Harley Davidson FLH Shovelhead 1979 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLH Shovelhead Year: 1979 Codes Model Code: FLH-80 Engine Family Code: Shovelhead 👋 Introduction Market Position Vintage Appeal: Targets owners and enthusiasts of...

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类型: Motorcycle

斯库: 484085

标签: 1979 FLH Shovelhead Harley Davidson Misc Motorcycle Motorcycles

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

FLH Shovelhead

Year:

Codes

Model Code:

FLH-80

Engine Family Code:

Shovelhead

👋 Introduction

Market Position

Vintage Appeal:

Targets owners and enthusiasts of classic Harley-Davidson motorcycles, particularly the iconic Shovelhead era.

Competitive Analysis

Value Proposition:

Provides essential, hard-to-find technical information for maintaining and repairing a significant model in Harley-Davidson's history, enabling DIY repairs and professional service.

Key Features

Digital Accessibility:

PDF format offers convenience, searchability, and easy access on multiple devices, unlike fragile paper manuals.

Comprehensive Data:

Contains factory-level detail crucial for accurate diagnostics and repairs, reflecting the original intent of the manufacturer.

📋 Manual Details

Coverage Areas

Coverage:

Comprehensive service and repair for 1979 Harley-Davidson FLH Shovelhead models.

Page Count

Page Count:

Estimated 300-400 pages (typical for this era of manual).

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

V-Twin OHV air-cooled engine, including top-end, bottom-end, lubrication, cooling, and ignition systems.

Fuel System:

Carburetor (e.g., Keihin Butterfly, Bing), fuel tanks, fuel lines, petcock, and fuel pump (if applicable).

Transmission:

4-speed constant mesh transmission, clutch assembly, primary drive, and gearbox lubrication.

Electrical System:

Battery, charging system (generator/alternator), ignition system (points, coil, spark plugs), lighting, starting system, and wiring diagrams.

Chassis:

Frame, suspension (forks, shocks), wheels, tires, steering, and controls.

Brakes:

Front and rear brake systems (hydraulic drum or disc, depending on specific FLH variant), brake lines, master cylinders, and calipers.

Bodywork:

Fenders, fuel tank, seat, handlebars, and minor fairings/covers.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug inspection/replacement, chain adjustment, tire pressure checks, brake adjustments.

Engine Repair:

Top-end rebuild (cylinder heads, valves, pistons), bottom-end overhaul (crankshaft, connecting rods, bearings), camshaft installation.

Transmission Repair:

Clutch plate replacement, gear inspection and replacement, seal replacement, troubleshooting shifting issues.

Electrical Troubleshooting:

Diagnosing starting problems, charging system faults, ignition timing issues, and wiring harness repairs using provided diagrams.

Carburetor Service:

Disassembly, cleaning, adjustment, and rebuilding of common carburetors for the era.

Suspension Service:

Fork oil changes, seal replacement, rear shock absorber inspection and replacement.

Brake Service:

Brake fluid bleeding, pad/shoe replacement, caliper/wheel cylinder inspection.

Technical Depth

Depth:

Detailed step-by-step repair instructions, diagnostic procedures, torque specifications, electrical schematics, and part identification.

Diagnostic Capability:

Includes common symptoms and potential causes for mechanical and electrical issues, guiding the technician towards accurate diagnosis.

Rebuild Procedures:

Covers complete engine and transmission overhauls, with clear instructions for disassembly, cleaning, inspection, and reassembly.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text content for quick information retrieval.

Resolution:

High-resolution scans for clear text and legible diagrams.

Print Quality

Printability:

Printable pages for on-hand reference during service.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 45-degree V-twin, OHV (Overhead Valve)

Displacement:

74 cubic inches (1200cc)

Bore X Stroke:

3.4375 in x 4.25 in (87.3 mm x 107.95 mm)

Compression Ratio:

Approximately 8.0:1 (may vary slightly with specific configurations)

Valve Train:

Pushrod actuated overhead valves

Performance

Horsepower:

Estimated 60-65 HP (at crankshaft, may vary)

Torque:

Estimated 65-70 ft-lbs (at crankshaft, may vary)

Fuel System

Carburetor Type:

Typically Keihin Butterfly, Bing, or Linkert (depending on original equipment and changes).

