Segment:
Full-size touring motorcycle
Target Audience:
Touring riders, enthusiasts, custom builders
Competitors:
Indian Chief, Triumph Bonneville, BMW R series (at the time of production)
Design Philosophy:
Robust V-twin engine, comfortable ride for long distances, classic Harley-Davidson styling
Model Significance:
Established Harley-Davidson's dominance in the touring segment, iconic styling and performance
Primary Coverage:
Mechanical, electrical, and bodywork repair and maintenance
Secondary Coverage:
Troubleshooting, diagnostics, specifications, and component identification
Estimated Page Count:
~300-400 pages (typical for comprehensive workshop manuals of this era)
Type:
Workshop Service Repair Manual
Format:
Digital (PDF) likely, though original could be print
Engine Systems:
Engine assembly, top end, bottom end, lubrication, cooling (air-cooled), ignition, carburetor(s)
Transmission Drivetrain:
Clutch, gearbox, primary drive, final drive (chain)
Electrical System:
Wiring diagrams, lighting, battery, generator/alternator, starter, ignition system components, instruments
Chassis Suspension:
Frame, front forks (telescopic), rear suspension (swingarm, shock absorbers)
Braking System:
Front drum brake, rear drum brake, brake linkage and cables
Fuel System:
Fuel tank, fuel lines, fuel petcock, carburetor tuning and rebuild
Exhaust System:
Exhaust pipes, mufflers, mounting hardware
Bodywork Fittings:
Fenders, fairing (if applicable), seat, handlebars, controls, instrumentation, luggage (saddlebags, tour pack)
Maintenance:
Regular service intervals, lubrication, adjustments, fluid changes, filter replacement
Troubleshooting:
Diagnostic charts, common problems and solutions, symptom-based troubleshooting
Repair:
Detailed step-by-step instructions for component disassembly, overhaul, and reassembly
Overhaul:
Complete engine rebuild, gearbox overhaul, carburetor rebuilding
Adjustments:
Valve adjustments, ignition timing, carburetor synchronization, clutch and brake adjustments
Electrical Diagnostics:
Testing of electrical components, circuit tracing, wiring harness repair
Depth:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts
Diagnostics:
Advanced diagnostic procedures and troubleshooting trees
Special Tools:
Identification and usage of specialized tools required for specific procedures
Engine Type:
Air-cooled, four-stroke, OHV V-twin
Displacement:
74 cubic inches (1208cc)
Bore X Stroke:
3.4375 in x 4.25 in (87.3 mm x 108 mm)
Compression Ratio:
8.0:1 (typical for this era, may vary slightly)
Valve Train:
Overhead Valves (OHV), pushrod actuated
Cylinder Material:
Cast iron
Piston Material:
Aluminum alloy
Horsepower Rating:
Approximately 50-60 HP (at crank, estimated)
Torque Rating:
Approximately 60-70 ft-lbs (at crank, estimated)
Carburetor Type:
Linkert M-series or Keihin butterfly (depending on specific model year and options)
Fuel Type:
Unleaded gasoline (minimum 87 octane)
Fuel Capacity:
Typically 4-5 gallons (refer to specific model specifications)
Oil System Type:
Dry sump with oil tank mounted separately (typical for Shovelhead era)
Oil Capacity:
Approximately 4 quarts (including oil filter and lines)
Recommended Oil Viscosity:
20W-50 (typical, refer to manual for exact spec)
Ignition System:
Battery and coil, points ignition
Spark Plug Type:
Champion H12 or equivalent (verify in manual)
Wheelbase:
Approximately 62.5 inches (1588 mm)
Length:
Approximately 92 inches (2337 mm)
Seat Height:
Approximately 29-30 inches (737-762 mm)
Dry Weight:
Approximately 650-700 lbs (295-318 kg)
Gross Vehicle Weight Rating:
Approximately 1000 lbs (454 kg)
Front Wheel:
19-inch steel spoked
Rear Wheel:
16-inch steel spoked
Front Tire Size:
3.00-19 or 3.25-19
Wheel Bolt Pattern:
N/A (spoked wheels with hub assembly)
Crash Safety Ratings:
Not applicable/tested under modern standards for vintage motorcycles
Braking System:
Front and rear drum brakes, mechanical actuation
Frame Construction:
Steel tube cradle frame providing structural integrity
Lighting:
Headlight, taillight, brake light, turn signals
Initial Service:
First service typically at 500-1000 miles (check oil, adjust primary chain, check fasteners)
Regular Oil Change:
Every 2000-3000 miles (or as per manual)
Primary Chain Adjustment:
Every 2000-3000 miles
Valve Adjustment:
Every 5000-10000 miles (critical for performance and longevity)
Spark Plug Replacement:
Every 5000-10000 miles (or as needed)
Engine Oil:
Harley-Davidson 20W-50 or equivalent motorcycle-specific oil
Primary Chain Case Fluid:
Harley-Davidson Primary Chaincase Lubricant or SAE 70W GL-4 gear oil
Transmission Oil:
SAE 50 or Harley-Davidson 4-speed transmission oil
Brake Fluid:
DOT 3 or DOT 4 (verify drum brake specifications, may not use fluid)
Fork Oil:
Type 'E' or HD suspension fluid (refer to manual for specific viscosity and quantity)
Oil Leaks:
Common due to aging seals and gaskets (e.g., primary, transmission, crankcase)
Carburetor Issues:
Linkert carburetors can be finicky; require careful adjustment. Keihin butterfly carbs are generally more reliable.
Points Ignition:
Requires periodic inspection and adjustment for proper timing. Can be upgraded to electronic ignition.
Electrical System:
Wiring insulation can degrade over time; prone to shorts. Generator output may be lower than modern alternators.
Drum Brakes:
Require frequent adjustment and can be less effective than modern disc brakes, especially in wet conditions.
Primary Chain Tension:
Requires diligent adjustment to prevent wear on sprockets and chain.
Manufacturer:
Harley-Davidson Motor Company
Legacy:
Iconic American motorcycle manufacturer with a long history of V-twin engines and cruiser/touring designs
Electra Glide Introduction:
Introduced in 1965 as the first Harley-Davidson to feature an electric starter
Super Glide Introduction:
Introduced in 1971, a blend of the Electra Glide chassis with a more stripped-down Super Glide styling
Shovelhead Era:
These models fall within the 'Shovelhead' engine era (1966-1984), known for its distinctive look and sound.
Manufacturing Location:
York, Pennsylvania, USA
Key Innovations Era:
Introduction of the 'Shovelhead' engine (replacing the Panhead), electric start became more common.
