassembly, assembly, tuning, component identification, lubrication, cooling, ignition timing, carburetor adjustment (e.g., Keihin, S&S).

Transmission:

4-speed Cruise Drive transmission, clutch operation, gear selection, shifting mechanism, lubrication, seals, bearings.

Drivetrain:

Primary drive system (clutch, compensator sprocket), final drive (chain drive), belt drive (if applicable), tensioning, lubrication, sprocket replacement.

Electrical System:

Wiring diagrams, battery, charging system (alternator, regulator), ignition system (points, electronic ignition), lighting, starter motor, horn, diagnostic troubleshooting for electrical faults.

Braking System:

Front and rear disc brake systems, hydraulic components, brake fluid specifications, caliper service, rotor inspection, pad replacement, bleeding procedures.

Suspension:

Front fork (e.g., Showa, Telescopic), rear shock absorbers, fork oil specifications, seal replacement, damper adjustment, rear suspension linkage (if applicable).

Fuel System:

Fuel tank maintenance, fuel lines, fuel petcock operation, carburetor servicing and tuning (including specific models), fuel pump (if applicable).

Exhaust System:

Exhaust pipe mounting, mufflers, gaskets, heat shields, troubleshooting exhaust leaks.

Chassis And Frame:

Frame inspection, steering head bearings, swingarm pivot, wheel bearings, Jiffy stand, center stand.

Bodywork And Trim:

Fenders, fuel tank, seat, fairings, saddlebags, mounting hardware, cosmetic repairs.

Maintenance:

Routine checks, oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, battery maintenance, brake fluid checks.

Repair:

Complete engine teardown and rebuild, transmission overhauls, carburetor rebuilding, electrical component replacement, brake caliper rebuilding, fork seal replacement, wheel bearing replacement.

Troubleshooting:

Systematic diagnosis of common and uncommon mechanical and electrical problems, symptom-based troubleshooting guides, diagnostic charts.

Diagnostics:

Component testing procedures, multimeter usage for electrical diagnosis, compression testing, vacuum testing.

Technical Specifications:

Torque values for all fasteners, clearance specifications, fluid capacities, electrical resistance values, performance tuning data.

Depth:

Comprehensive from basic servicing to complete engine and transmission rebuilds, including detailed diagrams and step-by-step instructions.

Diagnostic Capability:

Advanced diagnostic procedures for engine, electrical, and mechanical systems, enabling technicians to identify root causes of failures.

Rebuild Procedures:

Detailed instructions for complete engine, transmission, and carburetor rebuilds, including parts identification and special tool requirements.

📊 Manual Specifications

Format:

Digital (PDF)

Searchability:

Searchable text for quick information retrieval.

Resolution:

High-resolution scans suitable for printing.

Clarity:

Clear diagrams, illustrations, and text.

Binding:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

Harley-Davidson Shovelhead V-Twin

Displacement:

80 cubic inches (approx. 1310cc) standard for FLH models of this era.

Configuration:

45-degree V-Twin, air-cooled

Bore X Stroke:

Typically 3.4375 in x 4.25 in (87.31 mm x 107.95 mm) for the 80ci engine.

Compression Ratio:

Varies by specific configuration, but typically around 8.0:1 to 8.5:1 for stock models.

Horsepower:

Estimated 60-70 HP (Varies by tuning and specific model year variations).

Torque:

Estimated 75-85 ft-lbs (Varies by tuning and specific model year variations).

Carburetor:

Typically Keihin butterfly style or S&S Super E/G carburetors may be fitted by owners or dealers. Original Harley-Davidson carburetors of the era would also be covered.

Fuel Type:

Unleaded gasoline, 87-91 octane (check specific recommendations in manual).

Fuel Delivery:

Gravity feed from fuel tank through petcock to carburetor.

🔧 Transmission

Type:

4-speed constant mesh, foot shift, hand clutch.

Optional Features:

N/A (4-speed was standard for this era FLH).

Gear Ratios:

Specific gear ratios are detailed within the manual for each gear.

Transmission Fluid Type:

Typically Harley-Davidson Formula + Transmission and Primary Chaincase Lube, or equivalent SAE 50 weight gear oil (check manual for exact specifications).

