Brand Positioning:
Harley-Davidson occupied a significant niche in the American motorcycle market, appealing to riders seeking touring capability and classic American V-twin power.
Key Competitors:
During this era, competitors included models from Indian (briefly revived), and to a lesser extent, imported Japanese touring bikes which were gaining market share.
Vehicle Appeal:
Known for their distinctive V-twin engines, comfortable riding position for touring, robust construction, and iconic American styling.
Manual Value Proposition:
Provides essential information for maintaining, troubleshooting, and repairing these classic Harley-Davidson motorcycles, crucial for preserving their value and performance.
Engine Systems:
Engine disassembly, assembly, tuning, lubrication, cooling (air), fuel delivery (carburetion), ignition system, exhaust system
Transmission Drivetrain:
Transmission removal, disassembly, assembly, service, clutch operation, final drive (chain), primary drive
Chassis Suspension:
Front forks (Shovelhead era), rear shock absorbers, frame, swingarm, steering head bearings, wheel bearings
Braking System:
Front and rear brake caliper service, master cylinder, brake lines, brake pad replacement, hydraulic system bleeding
Electrical System:
Wiring diagrams, lighting (headlight, tail light, turn signals), battery, charging system (generator/alternator), starter motor, ignition switch, horn
Fuel System:
Carburetor service (e.g., Keihin, Linkert), fuel tank, fuel lines, fuel filter, fuel pump (if applicable)
Bodywork Fittings:
Fender removal/installation, fairing components (if applicable to specific models), seat mounting, saddlebags, handlebars, controls
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, spark plug service, chain adjustment, lubrication points, brake adjustments
Diagnostic Procedures:
Troubleshooting common problems, symptom-based diagnostics, testing electrical components, engine performance diagnosis
Repair Procedures:
Component disassembly, inspection, repair, and reassembly for all major vehicle systems
Engine Rebuild:
Detailed steps for complete engine teardown, inspection of internal components (pistons, cylinders, crankshaft, valves), and reassembly
Transmission Overhaul:
Procedures for complete transmission disassembly, gear inspection, bearing replacement, and reassembly
Electrical Troubleshooting:
Using wiring diagrams to diagnose and repair electrical faults, testing circuits, charging system diagnostics
Depth:
Factory-level technical information, including specifications, tolerances, torque values, and diagnostic charts
Detail Level:
Suitable for professional technicians and experienced DIY mechanics; covers complete rebuilds and in-depth troubleshooting
Engine Type:
Air-cooled, 45-degree V-twin OHV (Shovelhead engine architecture)
Displacement:
1207 cc (73.7 cubic inches)
Bore X Stroke:
3.4375 in x 4.25 in (87.3 mm x 108 mm)
Compression Ratio:
Typically 7.5:1 to 8.0:1 (depending on specific year and model variant)
Horsepower Est:
Approx. 60-65 HP @ 5000-5500 RPM (factory estimates, often higher in practice)
Torque Est:
Approx. 68-72 ft-lbs @ 3000-4000 RPM
Carburetor Variants:
Typically Keihin Butterfly, Linkert (earlier models), or S&S Super E/G (aftermarket upgrades)
Fuel Type:
Unleaded gasoline (minimum 87 octane recommended)
Oil Capacity With Filter:
Approx. 3 quarts (2.84 liters)
Oil Type Recommendation:
Harley-Davidson 20W-50 or equivalent motorcycle-specific oil meeting API SF or SG classification.
Wheelbase:
Approx. 60.5 inches (1537 mm)
Length:
Approx. 91.5 inches (2324 mm)
Dry Weight:
Approx. 620-650 lbs (281-295 kg) depending on model and equipment
Front Tire Size:
3.00 x 19 (often bias-ply)
Rear Tire Size:
4.00 x 18 (often bias-ply)
Front Brake Type:
Single Disc (introduced during this era, or Drum brakes on earlier models/variants)
Rear Brake Type:
Drum brake
Oil Change Interval:
Every 2,000-3,000 miles (3,200-4,800 km) or annually, whichever comes first.
Primary Chain Tensioner Check:
Check and adjust primary chain tension every 2,000 miles.
Spark Plug Replacement Interval:
Every 4,000-6,000 miles (6,400-9,600 km).
Wheel Bearing Lubrication:
Lubricate wheel bearings at major service intervals (e.g., every 10,000 miles) or as specified.
Brake Fluid Type:
DOT 4 or DOT 5 Silicone Brake Fluid (check specific model year recommendations as system changes occurred)
Fork Oil Type:
Harley-Davidson Type 'E' or 'B' Fork Oil (or equivalent SAE 10W or 15W fork oil).
Carburetor Leaks:
Potential for fuel leaks from older carburetor gaskets or seals.
Ignition System Reliability:
Contact breaker points and condensers can require frequent adjustment and can be a source of starting/running issues.
Oil Leaks:
Common across vintage motorcycles, especially around crankcase seals, valve guides, and rocker boxes.
Charging System Performance:
Generator or early alternator output may be marginal, especially under heavy electrical load.
Frame Cracks:
Less common but possible at weld points or stress areas on older frames, especially with heavy use.
Founding:
Harley-Davidson Motor Company founded in 1903, known for its long-standing tradition of American motorcycle manufacturing.
Electraglide Genesis:
The Electra Glide, introduced in 1965, revolutionized touring motorcycles with its full fairing, saddlebags, and comfortable seating.
Shovelhead Era:
This period (1966-1984) is characterized by the Shovelhead engine design, which replaced the Panhead and evolved through various iterations, including the 1200cc variants.
Fx Series Introduction:
The FX series (e.g., FX, FXE, FXS) emerged as distinct models, often featuring different frame designs or engine configurations (e.g., Swingarm frame vs. Hardtail frame on early FX models).
Manufacturing Location:
Milwaukee, Wisconsin, USA
