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

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Shovelhead & Evolution Big Twins Engine Families: Shovelhead, Evolution Big Twin Codes Engine Designations: Shovelhead (F-head, OHV), Evolution (OHV) 👋 Introduction Market Position...

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Type: Motorcycle

Vendor:

Sku: 445497

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:

Shovelhead & Evolution Big Twins

Engine Families:

Shovelhead, Evolution Big Twin

Codes

Engine Designations:

Shovelhead (F-head, OHV), Evolution (OHV)

👋 Introduction

Market Position

Positioning:

Essential resource for owners and independent mechanics working on classic Harley-Davidson Big Twins, covering two iconic engine platforms.

Competitive Analysis

Competitors:

Covers the period when Harley-Davidson transitioned from the Shovelhead to the Evolution engine, making it uniquely valuable for this long span.

Key Features

Features:

Detailed diagrams, torque specifications, troubleshooting flowcharts, and step-by-step repair instructions.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Workshop Service and Repair

Year Coverage:

1970 through 1999

Model Variants Covered:

Includes FX, FL, FXR, and FLT chassis configurations (Big Twins) equipped with Shovelhead and Evolution engines.

Page Count

Estimated Page Count:

Manual Type

Type:

Factory-authorized style service manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine overhaul, cylinder heads, cylinders, pistons, crankshaft, camshaft, timing, lubrication, cooling (air), fuel delivery (carburetor/EFI), ignition system, starting system

Drivetrain Systems:

Transmission overhaul, clutch, primary drive, final drive, drive belts, chain maintenance

Chassis Systems:

Frame, suspension (forks, shocks), steering, brakes (hydraulic/mechanical), wheels, tires

Electrical Systems:

Wiring diagrams, lighting, charging system (alternator/generator), battery, ignition controls, instrumentation, diagnostic codes (OBD-I/OBD-II for Evolution)

Body And Frame:

Body panels, fenders, fuel tanks, seat, handlebars, fairings, luggage systems, frame inspection and repair.

Procedures Included

Maintenance:

Scheduled maintenance, lubrication, fluid changes, filter replacements, inspection checklists

Repair:

Component removal, installation, adjustment, troubleshooting, diagnostics, rebuilding procedures

Troubleshooting:

Step-by-step diagnostic guides for common and uncommon issues

Rebuilds:

Complete procedures for engine and transmission teardown, inspection, component replacement, and reassembly with specified clearances and torque values.

Wheel And Tire:

Wheel bearing replacement, tire mounting and balancing, spoke tensioning.

Technical Depth

Depth:

Comprehensive from basic service to complete engine and transmission rebuilds, including electrical system diagnostics and component replacement.

Diagnostics:

Covers diagnostic procedures for both electrical and mechanical faults. Includes troubleshooting charts and symptom-based fault finding.

Specifications Data:

Detailed torque values, clearances, assembly dimensions, and wiring schematics.

📊 Manual Specifications

File Format

Digital Format:

Searchable PDF, printable pages

Print Quality

Quality:

High-resolution scans with clear text and diagrams

Binding Type

Binding:

N/A (Digital)

Paper Type

Paper:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine Shovelhead

Engine Type:

Air-cooled, OHV V-Twin

Displacement Options:

74 cu in (1200cc), 80 cu in (1340cc)

Compression Ratio:

Varies by model and year, typically ranging from 8.0:1 to 9.0:1.

Primary Engine Evolution

Engine Type:

Air-cooled, OHV V-Twin

Displacement Options:

80 cu in (1340cc), 82 cu in (1340cc - later variants)

Compression Ratio:

Varies by model and year, generally higher than Shovelheads, often 9.0:1 or more.

Performance Shovelhead

Horsepower Torque:

Varies by year and specific model, but typically in the 55-65 HP range. Torque figures are substantial for cruising.

Performance Evolution

Horsepower Torque:

Varies by year and specific model, generally offering more consistent power and torque than earlier Shovelheads, often in the 60-70 HP range.

