Harley Davidson FLHS Shovelhead 1981 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHS Shovelhead Year: 1981 Codes Engine Family Code: Shovelhead 👋 Introduction Market Position Vehicle Class: Full-size cruiser motorcycle Target Demographic: Enthusiasts and owners...

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Type: Motorcycle

Vendor:

Sku: 484092

Tags: 1981 FLHS Shovelhead Harley Davidson Misc Motorcycle Motorcycles

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

FLHS Shovelhead

Year:

Codes

Engine Family Code:

Shovelhead

👋 Introduction

Market Position

Vehicle Class:

Full-size cruiser motorcycle

Target Demographic:

Enthusiasts and owners seeking to maintain or repair their classic Harley-Davidson cruiser.

Competitive Analysis

Competitors 1981:

Indian (limited production), custom choppers, other V-twin motorcycles.

Key Features

Engine Layout:

Air-cooled V-twin

Transmission Type:

4-speed

Style:

Classic cruiser styling with touring elements (FLHS designation usually implies fairing and saddlebags).

📋 Manual Details

Coverage Areas

Primary Coverage:

Harley-Davidson FLHS Shovelhead 1981

Page Count

Estimated Page Count:

Varies by specific edition; typically 300-500 pages for a comprehensive service manual.

Manual Type

Manual Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

PDF (Digital)

📖 Manual Coverage

Systems Covered

Engine Mechanics:

Detailed disassembly, inspection, and reassembly of Shovelhead engine components (cylinders, pistons, heads, crankshaft, camshafts, valve train).

Fuel System:

Carburetor (likely Keihin butterfly or Linkert, depending on specific FLHS configuration) service, adjustment, and troubleshooting; fuel tank, lines, and petcock maintenance.

Ignition System:

Points ignition system service, timing adjustment, coil testing, spark plug selection, and troubleshooting.

Transmission And Drivetrain:

4-speed constant mesh transmission service, clutch operation and adjustment, primary chain maintenance, final drive belt/chain inspection and adjustment.

Electrical System:

Wiring diagrams, lighting systems, battery maintenance, charging system (generator/alternator), starter system, ignition switches, and accessory circuits.

Brakes:

Front and rear brake system service, hydraulic fluid changes, caliper and master cylinder overhaul, brake pad/shoe replacement, and drum brake adjustment.

Suspension And Steering:

Front fork (likely hydraulic with air assist or spring-over-oil) service, rear shock absorber inspection and replacement, steering head bearing adjustment.

Chassis And Frame:

Frame inspection, fork triple tree service, wheel bearing maintenance, axle removal and installation.

Bodywork And Trim:

Fender removal/installation, fuel tank mounting, seat adjustment, handlebar and control lever servicing, basic panel fitting.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, chain/belt lubrication and adjustment, brake adjustments, tire pressure checks.

Troubleshooting:

Diagnostic flowcharts and common problem-solving techniques for engine, electrical, and mechanical issues.

Major Repairs:

Complete engine rebuilds, transmission overhauls, fork seal replacements, brake caliper rebuilds.

Component Replacement:

Step-by-step guides for replacing specific parts like pistons, valves, bearings, clutches, ignition components, etc.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from basic rider maintenance to full engine and transmission overhauls.

Diagnostic Capabilities:

Detailed instructions for diagnosing electrical faults, carburetor issues, ignition timing problems, and mechanical noises.

Special Tools:

Identification of required special tools and their usage for specific procedures (e.g., flywheel puller, valve spring compressor).

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable if a well-scanned original document.

Print Quality:

Depends on the source scan; generally optimized for readability.

Binding Type

Binding Type:

Not applicable for digital PDF format.

Paper Type

Paper Type:

Not applicable for digital PDF format.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Harley-Davidson Shovelhead Evolution V-twin

Displacement:

74 cubic inches (1200cc) or 80 cubic inches (1340cc) depending on specific FLHS variant for 1981.

Bore X Stroke:

Varies by displacement: 74ci (3.4375 in x 4.00 in), 80ci (3.50 in x 4.25 in)

Compression Ratio:

Typically around 7.0:1 to 8.0:1 for Shovelheads of this era.

Valve Train:

Overhead Valve (OHV), pushrod actuated.

Performance

Horsepower:

Estimated 55-65 HP, highly dependent on tuning and exact configuration.

