Harley Davidson Shovelhead Evolution Big Twins 1970-1999 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Big Twin (Shovelhead & Evolution) Model Generations Covered: Shovelhead (1970-1984), Evolution Big Twin (1984-1999) Codes Engine Code Family: Shovelhead (F-Series), Evolution Big Twin...

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Type: Motorcycle

Vendor:

Sku: 470676

Tags: 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 Evolution Big Twins Harley Davidson Misc Motorcycle Motorcycles Shovelhead

Product variants

Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Big Twin (Shovelhead & Evolution)

Model Generations Covered:

Shovelhead (1970-1984), Evolution Big Twin (1984-1999)

Codes

Engine Code Family:

Shovelhead (F-Series), Evolution Big Twin (1340cc - '93-'98 models often have 'FXST', 'FLST', 'FXR', 'FLT' prefixes followed by engine displacement designation)

👋 Introduction

Market Position

Positioning:

Essential diagnostic and repair resource for owners and independent mechanics of iconic Harley-Davidson Big Twin motorcycles.

Competitive Analysis

Value Proposition:

Provides factory-level information, critical for accurate maintenance and repair, saving time and money compared to dealership service or less comprehensive manuals.

Key Features

Features:

Covers two distinct, yet related, engine platforms, offering extensive coverage over a 30-year period of Big Twin evolution. Instant PDF download eliminates waiting time.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Repair, Workshop

Supported Models:

All Big Twin Shovelhead and Evolution engine models (e.g., FL, FX, FXR, FLT, FXST, FLST, Dyna) within the specified years.

Page Count

Estimated Pages:

Likely over 500 pages (typical for comprehensive factory service manuals covering multiple engine/chassis configurations and years).

Manual Type

Type:

Factory Service Manual (FSM) / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (Shovelhead, Evolution Big Twin 1340cc), Transmission (4-speed, 5-speed), Drivetrain (Primary, Final Drive)

Chassis:

Frame, Suspension (Front & Rear), Brakes (Front & Rear), Wheels, Tires, Steering

Electrical:

Ignition System, Lighting, Charging System, Starting System, Wiring Diagrams, Gauges, Controls

Bodywork:

Fuel Tanks, Fenders, Seat, Handlebars, Controls, Fairings (if applicable to specific models within the range)

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacement, lubrication, adjustments (carburetor, ignition timing, clutch, brakes)

Repair:

Engine teardown and reassembly, transmission overhaul, brake system repair, electrical component replacement, suspension servicing, carburetor rebuilding, fuel injection diagnosis (Evolution models)

Troubleshooting:

Diagnostic charts for common problems, identification of causes and solutions for performance issues, electrical faults, starting problems.

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds)

Diagnostic Capabilities:

Includes specific diagnostic procedures and specifications for identifying and rectifying issues across all major systems.

📊 Manual Specifications

File Format

File Format:

Searchability:

Likely text-searchable if professionally scanned/created.

Print Quality

Quality:

Digital PDF, quality depends on the source scanning/creation.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type Shovelhead:

Air-cooled V-twin

Engine Type Evolution:

Air-cooled V-twin (with some liquid-cooled variants in later Softail models, though this manual likely focuses on air-cooled Big Twins)

Displacement Shovelhead:

74 cubic inches (1200cc), 80 cubic inches (1340cc)

Displacement Evolution:

80 cubic inches (1340cc)

Performance

Horsepower Range:

Varies by year and model, typically 50-65 HP for stock configurations.

Torque Range:

Varies by year and model, typically 65-85 ft-lbs for stock configurations.

Fuel System

Fuel System Shovelhead:

Carbureted (e.g., Keihin Butterfly, Linkert (early), Mikuni optional)

Fuel System Evolution:

Carbureted (e.g., Keihin CV 40mm) and Fuel Injection (H-D Electronic Sequential Port Fuel Injection - ESPFI) for later models.

Ignition

Ignition System:

Contact Breaker Points (early Shovelhead), Electronic Ignition (later Shovelhead and Evolution models), Single Fire/Dual Fire ignition systems.