Fuel System

Carburetors:

Keihin Butterfly, Keihin CV, S&S Carburetors (common aftermarket)

Fuel System Evolution

Fuel Injection:

Electronic Fuel Injection (EFI) systems introduced in later Evolution models.

🔧 Transmission

Standard

Type:

4-speed, 5-speed constant mesh manual (depending on year and model).

Optional

Options:

Primarily 4-speed until the introduction of the 5-speed in 1980 for Shovelheads, and standard on Evolution Big Twins.

Features

Clutch:

Wet multi-plate clutch

Primary Drive:

Chain drive (single row) for Shovelheads, Rubber isolated chain drive for Evolution Big Twins.

📐 Dimensions

Exterior

Wheelbase:

Varies by model (e.g., FXWG, FLHT), typically around 60-63 inches.

Weights

Dry Weight:

Varies significantly by model, ranging from approximately 550-650 lbs.

🛡️ Safety Features

Ratings

Safety Ratings:

Not applicable for this era of motorcycle in terms of standardized crash ratings. Focus is on mechanical reliability and operational safety.

Active Features

Active Safety:

Disc brakes (front and rear, with single or dual calipers depending on model and year).

Passive Features

Passive Safety:

Robust frame construction, rider controls designed for intuitive operation.

💡 Technology Features

Infotainment

Infotainment Systems:

Basic analog instrumentation (speedometer, tachometer, oil pressure, voltage meter). Later Evolution models might feature cassette players or rudimentary CB radios on touring models.

Driver Assistance

Assistance Features:

None in the modern sense. ABS was not common or standard during this period. Focus is on rider control.

Connectivity

Connectivity Options:

Not applicable for this era.

🔧 Maintenance

Service Intervals

Oil Change:

Typically every 2,500-5,000 miles or annually, depending on usage and oil type.

Primary Chain Tension:

Regular checks and adjustment are critical, often recommended every 1,000-2,000 miles.

Tune Up:

Spark plug replacement, ignition timing checks, carburetor adjustments every 5,000-7,500 miles.

Fluid Specifications

Engine Oil:

Viscosity: 20W-50 or 10W-40 (API SG or higher). Specific Harley-Davidson recommendations apply. Check manual for exact types (e.g., Harley-Davidson 360).

Transmission Oil:

Harley-Davidson Formula + or equivalent 85W-140 gear oil.

Primary Chain Case Fluid:

Harley-Davidson Formula + or equivalent.

Brake Fluid:

DOT 4 (for most models, verify in manual).

Fork Oil:

Specific viscosity grade depends on fork type and year; manual provides precise recommendations (e.g., 10W).

Known Issues

Shovelhead Common:

Oil leaks (especially from pushrod tubes, rocker boxes), valve adjustments, primary chain adjustment, ignition points (pre-electronic ignition), carburetor tuning.

Evolution Common:

Cam chain tensioners (especially earlier models), oil leaks (less common than Shovelhead but still possible), starter issues, EFI sensor calibration.

📚 Vehicle History

Brand Heritage

Brand Legacy:

Harley-Davidson is synonymous with American motorcycle culture, known for its V-twin engines and distinctive styling.

Model Evolution

Shovelhead Era:

The Shovelhead engine (introduced 1966) was a significant development from the Panhead, featuring improved lubrication and a distinct cylinder head design. Dominated Harley's Big Twin lineup until the mid-1980s.

Evolution Introduction:

The Evolution engine (introduced 1984) was a revolutionary redesign for Harley-Davidson, improving reliability, performance, and emissions. It became the backbone of their Big Twin motorcycles.

Production

Production Span:

Shovelhead: 1966-1984 (though manual covers up to 1984 for Shovelhead variants). Evolution Big Twins: 1984-1999 and beyond.

🏆 Awards & Recognition

Recognitions

Model Recognition:

Harley-Davidson Big Twins, both Shovelhead and Evolution, are cultural icons and highly sought after by collectors and riders. Their enduring popularity is their primary recognition.