Torque:

Estimated 65-75 lb-ft, also dependent on tuning.

Fuel System

Carburetor Type:

Likely Keihin butterfly carburetors (e.g., CV or butterfly models) or potentially a Linkert depending on late-model application.

Fuel Type:

Unleaded gasoline, octane rating recommendation will be specified in the manual (typically 87-91 AKI).

Lubrication System

Oil Type:

Viscosity and type will be specified, commonly SAE 20W-50 motorcycle oil.

Oil Capacity:

Approx. 3-4 quarts (depending on filter).

Ignition System

Ignition Type:

Battery and Coil with points and condenser.

Engine Cooling

Cooling Method:

Air-cooled

🔧 Transmission

Standard

Transmission Type:

4-speed constant mesh, foot shift with heel-toe lever.

Optional

Optional Transmissions:

None for this model year/type.

Features

Clutch Type:

Wet, multi-plate, cable-actuated.

Primary Drive:

Duplex chain drive from engine to transmission.

Final Drive:

Belt drive (typically 132-tooth belt).

Fluid Specifications

Transmission Oil Type:

Harley-Davidson recommends specific transmission fluids; SAE 75W-90 or similar gear oil often used, consult manual for exact spec.

📐 Dimensions

Exterior

Wheelbase:

Approximately 62.5 inches.

Length:

Approximately 90 inches (varies with fairing).

Weights

Dry Weight:

Approximately 600-650 lbs.

Gvwr:

Not typically specified by manufacturer for motorcycles in the same way as cars.

Fuel Capacity:

Approx. 4.0 US gallons (including reserve).

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not applicable to motorcycles in the traditional automotive sense.

Active Features

Braking System:

Dual disc front, single disc rear (standard on FLHS).

Lighting:

Halogen headlight, taillight, brake light, turn signals.

Passive Features

Frame Construction:

Steel frame with robust construction.

Rider Protection:

Handlebar controls, footboards, seat providing rider contact points.

💡 Technology Features

Infotainment

Infotainment System:

Not applicable; this era of motorcycle features basic analog instrumentation.

Driver Assistance

Driver Assistance Features:

Not applicable.

Connectivity

Connectivity Options:

Not applicable.

Instrumentation

Dashboard Features:

Analog speedometer, tachometer (optional), odometer, ammeter, oil pressure gauge, indicator lights.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 2,000-3,000 miles or annually, as per original service manual recommendations.

Primary Chain Tensioner Adjustment:

Check/adjust every 5,000-10,000 miles.

Valve Lash Adjustment:

Recommended every 5,000-10,000 miles, or as needed for optimal performance.

Spark Plug Replacement:

Every 5,000-10,000 miles, or as indicated by wear.

Fluid Specifications

Engine Oil Viscosity:

SAE 20W-50 recommended for air-cooled V-twins of this era.

Transmission Oil Type:

Consult manual for specific H-D or equivalent gear oil.

Brake Fluid Type:

DOT 4 (typically for hydraulic systems of this period).

Known Issues

Shovelhead Common Issues:

Oil leaks (especially rear main seal), oil consumption, primary chain adjuster wear, valve seat recession (with unleaded fuel), points ignition timing drift.

Electrical Issues:

Aging wiring harnesses, voltage regulator failures, charging system issues.

Transmission Issues:

Clutch drag, shift linkage adjustment.

📚 Vehicle History

Brand Heritage

Brand Origin:

Founded in Milwaukee, Wisconsin, USA in 1903.

Brand Reputation:

Iconic American motorcycle manufacturer renowned for V-twin engines and distinctive styling.

Model Evolution

Shovelhead Era:

Shovelhead engine was produced from 1966 to 1984, a significant period in Harley-Davidson's history.

Flhs Designation:

FLHS typically denoted a 'Sport-Touring' model, often featuring a fairing and saddlebags.

Production

Production Years:

The Shovelhead engine was produced from 1966 to 1984. The FLHS model was produced during various years within this range, with 1981 being a specific target.

Manufacturing Location:

Milwaukee, Wisconsin, USA.

🏆 Awards & Recognition

Recognitions

Model Recognition:

The Shovelhead engine is a highly sought-after and iconic powerplant in the vintage motorcycle community, often featured in custom builds and recognized for its character.