Engine:
1340cc (80ci) Evolution Engine, Shovelhead Evolution Engine Service, Engine Disassembly and Reassembly, Cylinder Head Service, Piston and Connecting Rod Service, Crankshaft Service, Camshaft Service, Valve Train Service, Lubrication System Service, Cooling System (Air-Cooled), Ignition System, Carburetion System, Exhaust System
Transmission:
4-Speed Constant Mesh Transmission, Transmission Disassembly and Reassembly, Gearbox Components, Clutch Service, Primary Drive Service, Final Drive Service
Electrical:
Wiring Diagrams, Lighting System, Starting System, Charging System (Generator/Alternator), Ignition System Components, Ignition Timing, Battery Service, Fuses and Relays, Instrument Cluster Service, Horn and Audio Systems
Chassis And Body:
Frame and Suspension, Front Fork Service (including Springer, Glide), Rear Shock Absorber Service, Wheel and Tire Service, Brake System Service (Front and Rear Drum/Disc), Steering System Service, Fuel Tank and Seat Service, Fender and Bodywork Repair, Fairing and Saddlebag Installation/Service, Electrical Components Mounting and Service, Fastener Torque Specifications
Fuel System Details:
Fuel tank repair, fuel lines, petcock service, carburetor overhaul (Keihin CV), fuel pump (if equipped).
Exhaust System:
Exhaust pipe mounting, muffler replacement, heat shield installation.
Clutch System:
Clutch cable adjustment, clutch plate replacement, primary drive chain adjustment and replacement.
Maintenance:
Scheduled Maintenance Intervals, Oil and Filter Changes, Spark Plug Replacement, Air Filter Cleaning/Replacement, Brake Pad Replacement, Clutch Adjustment, Chain/Belt Adjustment, Lubrication Points
Troubleshooting:
Diagnostic Charts, Common Problem Diagnosis (e.g., starting issues, running problems, electrical faults), Symptom-Based Troubleshooting Guides
Repair And Rebuild:
Engine Rebuild Procedures, Transmission Overhaul, Carburetor Rebuild and Tuning, Brake System Overhaul, Electrical Component Replacement and Repair, Suspension Component Replacement
Frame And Suspension Repair:
Fork seal replacement, steering head bearing adjustment, swingarm pivot service, shock absorber replacement.
Wheel And Tire Service:
Tire mounting and balancing, wheel bearing replacement, spoke adjustment (if applicable).
Electrical Component Testing:
Testing of starter motor, generator/alternator, ignition coil, voltage regulator, switches, and lighting circuits.
Ignition Timing Adjustment:
Procedures for setting ignition timing using timing lights and timing marks.
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, with detailed diagnostic procedures.
Diagnostic Tools:
Procedures for using basic hand tools, multimeter for electrical diagnostics, and timing lights. Specialized Harley-Davidson tools may be mentioned.
Specifications Data:
Detailed torque specifications for all fasteners, clearance measurements for engine components, valve lash settings, timing marks.
Engine Type:
Air-cooled, 45-degree V-twin, OHV (Overhead Valve)
Displacement:
1340 cc (80 cubic inches)
Bore X Stroke:
3.4375 in x 4.25 in (87.3 mm x 108 mm)
Compression Ratio:
Approximately 8.0:1 (varies slightly by specific model/tuning)
Horsepower:
Estimated 60-65 HP (at the crankshaft, figures can vary)
Torque:
Estimated 70-75 ft-lbs (at the crankshaft, figures can vary)
Carburetor:
Keihin CV (Constant Velocity) carburetor, typically 36mm or 40mm
Fuel Type:
Unleaded gasoline, 91 octane (AKI) or higher recommended
Ignition Type:
Electronic Ignition (points were phased out on earlier Shovelheads, 1983 likely features electronic ignition or a distributor setup)
Oil Pump Type:
Gear-driven oil pump, typically integrated with the camshaft drive.
Oil Change Interval:
Typically every 2,500 - 5,000 miles or 6 months, whichever comes first. Consult the manual for precise intervals.
Spark Plug Replacement:
Every 5,000 - 10,000 miles, depending on spark plug type.
Transmission Fluid Change:
Every 10,000 - 15,000 miles or annually.
Engine Oil Type:
Specific Harley-Davidson 20W50 or equivalent (e.g., Valvoline VR1 20W50, Mobil 1 V-Twin 20W50). Manual will specify exact API service classification.
Engine Oil Capacity:
Approximately 3 quarts (2.8 liters) with filter change.
Primary Chain Case Oil Type:
Refer to manual; could be Harley-Davidson primary oil, Syn3, or engine oil depending on specific configuration and year.
Primary Chain Case Oil Capacity:
Approximately 1 quart (0.95 liters).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid, depending on caliper type. Consult manual for specific recommendation.
Oil Leaks:
Common on Shovelheads due to age and seal wear; manual provides guidance on gasket replacement and sealing.
Carburetor Tuning:
Keihin CV carburetors can require periodic adjustment for optimal performance and emissions.
Valve Adjustment:
Requires periodic adjustment for proper engine operation and longevity.
Electrical Gremlins:
Older wiring harnesses can degrade, leading to intermittent electrical issues; manual's diagrams are crucial.