Clutch Type:

Dry clutch, multi-plate, cable-actuated.

📐 Dimensions

Wheelbase:

Approximately 63.5 inches (1613 mm) for FLH models.

Length:

Approximately 93 inches (2362 mm) for FLH models with saddlebags and tour pak.

Dry Weight:

Around 700-750 lbs (318-340 kg) for fully equipped FLH models.

Gross Vehicle Weight Rating:

Typically around 1160-1200 lbs (526-544 kg).

🛡️ Safety Features

Safety Standards:

N/A (Motorcycles of this era were not subject to the same crash test ratings as automobiles).

Braking System:

Dual disc front brakes, single disc rear brake for enhanced stopping power. Linked braking was not standard.

Lighting:

Halogen headlight, taillight, brake light, turn signals for visibility.

Frame Construction:

Robust steel frame providing a stable platform.

💡 Technology Features

Infotainment System:

None (This era of FLH is pre-infotainment. Audio systems were aftermarket or basic radio/cassette units.)

Driver Assistance Features:

None (No electronic rider aids like ABS or traction control were standard).

Connectivity Options:

None (No integrated smartphone connectivity or Bluetooth).

Ignition Type:

Could be points-based ignition or early electronic ignition systems depending on the specific year and factory configuration, or aftermarket upgrades.

🔧 Maintenance

Oil Change Interval:

Typically every 2,500 to 3,000 miles or annually, whichever comes first (refer to manual for precise interval).

Primary Chaincase Lube Interval:

Check and top off as needed, change typically with primary chain or clutch service (refer to manual).

Transmission Oil Interval:

Typically every 5,000 to 10,000 miles or annually (refer to manual).

Spark Plug Replacement:

Recommended every 5,000 to 10,000 miles or as per manual.

Engine Oil Type:

Harley-Davidson 20W50 motorcycle oil or equivalent (e.g., Mobil 1 V-Twin 20W50, Spectro Golden 20W50). Check manual for exact API service classification.

Engine Oil Capacity:

Approximately 3 quarts (2.8 liters) with filter change (refer to manual for exact capacity).

Brake Fluid Type:

DOT 4 or DOT 5 silicone brake fluid (Harley-Davidson recommended DOT 5 for this era, but check manual and personal preference as DOT 5 is not compatible with DOT 4/5.1). Note: DOT 5 silicone brake fluid is not compatible with standard rubber brake lines and seals if not originally equipped.

Shovelhead Engine:

Oil leaks (especially around tappet blocks and pushrod tubes), oil consumption, potential for valve seat wear (especially with unleaded fuel if not modified), carburetor tuning sensitivity.

Electrical System:

Aging wiring harnesses can become brittle, regulator/rectifier failures, intermittent electrical connections, battery charging issues.

Transmission:

Clutch adjustment and wear, potential for shifting issues if not properly maintained, common wear on shifting forks or gears over high mileage.

Wear Items:

Clutch plates, brake pads, fork seals, wheel bearings, drive chain and sprockets, tires, spark plugs.

📚 Vehicle History

Heritage:

Harley-Davidson, an iconic American motorcycle manufacturer with a long history of producing reliable and powerful motorcycles.

Shovelhead Era:

The Shovelhead engine was produced from 1966 to 1984, evolving through various configurations. The FLH represents the touring model of the Harley-Davidson lineup during this period.

Flh Significance:

The FLH (often referred to as the Electra Glide) was Harley-Davidson's flagship touring motorcycle, known for comfort, power, and capability for long-distance travel.

Production Years For Model:

The FLH model in its Shovelhead configuration was produced from the mid-1970s through 1984.

Manufacturing Location:

Milwaukee, Wisconsin, USA.

🏆 Awards & Recognition

Model Recognition:

The Shovelhead FLH is a highly sought-after model for its classic styling, distinctive sound, and the robust engineering characteristic of Harley-Davidson's golden era. It's a staple in motorcycle collections and popular for custom builds and restoration projects.

Reliability Rating:

Reliability is generally considered good with proper maintenance, though specific component wear and age can be factors. The manual is key to addressing these.

Manual Certification:

Not applicable (This is a third-party service manual, not a manufacturer certification).