Original Market:
Flagship touring motorcycle, premium segment for long-distance riding and police use.
Competitors:
Triumph Bonneville, BSA models, Indian Chief (though Indian's production was declining).
Design Philosophy:
Robust construction, powerful V-twin engine, comfortable riding position, ample luggage capacity (optional).
Innovation:
Introduction of the distinctive Hydra-Glide fork on some models offered improved front suspension characteristics.
Value Proposition For Manual
Target Audience:
Harley-Davidson Electra Glide owners, restorers, mechanics, and enthusiasts seeking to maintain or repair these classic motorcycles.
Manual Utility:
Essential resource for accurate maintenance, diagnostics, and repairs, ensuring longevity and originality of vintage bikes.
Years Covered:
1959, 1960, 1961, 1962, 1963, 1964, 1965, 1966, 1967, 1968, 1969
Models Covered:
Electra Glide (FLHF, FLH variants)
Estimated Page Count:
500+
Manual Type:
Workshop Service Repair Manual
Engine:
Panhead (998cc, 1200cc) and early Shovelhead (1200cc) engine overhauls, tuning, specifications, and troubleshooting.
Transmission:
4-speed constant mesh transmission, including disassembly, assembly, troubleshooting, and fluid specifications.
Electrical System:
Ignition system (points, coils, condensers), lighting, charging system (generator/alternator), starting system, wiring diagrams for all models and years.
Fuel System:
Carburetor (Linkert, Keihin) tuning, rebuilding, and specifications; fuel tank, lines, and pump.
Brakes:
Drum brake systems (front and rear), including adjustment, lining replacement, and troubleshooting.
Suspension:
Hydra-Glide fork (FLHF) and conventional fork (FLH) maintenance, seal replacement, and adjustment; rear shock absorber service.
Chassis And Frame:
Frame inspection, repair, and specifications; steering head bearing adjustment.
Bodywork And Trim:
Fenders, fuel tanks, fairings (if applicable to early models), saddlebags, and trim piece removal, installation, and maintenance.
Wheels And Tires:
Wheel bearing service, spoke tension adjustment, tire fitting, and specifications.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication points, spark plug checks, battery care.
Troubleshooting:
Diagnostic guides for common and uncommon issues related to engine performance, electrical faults, starting problems, and braking.
Repair:
Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.
Engine Rebuild:
Comprehensive procedures for top-end and bottom-end engine rebuilds, including piston ring replacement, valve grinding, bearing inspection, and gasket replacement.
Transmission Overhaul:
Complete overhaul procedures for the 4-speed gearbox, including gear inspection, shift drum and fork alignment, and clutch service.
Electrical Diagnostics:
Wiring diagram interpretation, fault finding, and repair for all electrical circuits.
Depth:
Factory-level technical data, including torque specifications, clearance measurements, timing procedures, and component tolerances.
Diagnostics:
In-depth diagnostic procedures for identifying root causes of mechanical and electrical failures.
Rebuild Procedures:
Complete disassembly and reassembly instructions for major components and sub-assemblies.
Engine Type:
Air-cooled, 45-degree V-twin
Engine Families Covered:
Panhead (998cc, 1200cc), early Shovelhead (1200cc)
Bore X Stroke 998Cc:
3.4375 in x 4.25 in (87.3 mm x 107.95 mm)
Bore X Stroke 1200Cc:
3.4375 in x 4.75 in (87.3 mm x 120.65 mm)
Compression Ratio:
Approx. 7.0:1 to 8.0:1 (varies by year and model)
Horsepower 998Cc:
Approx. 50-55 hp
Horsepower 1200Cc:
Approx. 58-65 hp
Torque Peak:
Approx. 65-75 ft-lbs (varies by displacement)
Carburetor Types:
Linkert (M Series), Keihin (early CV style)
Fuel Type:
Unleaded gasoline (Octane rating as per manual recommendations, typically 91+)
Valve Train:
OHV (Overhead Valve), pushrod actuated
Transmission Type:
4-speed constant mesh, foot shift with heel-and-toe lever
Transmission Options:
None (4-speed was standard for this era)
Clutch Type:
Wet multi-plate, foot-actuated
Primary Drive:
Duplex chain
Transmission Oil Type:
Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant (or equivalent high-quality gear oil, e.g., SAE 50 or 60)
Transmission Oil Capacity:
Approx. 20-24 oz (0.6 - 0.7 L)
Safety Ratings:
No formal crash ratings for this era of motorcycle.
Braking System:
Front and rear drum brakes. Brake system is mechanical with cable actuation.
Lighting:
Headlight, taillight, brake light, turn signals (depending on market and year), running lights.
Frame Construction:
Steel tube frame designed for stability and durability.
Suspension Design:
Telescopic front fork (Hydra-Glide or conventional) and dual rear shock absorbers provide ride comfort and control.
Oil Change Interval:
Every 2,000-3,000 miles or annually, whichever comes first. Primary and transmission oil changes are often recommended at similar intervals.
Spark Plug Replacement:
Every 6,000-10,000 miles or as recommended in the manual.
Chain Adjustment:
Regularly check and adjust primary chain and belt drive tension as per manual specifications.
Engine Oil Type:
Motorcycle-specific mineral oil (e.g., 20W50 or 50W depending on temperature and manual recommendation). Avoid modern synthetic oils not specified for vintage engines.
Engine Oil Capacity:
Approx. 4 US quarts (3.8 L)
Brake Fluid Type:
Not applicable for hydraulic brakes; drum brakes are mechanical.
Fork Oil Type:
Specific motorcycle fork oil (e.g., SAE 10W or 20W), capacity varies by fork type and year.
Common Wear Items:
Valve guides, piston rings, generator/alternator brushes, clutch plates, brake linings, wiring insulation degradation.
Electrical Aging:
Aging wiring harnesses and components can lead to intermittent electrical faults. Generator output may decrease over time.
Carburetor Performance:
Linkert carburetors can be prone to wear and require frequent adjustment or rebuilding for optimal performance.
Engine Leaks:
Likely to experience oil leaks from pushrod tubes, crankcase seals, and head gaskets due to aging rubber and cork seals.
Brand Identity:
Iconic American motorcycle manufacturer known for its V-twin engines, touring capabilities, and distinct styling.
Electra Glide Introduction:
Introduced in 1965 as a successor to the Duo-Glide, featuring the iconic large fairing and extensive touring amenities.
Panhead Era End:
The Panhead engine design, prevalent in early Electra Glides, was phased out with the introduction of the Shovelhead in 1966.
Hydra Glide Transition:
The Hydra-Glide front suspension system was a significant development, offering smoother travel than earlier springer forks.
Manufacturing Location:
Milwaukee, Wisconsin, USA
Significance Of Era:
This decade represents a critical transition period for Harley-Davidson, from the iconic Panhead to the introduction of the Shovelhead engine, and refinement of their large touring platform.