Fuel Grade:

Unleaded gasoline, 91 octane (AKI) or higher recommended.

Ignition System

Ignition Type:

Contact breaker points ignition system with a single dual-output ignition coil.

🔧 Transmission

Standard

Type:

4-speed constant mesh, manual transmission

Primary Drive:

Duplex chain drive with a wet multi-plate clutch.

Optional

Gear Ratios:

Manual specifies ratios for each gear (e.g., 1st: 2.44, 2nd: 1.52, 3rd: 1.15, 4th: 0.86).

Features

Fluid Type:

Harley-Davidson recommends specific primary lubricant or equivalent SAE 50W motorcycle oil.

Fluid Capacity:

Approximately 24 US fl oz (0.7 L) for the primary drive/transmission.

📐 Dimensions

Exterior

Wheelbase:

Approximately 60.5 inches (1537 mm)

Overall Length:

Approximately 93 inches (2362 mm)

Weights

Dry Weight:

Approximately 640 lbs (290 kg) for FLH models.

Fuel Capacity:

Typically 5 US gallons (19 L) for the main tank.

Oil Capacity:

Approximately 4 US quarts (3.8 L) for the engine oil sump.

🛡️ Safety Features

Ratings

Crash Safety Standards:

N/A (Pre-dates modern motorcycle safety rating systems like NHTSA or Euro NCAP for bikes).

Active Features

Braking System:

Hydraulic disc brake on front, drum or disc brake on rear (depending on FLH variant), requiring careful maintenance for optimal performance.

Passive Features

Lighting:

Headlight, taillight, brake light, turn signals (if equipped), crucial for visibility.

💡 Technology Features

Infotainment

Audio System:

Optional AM radio with CB and intercom capabilities on some touring models, often aftermarket additions.

Driver Assistance

Not applicable (ABS was not a feature in 1979).

Connectivity

Bluetooth:

Not applicable (Bluetooth was not a feature in 1979).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 2,000-3,000 miles (or 3-4 months), whichever comes first.

Primary Lubricant Change:

Every 5,000-6,000 miles (or annually).

Spark Plug Inspection:

Inspect every 2,500 miles, replace as needed. Torque: 15-20 ft-lbs.

Chain Adjustment:

Check and adjust primary chain tension at regular intervals, typically within a specified slack range (e.g., 1/2 inch to 3/4 inch).

Fluid Specifications

Engine Oil:

Harley-Davidson 20W-50 (or equivalent quality motorcycle-specific oil).

Primary Lubricant:

Harley-Davidson Primary Lubricant or SAE 50W motorcycle oil.

Brake Fluid:

DOT 4 hydraulic brake fluid (for disc brakes).

Known Issues

Oil Leaks:

Common for older Shovelheads to develop minor oil leaks from gaskets, seals, and pushrod tubes.

Carburetor Tuning:

May require frequent adjustments due to wear or variations in fuel quality.

Electrical Reliability:

Older wiring harnesses and components can degrade, leading to intermittent electrical faults.

Charging System:

Generators/alternators and voltage regulators can be prone to failure over time.

📚 Vehicle History

Brand Heritage

Legacy:

Harley-Davidson, an iconic American motorcycle manufacturer with a rich history dating back to 1903.

Model Evolution

Shovelhead Era:

The Shovelhead engine replaced the Panhead engine in 1966 and was produced until 1983, representing a significant period of development for Harley-Davidson's big twins.

Flh Designation:

FLH signifies the 'Electra Glide' touring model, characterized by its larger frame, fairings, saddlebags, and passenger comfort features.

Production

Manufacturing Location:

Milwaukee, Wisconsin, USA

🏆 Awards & Recognition

Recognitions

Motorcycle Icon:

The Shovelhead engine and the FLH platform are considered cultural icons within motorcycling, representing a golden era of American V-twin cruisers.

Ratings

Reliability Rating:

Variable, highly dependent on maintenance and previous ownership. Manual provides the means to improve reliability.

Certifications

Oem Standards:

Adheres to original Harley-Davidson factory service standards.