🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLH Shovelhead

Year:

1982

Model Code:

FLH (typically represents the Electra Glide model series)

Engine Code:

Shovelhead (refers to the characteristic cylinder head design)

👋 Introduction

Positioning:

A critical resource for owners and independent mechanics of the iconic Harley-Davidson FLH Shovelhead series from 1982. Targets enthusiasts seeking to maintain, repair, or restore these classic motorcycles.

Value Proposition:

Provides essential technical data and procedural guidance that may be difficult to obtain elsewhere for a motorcycle of this vintage. Offers significant cost savings compared to dealership-only service for owners performing their own maintenance.

Manual Benefit:

Enables DIY maintenance and repair, aids in diagnosing and fixing common Shovelhead issues, and facilitates proper restoration by providing factory-level technical information.

Historical Significance:

Covers a pivotal year in Harley-Davidson's history, bridging the AMF era and the emergence of Harley-Davidson Motor Company under new ownership, featuring key Shovelhead engine developments.

📋 Manual Details

Manual Type:

Service Repair Manual

Language:

English

Format:

PDF

Page Count Estimated:

Estimated 300-500 pages (typical for a comprehensive service manual of this era)

📖 Manual Coverage

Engine:

Shovelhead V-Twin, carburetor systems (e.g., Keihin butterfly, VM series), ignition system (points/electronic), lubrication system (oil pump, filter), cooling (air-cooled), exhaust system, engine assembly/disassembly.

Transmission:

4-speed constant mesh transmission, clutch system (wet multi-plate), shifter linkage, gearbox disassembly/assembly, lubrication.

Chassis And Suspension:

Frame inspection and repair, front fork (Guelph, possibly AMF era designs), rear shock absorbers, swingarm, bearings (steering head, wheel), suspension adjustments.

Brakes:

Front disc brake (single or dual caliper depending on FLH variant), rear drum brake, brake system bleeding, caliper/master cylinder overhaul, brake pad replacement, linkage.

Electrical:

Wiring diagrams, lighting (headlight, tail light, turn signals), battery system, charging system (alternator, regulator), starter motor, ignition switch, switches (handlebar controls), instrumentation, horn.

Fuel System:

Fuel tank removal/installation, fuel lines, fuel petcock, carburetor adjustment/rebuild, fuel pump (if applicable).

Bodywork And Trim:

Fender removal/installation, fairing (if equipped), seat, saddlebags, fuel tank painting/decals, chrome parts, fairing mounting.

Maintenance:

Oil changes, filter replacement, spark plug inspection/replacement, chain adjustment (if applicable), battery care, brake fluid checks, tire pressure checks, air filter cleaning/replacement.

Troubleshooting:

Diagnostic charts for common starting problems, engine misfires, electrical faults, braking issues, transmission noise, and suspension problems.

Repair:

Engine overhaul, transmission rebuild, carburetor tuning, brake caliper rebuild, electrical component replacement, suspension fork service, clutch adjustment, starter motor service.

Technical Specifications:

Torque specifications for all fasteners, engine timings, valve clearances, fluid capacities, ignition timing settings, electrical resistance values.

Depth:

Comprehensive: Covers everything from basic preventative maintenance and adjustments to complete engine, transmission, and electrical system teardowns and rebuilds. Includes detailed diagrams and troubleshooting guides.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable if OCR'd properly, allowing quick navigation to specific topics.

Printability:

Printable, allowing users to create physical copies of specific sections or the entire manual.

Quality Description:

Depends on the source scan quality. Good quality scans will have clear text and legible diagrams. Poor quality scans may have blurry images or missing text.

Binding Description:

N/A (Digital PDF format)

Paper Description:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Type:

Air-cooled, V-twin, 45-degree cylinder angle

Engine Displacement Cc:

1200cc (74 cubic inch) and potentially 1340cc (82 cubic inch) for later 1982 models or variants.

Engine Designation:

Shovelhead

Bore X Stroke In:

Approx. 3.4375 in x 4.25 in (for 74ci); Approx. 3.4375 in x 4.25 in (for 80ci) / Approx. 3.4375 in x 4.25 in (for 82ci).

Compression Ratio:

Typically 8.0:1 to 8.5:1 depending on variant.

Valve Train:

OHV (Overhead Valve) with pushrods

Horsepower Hp:

Approx. 60-70 HP (estimated, varies by model and tuning)

Torque Lb Ft:

Approx. 75-85 lb-ft (estimated, varies by model and tuning)

Carburetor Type:

Keihin butterfly, or possibly a later CV (Constant Velocity) carburetor for some 1982 models.