🔧 Transmission

Standard

Transmission Type Early:

4-speed Constant Mesh (Trapezoidal gear sets in Shovelhead)

Transmission Type Late:

5-speed Constant Mesh (Newer gear sets in Evolution)

Optional

Optional Gearsets:

Performance gear sets or aftermarket 6-speed conversions are not covered by this factory manual but may be referenced for comparison of specifications.

Features

Clutch Type:

Wet multi-plate clutch

Transmission Fluid:

Specific Harley-Davidson or recommended aftermarket transmission fluids (e.g., Syn3, Formula+).

📐 Dimensions

Exterior

Wheelbase:

Varies significantly by model (e.g., FL models generally longer than FX models). Typical range: 60-64 inches.

Seat Height:

Varies by model and suspension. Typical range: 25-28 inches.

Weights

Dry Weight:

Varies by model. Typical range: 550-650 lbs.

Gross Vehicle Weight Rating:

Varies by model, typically around 900-1000 lbs.

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not applicable for motorcycles of this era in the same way as passenger cars; focus is on mechanical integrity and rider protection.

Active Features

Active Safety Features:

Primarily relies on rider skill and well-maintained braking systems. ABS was not common during most of this period.

Passive Features

Passive Safety Features:

Frame integrity, rider controls, lighting for visibility.

💡 Technology Features

Infotainment

Infotainment Systems:

Basic instrumentation (speedometer, tachometer, oil pressure, neutral indicator, turn signals). Higher-end touring models may have rudimentary radio/cassette players.

Driver Assistance

Driver Assistance Features:

None in the modern sense. ABS not standard for most of this period. Rider aids are limited to basic controls.

Connectivity

Connectivity Features:

None.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 2,000-5,000 miles or 6-12 months, depending on oil type and operating conditions.

Primary Chain Adjustment:

Recommended at specified mileage intervals or when clutch slippage is noticed (critical for drivetrain longevity).

Spark Plug Replacement:

Typically every 10,000-15,000 miles.

Fluid Specifications

Engine Oil Type:

Viscosity varies by temperature, but typically 20W50 (e.g., Harley-Davidson Genuine Motor Oil, Mobil 1 V-Twin 20W50, Valvoline V-Twin 20W50).

Transmission Oil Type:

Harley-Davidson Formula+ or equivalent 80W90 gear oil.

Primary Chain Case Oil Type:

Harley-Davidson Formula+ or equivalent 30W motor oil.

Brake Fluid Type:

DOT 4 recommended for most models in this range.

Known Issues

Shovelhead Common Issues:

Oil leaks (especially at the rocker boxes and pushrod tubes), carburetor tuning difficulties, starter issues, transmission seal leaks, valve seat wear.

Evolution Common Issues:

Oil leaks (though generally less than Shovelheads), cam chain tensioner wear (especially on early Evo models), primary compensator issues, carburetor (CV) tuning quirks, starter clutch failure.

📚 Vehicle History

Brand Heritage

Heritage:

Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903, known for its V-twin engines and distinctive styling.

Model Evolution

Shovelhead Introduction:

Introduced in 1966 to replace the Panhead, featuring an updated engine design, primarily in 74ci and later 80ci configurations.

Evolution Introduction:

Introduced in 1984 as the 'Evolution' (or 'Evo') Big Twin, a significant redesign offering improved reliability, performance, and reduced vibration. Replaced the Shovelhead.

Production

Production Period:

Shovelhead: 1966-1984. Evolution Big Twin: 1984-2000 (though this manual covers up to 1999 for specific models like Dyna/Touring).

🏆 Awards & Recognition

Recognitions

Model Recognition:

The Shovelhead and Evolution Big Twins are considered cultural icons and have a strong following among motorcycle enthusiasts and collectors.

Ratings

Reliability Perception:

Generally good reliability when properly maintained, though Shovelheads are known for requiring more frequent attention than Evolution models.

Certifications

Manual Certification:

This is a service manual, not a vehicle certification. Its value lies in its official or de facto factory content.