Engine:
Shovelhead V-Twin (including assembly, disassembly, timing, cooling, lubrication, ignition)
Fuel System:
Carburetor (e.g., Keihin Butterfly, CV), fuel lines, fuel pump (if applicable)
Ignition System:
Points and Condenser, Electronic Ignition (e.g., early solid-state), spark plugs, coils, timing
Transmission:
4-speed Cruise Drive Transmission (including clutch, primary drive, gearbox, shifter linkage)
Electrical System:
Battery, charging system (generator/alternator), lighting (headlight, taillight, signals), starter motor, wiring diagrams, fuses
Brakes:
Hydraulic disc brakes (front and rear), master cylinders, calipers, brake lines, bleeding procedures
Suspension:
Front forks (e.g., 35mm conventional), rear shock absorbers, swingarm, wheel bearings
Chassis Frame:
Frame construction, steering head bearings, body mounting
Wheels Tires:
Spoked wheels, wheel balancing, tire mounting and specifications
Controls:
Handlebars, throttle, clutch, brake levers, foot controls, cables
Exhaust System:
Exhaust pipes, mufflers, mounting
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, lubrication points, tune-ups
Engine Overhaul:
Top-end rebuild (cylinders, pistons, heads), bottom-end overhaul (crankshaft, bearings)
Transmission Repair:
Clutch replacement, gear inspection, bearing replacement, seal replacement
Electrical Troubleshooting:
Wiring diagram interpretation, diagnostic procedures for charging, starting, and lighting issues
Brake System Service:
Pad replacement, caliper service, master cylinder rebuild, brake fluid bleeding
Suspension Fork Service:
Fork oil replacement, seal replacement, fork component inspection
Carburetor Adjustment Rebuild:
Disassembly, cleaning, reassembly, jetting, idle speed and mixture adjustments
Ignition Timing Adjustment:
Setting ignition timing using static or dynamic methods
Wheel Alignment And Truing:
Checking and adjusting wheel spoke tension for trueness
Depth:
Comprehensive (covers disassembly, repair, reassembly, and troubleshooting for most components)
Diagnostic Procedures:
Detailed troubleshooting charts and step-by-step diagnostic guides
Torque Specifications:
Precise torque values for critical fasteners and engine components
Special Tools:
Identification and usage of specialized tools required for specific procedures
Engine Family:
Shovelhead V-Twin
Engine Configuration:
Air-cooled, 45-degree V-twin
Displacement Variants:
Typically 74 cubic inches (1210cc) and 80 cubic inches (1310cc)
Bore X Stroke 74Ci:
3.4375 in x 4.25 in (87.3 mm x 108.0 mm)
Bore X Stroke 80Ci:
3.50 in x 4.25 in (88.9 mm x 108.0 mm)
Horsepower Approximate 74Ci:
Approximately 55-60 HP (at crankshaft, stock configuration)
Torque Approximate 74Ci:
Approximately 60-65 ft-lbs (at crankshaft, stock configuration)
Carburetor Types:
Keihin Butterfly, Keihin Constant Velocity (CV) carburetor common for this era, some may have aftermarket options.
Fuel Type:
Unleaded gasoline (typically 87-91 octane)
Oil Change Interval:
Typically every 2,000-3,000 miles or 6 months (check manual for exact recommendation based on riding conditions)
Primary Chain Tension Adjustment:
Check every 5,000 miles, adjust as needed
Spark Plug Replacement:
Every 5,000-10,000 miles (depending on plug type)
Engine Oil Type:
Varies by preference and climate. Historically, straight-weight oils (e.g., SAE 50 or 60) were common. Modern recommendations often include specific motorcycle-grade synthetics or semi-synthetics (e.g., 20W-50).
Engine Oil Capacity:
Approximately 3 quarts (2.8 liters) for 74ci, 3.5 quarts (3.3 liters) for 80ci (check manual)
Transmission Oil Type:
API GL-4 gear oil (e.g., SAE 80W-90 or 85W-140)
Transmission Oil Capacity:
Approximately 1 quart (0.95 liters) (check manual)
Brake Fluid Type:
DOT 4 or DOT 5 silicone fluid (verify specific model recommendation, DOT 5 was common for later H-D models of this era, but DOT 4 is also used)
Oil Leaks:
Common across Shovelheads due to aging seals and gaskets. Manual provides procedures for replacement.
Carburetor Tuning:
Can be finicky; requires regular adjustment and cleaning. Manual covers tuning procedures.
Primary Chain Tension:
Can loosen over time, leading to premature wear. Manual details adjustment.
Kickstand Switch:
May fail, preventing starting. Manual covers troubleshooting.
Carburetor Float Bowl Leaks:
Can occur if the float needle and seat are worn. Manual details replacement and adjustment.
