Historical Context:
The Electra-Glide models of this era represented Harley-Davidson's flagship touring motorcycles, combining comfort and performance for long-distance riding. The Shovelhead engine was a significant evolution from the Panhead.
Competitors:
In its time, the Electra-Glide competed with other large-displacement V-twin motorcycles, though Harley-Davidson held a dominant position in the American market for this class of touring machine.
Motorcycle Attributes:
Air-cooled V-twin engine, robust frame, comfortable seating for rider and passenger, large fuel tank, often equipped with saddlebags and windshields for touring.
Usefulness:
Essential for owners and mechanics seeking to maintain, repair, and restore these iconic motorcycles, providing factory-accurate procedures and specifications.
Primary Coverage:
Service, Repair, Maintenance, Troubleshooting
Specific Models Covered:
Harley-Davidson FL Electra-Glide, Harley-Davidson FLH Electra-Glide
Applicable Years Detailed:
1966, 1967, 1968, 1969
Estimated Page Count:
Likely 300-500 pages (typical for this era of service manual)
Type:
Service Repair Manual
Format:
Digital Download (PDF)
Engine Mechanical:
Full overhaul, disassembly, inspection, reassembly of Shovelhead OHV engine (cylinder heads, cylinders, pistons, crankshaft, connecting rods, camshafts, lifters, pushrods, timing components)
Fuel System:
Carburetor service and adjustment (e.g., Linkert, Keihin), fuel lines, fuel pump (if applicable to specific models), fuel tank maintenance
Ignition System:
Magneto/generator systems, ignition timing, spark plugs, ignition coils, wiring
Transmission Drivetrain:
4-speed constant mesh transmission overhaul, clutch assembly, primary drive, final drive chain maintenance, gear ratios
Electrical System:
Wiring diagrams, lighting system (headlight, taillight, turn signals), charging system (generator/regulator), battery service, starter motor, horn, switches
Braking System:
Front and rear brake system service (drum brakes prevalent in this era), brake shoe replacement, brake linkage adjustment
Suspension Steering:
Front fork service (Girling or similar), rear shock absorber replacement, steering head bearing adjustment, wheel bearings
Frame Bodywork:
Frame inspection, fender removal/installation, seat mounting, handlebar service, basic body component adjustments
Maintenance Procedures:
Oil changes, filter replacement, spark plug replacement, chain lubrication and adjustment, brake adjustments, battery charging, general inspection checklists
Repair Procedures:
Complete engine rebuilds, transmission rebuilds, carburetor tuning and rebuilding, electrical component testing and replacement, brake system overhauls, suspension fork rebuilds
Troubleshooting Diagnostics:
Systematic diagnostic flowcharts for common problems, identification of symptoms and potential causes for engine, electrical, and drivetrain issues
Special Tool Requirements:
Identification and use of specialized Harley-Davidson tools required for specific repairs and adjustments
Depth:
Comprehensive, covering from basic routine maintenance to complete engine and transmission rebuilds. Detailed specifications and tolerances for internal engine components.
Searchability:
Likely text-searchable if digitally produced with OCR
Quality:
Dependent on the source scan/creation, but typically aims for clear text and legible diagrams.
Original Binding:
Likely a bound book (hardcover or softcover), wire-o, or comb-bound for factory/dealer manuals.
Digital Format Consideration:
Printable pages for easy referencing during work.
Original Paper:
Typically durable paper stock suitable for workshop environments.
Engine Type:
Air-cooled, 45-degree V-twin, OHV (Overhead Valve)
Engine Family:
Shovelhead
Displacement:
74 cubic inches (1213 cc)
Bore X Stroke:
3.4375 in x 4.25 in (87.3 mm x 108 mm) (typical for 74ci OHV)
Compression Ratio:
Approximately 8.0:1 (varies slightly by year/model)
Horsepower:
Estimated 60-65 HP (at rear wheel, varies by tuning and year)
Torque:
Estimated 75-80 ft-lbs (at rear wheel, varies by tuning and year)
Carburetion:
Single carburetor, typically Linkert (e.g., M74B) or early Keihin butterfly type.
Fuel Type:
Leaded or unleaded gasoline (depending on engine modifications for unleaded use).
Oil System:
Dry sump lubrication with oil tank mounted separately (typically in the frame downtube or battery compartment).
Transmission Type:
4-speed constant mesh manual transmission
Clutch Type:
Wet multi-plate clutch
Primary Drive:
Duplex chain drive within a primary cover.
Final Drive:
Chain drive to rear wheel.
Shift Mechanism:
Foot shift lever (left side) with toe and heel operation, typically linked to a hand clutch lever (left handlebar).
Transmission Fluid Type:
Gear oil, typically SAE 80W-90 or SAE 50. Specifics in manual.
Safety Standards Era:
Motorcycles of this era were not subject to the same stringent crash testing and safety rating systems as modern automobiles. Safety features focused on mechanical reliability and basic rider visibility.
Braking System:
Mechanical drum brakes (front and rear) requiring manual adjustment and maintenance.
Lighting:
Headlight, taillight, brake light, and turn signals for visibility. Reflectors.
Frame Construction:
Steel tube frame providing structural integrity.
Rider Ergonomics:
Designed for long-distance comfort, with rider controls positioned for efficient operation.
Engine Oil Change:
Typically every 1,000-2,000 miles or 6 months, whichever comes first. Specific interval detailed in the manual.
Primary Chain Adjustment:
Recommended every 500-1000 miles or as needed, depending on chain stretch. Manual provides precise procedure.
Spark Plug Replacement:
Typically every 6,000-10,000 miles. Manual will specify plug type and gap.
Engine Oil:
Viscosity typically SAE 20W-50 or SAE 50, often a motorcycle-specific oil. Manual specifies type and capacity.
Transmission Oil:
SAE 80W-90 gear oil or SAE 50 motorcycle oil. Manual specifies type and capacity.
Primary Chain Case Oil:
Typically the same as engine oil, but manual must be consulted for exact specification and quantity.
Engine Oil Leaks:
Common with vintage motorcycles; gasket and seal integrity is crucial. Manual covers seal replacement procedures.
Carburetor Tuning:
Linkert carburetors can be finicky and require precise adjustment. Manual provides tuning guides.
Electrical System Reliability:
Older wiring and components can degrade; proper insulation and connection maintenance are key. Wiring diagrams are vital (included).
Brake Performance:
Drum brakes offer less stopping power than modern disc brakes; regular adjustment and maintenance are essential for safety. Manual details adjustments.
Rocker Box Gaskets:
A common source of oil leaks on Shovelhead engines. Manual details replacement procedure.
Harley Davidson Legacy:
Harley-Davidson, founded in 1903, has a long and storied history of producing V-twin motorcycles, synonymous with American freedom and power. The Electra-Glide is a direct descendant of earlier large Harley touring models.
Electra Glide Lineage:
The Electra-Glide was introduced in 1965, succeeding the Panhead FL models. The 1966-1969 period marks the early introduction of the Shovelhead engine into this highly successful touring platform, evolving from the initial '65 Panhead era.
Shovelhead Introduction:
The Shovelhead engine, characterized by its distinctive rocker box covers resembling 'shovels,' replaced the Panhead engine in 1966, offering improved performance and reliability.
Manufacturing Location:
Milwaukee, Wisconsin, USA.
Significance:
These models are highly sought after by collectors and enthusiasts for their classic styling, powerful Shovelhead engine, and their role in defining the large American touring motorcycle.
