Target Audience:
Owners and technicians working on the 1980 Harley-Davidson FL 1200 model, including customizers and restorers.
Value Proposition:
Provides essential, factory-level information crucial for maintaining and repairing this iconic vintage Harley-Davidson, ensuring accuracy and authenticity in repairs.
Highlight:
Direct factory documentation offering detailed procedures and specifications often missing in aftermarket manuals.
Engine:
Complete overhaul, inspection, and repair procedures for the 1200cc Shovelhead V-twin engine, including carburetor adjustment, ignition system, lubrication system, cooling system (air-cooled), and exhaust system.
Transmission:
Disassembly, assembly, inspection, and repair of the 4-speed constant mesh transmission, clutch assembly, and primary drive system.
Chassis:
Frame, suspension (forks, rear shocks), wheels, brakes (front disc, rear drum), steering, and swingarm.
Electrical:
Wiring diagrams, lighting system, ignition system, battery, charging system (generator/alternator), and accessory circuits.
Bodywork:
Fenders, fuel tank, seat, handlebars, and related components.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug service, brake pad inspection, and battery care.
Troubleshooting:
Diagnostic charts and procedures for common problems related to starting, running, electrical systems, and braking.
Repair:
Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly.
Adjustments:
Carburetor tuning, ignition timing, clutch adjustment, and brake adjustment procedures.
Depth:
Comprehensive, suitable for both professional mechanics and experienced DIY enthusiasts. Covers everything from basic adjustments to full engine and transmission rebuilds.
Engine Type:
Air-cooled, 45-degree V-twin, four-stroke
Displacement:
73.7 cubic inches (1208 cc)
Bore X Stroke:
3.4375 in x 4.25 in (87.3 mm x 108 mm)
Compression Ratio:
8.0:1 (typical for Shovelhead)
Horsepower:
Approximately 60 HP @ 5000 RPM (estimate, specific rating may vary)
Torque:
Approximately 70 lb-ft @ 3000 RPM (estimate, specific rating may vary)
Carburetor:
Linkert M74B or equivalent Keihin (check manual for specifics)
Fuel Type:
Unleaded gasoline, minimum 87 octane (RON+MON)/2
Wheelbase:
Approximately 63.5 inches (1613 mm)
Length:
Approximately 90 inches (2286 mm)
Dry Weight:
Approximately 600 lbs (272 kg)
Gross Vehicle Weight Rating:
Approximately 950 lbs (431 kg)
Safety Standards:
No formal crash ratings for motorcycles of this era; focus is on mechanical integrity and rider control.
Braking System:
Front: Disc brake; Rear: Drum brake.
Lighting:
Headlight, taillight, stop light, turn signals, brake light.
Frame Construction:
Steel tube frame, designed for stability and rider feedback.
Oil Change Interval:
Every 2,000 miles or annually (refer to manual for precise interval and oil type).
Primary Chain Adjustment:
Every 1,000 miles or as needed.
Spark Plug Replacement:
Every 5,000-10,000 miles (check manual for specific plug type and gap).
Engine Oil Type:
Viscosity: SAE 20W-50 or SAE 50 (check manual for specific recommendations based on climate and oil type, e.g., mineral or synthetic).
Transmission Oil Type:
Harley-Davidson Transmission Lubricant (HTL) or equivalent SAE 80W-90 gear oil.
Primary Chain Case Oil:
Harley-Davidson Primary Chaincase Lubricant (or similar) SAE 70W-85.
Brake Fluid Type:
DOT 4 (for front disc brake system).
Common Concerns:
Shovelhead engines are known for oil leaks, valve seat wear, and the need for regular ignition timing adjustments. Carburetor tuning can be critical for smooth running. Primary chain tension needs consistent monitoring.
Heritage:
Harley-Davidson, established in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and classic styling.
Shovelhead Era:
The FL 1200 represents the evolution of Harley-Davidson's large displacement cruisers, featuring the Shovelhead engine introduced in 1966, known for its distinctive sound and power delivery.
Production Period:
1980 model year
