Target Audience:
Professional motorcycle technicians, experienced DIY mechanics, and dedicated Harley-Davidson enthusiasts.
Manual Advantage:
Authentic factory documentation provides the most accurate and complete repair information, surpassing aftermarket alternatives in detail and scope.
Content Focus:
Emphasis on practical, step-by-step procedures, ensuring users can confidently perform repairs and maintenance.
Instructional Style:
Clear, concise language accompanied by detailed diagrams and illustrations to aid comprehension.
Primary Engine Systems:
Engine disassembly, assembly, inspection, repair, and adjustment procedures for the Shovelhead engine.
Fuel And Intake:
Carburetor (likely Linkert or Keihin butterfly) service, fuel tank and lines, air cleaner assembly.
Ignition And Electrical:
Ignition system (points, condenser, coil), lighting, charging system (generator/alternator, regulator), battery, wiring diagrams.
Transmission And Drivetrain:
Four-speed constant mesh transmission service, clutch operation and adjustment, primary drive chain, final drive belt/chain.
Chassis And Suspension:
Front fork (likely FLH style) disassembly, repair, and adjustment; rear shock absorbers and swingarm assembly; frame inspection and repair.
Braking System:
Front and rear brake systems (likely drum brakes for 1979 FL models, possibly early disc in some variations), hydraulic lines, master cylinder, caliper/wheel cylinder.
Bodywork And Fittings:
Fender removal and installation, fuel tank mounting, seat assembly, handlebars, controls, and exhaust system.
Maintenance Tasks:
Routine maintenance checks, lubrication points, fluid changes (engine oil, transmission oil), filter replacements, spark plug service.
Repair Procedures:
Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.
Troubleshooting Guides:
Diagnostic procedures for common performance issues, starting problems, electrical faults, and mechanical noises.
Adjustment Procedures:
Precise instructions for adjusting clutch, brakes, carburetor idle and mixture, ignition timing, and suspension.
Diagnostic Capability:
Advanced diagnostics for electrical systems, mechanical component wear, and performance tuning.
Rebuild Scope:
Comprehensive rebuild instructions for major components, including engine top-end and bottom-end, transmission, and suspension units.
Specification Detail:
Detailed torque specifications, clearances, tolerances, and measurement procedures for all critical components.
Binding Type:
Professional binding (e.g., saddle-stitch, perfect binding) for durability in workshop environments.
Paper Type:
Durable, high-quality paper stock suitable for workshop use, resistant to grease and oil stains.
Print Quality:
Clear, legible print with high-resolution diagrams and illustrations for accurate component identification.
Engine Type:
Air-cooled, 45-degree V-twin OHV (Shovelhead)
Engine Displacement:
73.75 cubic inches (1200cc)
Bore X Stroke:
3.4375 in x 4.25 in (87.3 mm x 108 mm) (typical for 1200cc Shovelhead)
Horsepower Rating:
Approx. 60-65 HP (varies with tuning and specific build)
Torque Rating:
Approx. 65-70 ft-lbs (varies)
Carburetor Type:
Likely a Linkert M74B or Keihin butterfly carburetor (specific to model/emissions)
Fuel Requirement:
Unleaded gasoline, octane rating as specified by Harley-Davidson (typically 90+ octane)
Safety Standards:
N/A (Pre-dates standardized motorcycle safety ratings as known today).
Braking System Type:
Front: Drum brake (possibly hydraulic disc on some later 1979 models), Rear: Drum brake.
Lighting System:
Headlight, taillight, brake light, turn signals (indicators).
Frame Construction:
Steel tube frame for structural integrity.
Engine Oil Change:
Typically every 2,000-3,000 miles or annually, whichever comes first.
Transmission Oil Change:
Typically every 5,000-10,000 miles or annually.
Clutch Adjustment:
As needed, but often checked every 5,000 miles.
Engine Oil Type:
SAE 20W-50 or SAE 50 motorcycle specific oil (e.g., Harley-Davidson branded or equivalent).
Transmission Oil Type:
Harley-Davidson Glideshaft Transmission Oil (or SAE 50/75W-90 GL-5 gear oil, depending on specific manual recommendation).
Primary Chain Case Oil:
Typically the same as engine oil.
Oil Leaks:
Common with Shovelhead engines due to aging seals and gaskets, requiring regular inspection and potential gasket replacement.
Carburetor Tuning:
Linkert or early Keihin carburetors may require frequent tuning for optimal performance and emissions.
Ignition Timing:
Points ignition requires periodic adjustment and maintenance for correct timing.
Pushrod Tubes:
O-rings on pushrod tubes can degrade, leading to oil leaks.
Brand Legacy:
Harley-Davidson, an iconic American motorcycle manufacturer with a rich history dating back to 1903.
Shovelhead Era:
The FL 1200 (Shovelhead) represents a significant era of Harley-Davidson's big twin motorcycles, evolving from the Panhead and knucklehead designs.
Production Period:
The Shovelhead engine was produced from 1966 to 1984. The FL 1200 designation specifically refers to the larger displacement models of this period.
Manufacturing Location:
Milwaukee, Wisconsin, USA