Fuel Type:

Unleaded gasoline, typically 91 octane (AKI) or higher.

Fuel Capacity Gallons:

Varies by model (e.g., FLH models often had 5-gallon tanks).

Oil Type:

Viscosity grade typically SAE 20W-50 or SAE 50 (mineral oil recommended for vintage engines).

Oil Capacity Quarts:

Approx. 3 quarts (with filter change).

Oil Filter Part Number:

Generic equivalents like Harley-Davidson 63796-77A or aftermarket equivalent (e.g., Fram PH8A, Purolator L40015).

🔧 Transmission

Transmission Type:

4-speed constant mesh manual

Gear Ratios:

Specific ratios will be detailed in the manual, but typical for this era: 1st: ~2.44:1, 2nd: ~1.77:1, 3rd: ~1.36:1, 4th: 1.00:1.

Clutch Type:

Wet, multi-plate

Primary Drive:

Duplex chain drive to transmission.

Final Drive:

Belt drive (standard for FLH models) or chain drive (for some earlier or custom variants).

Transmission Fluid Type:

Harley-Davidson recommended primary lubricant, often a specific gear oil or heavier weight engine oil (e.g., SAE 50 or 60).

📐 Dimensions

Wheelbase In:

Approximately 60.5 inches

Seat Height In:

Varies by model and suspension, typically around 30-32 inches laden.

Dry Weight Lbs:

Approximately 650-700 lbs (depending on FLH variant and equipment).

Gross Vehicle Weight Rating Gvwr Lbs:

Not typically published as a strict GVWR but designed to carry rider and passenger plus luggage.

🛡️ Safety Features

Safety Ratings:

Not applicable for motorcycles of this era in the same way as modern cars. Safety is primarily dependent on rider skill and the motorcycle's mechanical condition.

Active Safety Features:

Disc brake (front), drum brake (rear). Rider skill and situational awareness are primary active safety features.

Passive Safety Features:

Robust frame construction, robust braking components for the era. No passive electronic safety features like ABS or airbags.

💡 Technology Features

Infotainment System:

Basic analog instrumentation: speedometer, tachometer (optional), ammeter, oil pressure gauge. No modern infotainment features.

Driver Assistance Features:

None. Relies entirely on rider input and control.

Connectivity Features:

None. Analog systems only.

🔧 Maintenance

Oil Change Interval Miles:

Typically every 2,000-3,000 miles or annually.

Spark Plug Replacement Miles:

Check every 5,000 miles, replace as needed or every 10,000-15,000 miles.

Drive Belt Inspection Miles:

Inspect tension and condition every 5,000 miles.

Brake Fluid Flush Months:

Recommended every 12-24 months, or sooner if fluid appears contaminated.

Engine Oil Viscosity:

SAE 20W-50 or SAE 50

Primary Chain Case Fluid:

SAE 50 or SAE 60 gear oil or Harley-Davidson Primary Chaincase Lubricant.

Brake Fluid Type:

DOT 3 or DOT 4 glycol-based brake fluid (check specific master cylinder)

Common Issues:

Oil leaks (pan gasket, primary cover, pushrod tubes), carburetor tuning sensitivity, weak charging systems (early regulators), points ignition calibration, clutch adjustment, starter clutch issues, tappet noise, fork seal leaks.

Common Issues Engine:

Valve seat wear, pushrod seal leaks, oil pump drive gear wear.

📚 Vehicle History

Brand Heritage:

Harley-Davidson, founded in 1903, has a long and storied history in American motorcycling, known for its V-twin engines and touring motorcycles.

Model Evolution:

The FLH is part of Harley-Davidson's long-standing line of large-displacement touring motorcycles. The Shovelhead engine was produced from 1966 to 1984, evolving through various iterations and improvements, including the introduction of electronic ignition and 5-speed transmissions in later years. 1982 represents a transition year as the company moved towards newer technologies.

Production Era:

Shovelhead engines were produced from 1966-1984. The FLH designation has been used for various touring models throughout Harley-Davidson's history.

Manufacturing Location:

York, Pennsylvania, USA and Milwaukee, Wisconsin, USA.

🏆 Awards & Recognition

Awards:

The Harley-Davidson FLH Shovelhead itself is an icon within the motorcycle community and is often recognized for its distinctive styling and sound, contributing to Harley-Davidson's enduring legacy, rather than receiving specific automotive awards.