Publisher Reputation:
Clymer is a highly respected publisher of service and repair manuals, known for their comprehensive coverage and accuracy for a wide range of vehicles, including classic motorcycles.
Alternatives:
While factory service manuals (FSMs) exist, Clymer manuals are often more accessible and provide detailed explanations tailored for the independent mechanic. Other aftermarket publishers may offer comparable information, but Clymer is consistently a top choice for its depth.
Unique Selling Points:
Covers a broad range of Shovelhead years and model variations. Features detailed troubleshooting sections and clear, step-by-step instructions with diagrams. Essential resource for maintaining and restoring these iconic motorcycles.
Years Covered:
1966, 1967, 1968, 1969, 1970, 1971, 1972, 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984
Approximate Page Count:
250+
Type:
Service Repair Manual
Engine:
Engine overhaul, tuning, carburetor service (Keihin, Linkert), ignition system (points, electronic), lubrication system, cooling system (air-cooled specific considerations).
Transmission:
4-speed constant mesh transmission overhaul, clutch service, primary drive maintenance, gear shifting mechanisms.
Electrical:
Wiring diagrams (color-coded where available), battery service, charging system (generator/alternator), lighting, ignition switches, starter system, accessory wiring.
Chassis:
Frame inspection and repair, suspension (forks, shocks), steering head bearings, wheel bearings, brake systems (drum, disc variants), final drive (belt, chain).
Bodywork And Trim:
Fender removal and installation, fuel tank mounting and servicing, seat removal, control cable routing and adjustment, minor body panel alignment.
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, spark plug service, chain/belt adjustment, brake adjustments, lubrication points.
Troubleshooting:
Diagnostic charts for common starting issues, running problems, electrical faults, braking performance issues, and transmission shifting difficulties.
Repair:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major systems.
Rebuilds:
Comprehensive instructions for engine and transmission rebuilds, including torque specifications, clearances, and assembly sequences.
Adjustments:
Carburetor jetting and idle speed adjustments, ignition timing, clutch and brake lever adjustments, primary chain tension.
Level:
In-depth, covering from basic maintenance to complete engine and transmission overhauls and rebuilds. Suitable for home mechanics and professional technicians.
File Type:
Physical Printed Book
Print Resolution:
High-quality professional printing with clear text and legible diagrams.
Binding:
Staple-bound or perfect-bound, designed for workshop durability.
Paper Quality:
Durable, often gloss or semi-gloss paper stock to withstand workshop environments and repeated use.
Engine Type:
Air-cooled, 45-degree V-twin OHV (Overhead Valve)
Engine Displacement Variants:
74 cubic inches (1200cc) and 80 cubic inches (1340cc) - Note: 80ci became standard later in the production run.
Horsepower Range:
Typically 50-65 HP, depending on specific year, configuration, and tuning.
Torque Range:
Typically 65-75 lb-ft, depending on specific year, configuration, and tuning.
Carburetor Types:
Primarily Keihin butterfly carburetors (e.g., 36mm, 38mm) and earlier models may feature Linkert carburetors. Some models might have had S&S Super E or G aftermarkets fitted.
Fuel Type:
Unleaded gasoline, octane rating as per owner's manual or service bulletin (typically 87-91 octane).
Ignition Type:
Contact breaker points ignition system (most common) or early electronic ignition systems. Manual covers tuning, replacement, and troubleshooting for both.
Oil Type Recommendation:
Varies, but typically Harley-Davidson proprietary oil, or high-quality motorcycle-specific V-twin oils (e.g., SAE 20W50). Manual will specify detailed requirements.
Oil Capacity:
Approximately 3 quarts (2.8 liters) for dry sump system, including oil filter and oil tank. Exact capacity specified in manual.
Transmission Type:
4-speed constant mesh manual transmission
Transmission Variants:
No factory automatic transmissions offered. Variants related to case design and gear ratios might exist across the years.
Clutch Type:
Wet multi-plate clutch, operated via cable.
Primary Drive:
Chain drive from engine crankshaft to transmission input shaft, enclosed in a primary chaincase.
Final Drive:
Belt drive (most common) or chain drive, depending on the specific FL or FX model configuration.
Wheelbase Range:
Approximately 60-63 inches (1524-1600 mm), depending on model and year.
Dry Weight Range:
Approximately 550-650 lbs (250-295 kg), depending on model and equipment.
Gross Vehicle Weight Rating:
Typically around 850-950 lbs (385-430 kg).
Safety Standards:
Motorcycles of this era were not subject to the same rigorous safety testing standards as modern vehicles. Manual focuses on mechanical safety aspects like brake effectiveness and chassis integrity.
Braking System:
Front and rear drum brakes common on early models, transitioning to front disc brakes on many later models within this range. Manual details maintenance and adjustment for both.
Lighting System:
Headlight, tail light, brake light, turn signals (on most models). Manual covers electrical system troubleshooting for these.
Oil Change Interval:
Typically every 2,000-3,000 miles or annually, whichever comes first. Specific interval detailed in manual.
Primary Chain Tension Adjustment:
Check and adjust as needed, typically every 5,000 miles or if noise is present. Manual provides specific procedure.
Spark Plug Replacement:
Recommended every 5,000-10,000 miles or as needed for optimal performance. Manual will list compatible spark plug types.
Brake Adjustment And Inspection:
Regularly inspect pads/shoes and adjust cables or hydraulic systems as required. Manual will specify intervals and procedures.
Engine Oil Specification:
Refer to manual for exact viscosity and type. Often 20W50 motorcycle-specific V-twin oil is recommended. Harley-Davidson's own oils are also specified.
Transmission Fluid Specification:
Typically dedicated motorcycle transmission oil or Harley-Davidson Formula + transmission lubricant. Manual will detail correct type and capacity.
Primary Chaincase Lubricant:
Often shares transmission lubricant or uses specific primary lubricant. Refer to manual for exact type and capacity (typically around 1 quart).
Oil Leaks:
Common on Shovelheads due to aging seals, gaskets, and primitive design. Manual covers seal replacement and troubleshooting.
Carburetor Tuning:
Carburetors can be finicky and require regular tuning for optimal performance and fuel efficiency. Manual provides detailed tuning procedures.
Points Ignition Maintenance:
Points require periodic cleaning, gapping, and adjustment. Manual covers this critical maintenance task.
Pushrod Tube Leaks:
Pushrod tube seals can degrade and leak oil. Manual details replacement procedures.
Alternator/Generator Issues:
Charging system components can fail. Manual provides testing and replacement procedures.
Harley Davidson Legacy:
Harley-Davidson has a long-standing reputation for building powerful, distinctive V-twin motorcycles. The Shovelhead era represents a significant period of evolution and enduring appeal.
Shovelhead Development:
The Shovelhead engine, introduced in 1966 as an evolution of the Panhead, featured revised cylinder heads with improved valve cooling, leading to its nickname. It powered models like the Electra Glide, Super Glide, and Low Rider, defining American motorcycle culture for nearly two decades.
Production Period:
1966-1984. Replaced by the Evolution (Evo) engine in 1984.
Cultural Impact:
The Shovelhead engine is an icon of American motorcycle culture, celebrated for its raw power, distinctive sound, and classic styling. Recognized for its role in shaping the chopper and custom motorcycle scene.
Magazine Reviews Era:
Contemporary motorcycle magazines of the era often praised the Shovelhead for its torque and cruising capability, while sometimes noting vibration and maintenance requirements.
Manual Certification:
Clymer manuals are not officially certified by manufacturers but are widely regarded as authoritative aftermarket resources.
