Category:
Cruiser Motorcycle - Performance & Custom
Target Audience:
Harley-Davidson FXWG Shovelhead owners, independent mechanics, restorers, enthusiasts.
Manual Availability:
Official factory manuals are essential for accurate and safe repairs on vintage models.
Completeness:
Official factory documentation ensures accuracy and adherence to manufacturer specifications.
Printability:
Allows users to create a physical copy for use in a workshop environment.
Diagnostic Focus:
Detailed troubleshooting guides aid in identifying and resolving complex issues.
Primary Coverage:
Complete Factory Service and Repair
Scope:
Mechanical, Electrical, Bodywork, Troubleshooting, Diagnostics
Estimated Pages:
Hundreds (exact count not specified, but described as 'complete')
Type:
Factory Service Manual / Repair Manual
Engine Mechanical:
Engine disassembly, assembly, internal components, lubrication, cooling, timing, compression testing.
Fuel System:
Carburetor (e.g., Keihin butterfly, CV variants), fuel delivery, fuel lines, fuel pump (if applicable).
Ignition System:
Spark plugs, ignition coils, points (if pre-electronic ignition), electronic ignition module, timing procedures.
Transmission:
Gearbox disassembly, assembly, shift mechanisms, clutch operation, primary drive, secondary drive (chain/belt).
Electrical System:
Wiring diagrams, lighting, battery, charging system (alternator, stator, regulator/rectifier), starter motor, switches, fuses.
Chassis And Suspension:
Frame inspection, front fork (e.g., FL style), rear suspension (shocks), wheel bearings, steering head bearings.
Brakes:
Front and rear brake systems (calipers, master cylinders, lines, pads, rotors), hydraulic systems, bleeding procedures.
Bodywork And Trim:
Fenders, fuel tank, seat mounting, handlebars, controls, instrument panel, external trim pieces.
Maintenance:
Oil changes, filter replacement, lubrication points, chain adjustment, battery maintenance, tire pressure.
Troubleshooting:
Diagnostic charts for common problems (e.g., starting issues, engine performance, electrical faults).
Repair:
Detailed step-by-step instructions for component replacement, overhaul, and system repairs.
Diagnostics:
Testing procedures for electrical components, engine performance checks, fuel system diagnostics.
Adjustments:
Carburetor tuning, ignition timing, clutch and brake lever adjustments, suspension adjustments.
Depth:
Comprehensive (from basic maintenance to full engine rebuilds and complex electrical diagnostics).
Level Of Detail:
Factory-level specifications, torque values, clearances, special tool requirements.
Configuration:
Air-cooled V-twin
Displacement:
Typically 80 cubic inches (1339 cc) for Shovelhead Big Twins, though 74 ci (1213 cc) variants also exist in this era.
Bore X Stroke:
80ci: 3.500 in x 4.250 in (88.9 mm x 107.95 mm)
Compression Ratio:
Typically 8.0:1 to 8.5:1 (varies by specific Shovelhead variant and tuning)
Horsepower:
Approximately 65-70 HP (Estimate based on typical Shovelhead configurations of the era)
Torque:
Approximately 70-80 ft-lbs (Estimate based on typical Shovelhead configurations of the era)
Carburetor:
Likely Keihin butterfly type or early CV carburetors.
Fuel Type:
Unleaded gasoline, minimum octane rating specified in manual (typically 87 or higher).
Oil System:
Dry-sump system with oil tank separate from engine crankcase.
Type:
4-speed constant mesh manual transmission
Clutch:
Wet multi-plate clutch, cable-actuated.
Primary Drive:
Chain drive (40-tooth engine sprocket, 22-tooth transmission sprocket typical).
Secondary Drive:
Belt drive (32-tooth pulley, 68-tooth sprocket typical).
Gear Ratios:
Ratios vary by specific gearbox but typically include: 1st: ~2.44, 2nd: ~1.77, 3rd: ~1.36, 4th: 1.00.
Transmission Fluid:
Harley-Davidson 3-speed or 4-speed transmission fluid, or equivalent 75W-90 GL-5 gear oil.
Oil Change:
Every 2,000-3,000 miles or 6 months (typical for the era, consult manual for precise recommendation).
Primary Chain Case Service:
Check tension at 1,000 miles, then every 5,000 miles (or as specified).
Spark Plug Replacement:
Every 5,000-10,000 miles (depending on plug type and condition).
Engine Oil:
Harley-Davidson SAE 20W-50 motorcycle oil or equivalent (e.g., Castrol GTX 20W-50). Capacity typically 3 quarts (2.8 liters) with filter.
Primary Chain Case Fluid:
Harley-Davidson primary lubricant, or SAE 50 weight motorcycle oil. Capacity approx. 1 quart (0.95 liters).
Brake Fluid:
DOT 4 hydraulic brake fluid (check manual for specific type and bleeding procedure).
Shifter Pawl Return Spring:
Can become weak, leading to false neutrals or difficulty shifting. Manual covers inspection and replacement.
Oil Leaks:
Common due to age and wear; manual details gasket and seal replacement procedures.
Carburetor Adjustment:
Can require frequent tuning for optimal performance; manual provides detailed adjustment procedures.
Electrical Connections:
Corrosion and loose connections can cause intermittent electrical problems. Manual includes wiring diagrams and testing methods.
Legacy:
Harley-Davidson's storied history in American motorcycling, known for its V-twin engines and iconic styling.
Fxwg Context:
The FXWG (Wide Glide) was a custom-styled cruiser, introduced in the late 1970s and evolving through the Shovelhead era, known for its raked-out front end and distinctive styling cues.
Shovelhead Era:
The Shovelhead engine, produced from 1966 to 1984, represented a significant period of Harley-Davidson's development before the introduction of the Evolution engine. 1984 was the final year for the Shovelhead, making this a notable model.
Manufacturing Location:
Milwaukee, Wisconsin, USA (Harley-Davidson's primary manufacturing site).
