Motorcycle Segment:
Cruiser / Touring
Target Audience:
Harley-Davidson owners, independent repair shops, vintage motorcycle enthusiasts
Competitors Era:
Honda Gold Wing, Kawasaki KZ series, Yamaha XS series, older Harley-Davidson models
Vehicle Appeal:
Iconic styling, V-twin rumble, classic American cruiser experience
Manual Value:
Essential for maintaining and repairing a vintage motorcycle, preserving its value and performance.
Engine Coverage:
Complete overhaul, repair, tuning, troubleshooting
Transmission Coverage:
Clutch, gearbox, primary drive, final drive
Electrical System Coverage:
Ignition, lighting, charging system, starter, wiring diagrams
Chassis Coverage:
Frame, suspension, steering, brakes, wheels, tires
Bodywork Coverage:
Fuel tank, fenders, seat, handlebars, controls
Troubleshooting Coverage:
Diagnostic procedures, common problems and solutions
Estimated Page Count:
500+
Type:
Workshop Service Repair Manual
Searchable:
Yes (typically text-searchable PDF)
Quality Description:
High-resolution digital scans ensuring clarity of text and diagrams.
Binding:
N/A (Digital Download)
Paper:
N/A (Digital Download)
Engine Management:
Carburetor tuning (Keihin, Mikuni), ignition timing, valve adjustment
Powertrain:
Engine disassembly/assembly, transmission rebuild, clutch service, final drive maintenance
Fuel System:
Fuel tank, fuel lines, fuel pump, carburetor overhaul and adjustment
Exhaust System:
Exhaust pipes, mufflers, heat shields inspection and replacement
Cooling System:
Air-cooled engine management, cylinder head cooling fin inspection
Ignition System:
Points, condenser, coil, spark plugs, timing procedures
Charging System:
Alternator, voltage regulator, battery maintenance
Starting System:
Starter motor, starter solenoid, bendix drive
Lighting System:
Headlight, taillight, turn signals, instrument panel illumination
Brakes:
Hydraulic front disc brake system, rear drum brake system maintenance and repair
Suspension:
Front fork (telescopic) overhaul, rear shock absorber inspection and replacement
Steering:
Steering head bearings, handlebar replacement, control cable adjustment
Wheels And Tires:
Wheel bearing service, tire mounting and balancing, spoke tension adjustment
Frame And Body:
Frame inspection, sheet metal repair, mounting hardware
Routine Maintenance:
Oil changes, filter replacements, lubrication points, chain adjustment
Major Overhauls:
Engine rebuild procedures, transmission disassembly and reassembly
Troubleshooting Guides:
Step-by-step diagnostic charts for common malfunctions
Repair Instructions:
Detailed instructions for component replacement and repair
Adjustments:
Carburetor, ignition timing, clutch, brakes, cables
Wiring Diagrams:
Comprehensive electrical schematics for troubleshooting and repairs
Depth:
Comprehensive: Covers all aspects from routine maintenance to full engine and transmission rebuilds.
Diagnostic Capabilities:
Advanced diagnostic procedures for identifying and resolving complex issues.
Special Tools:
Lists required special tools for specific procedures.
Engine Type:
Air-cooled, 45-degree V-twin
Displacement:
80 cu in (1300 cc)
Bore X Stroke:
3.4375 in x 4.25 in (87.3 mm x 108.0 mm)
Compression Ratio:
8.0:1 (typical for stock)
Valve Train:
Overhead valve (OHV), pushrod actuated
Carburetor:
Single Keihin Butterfly (e.g., CV or Concentric) or Mikuni
Horsepower Estimated:
Approx. 60-70 HP (varies with tuning)
Torque Estimated:
Approx. 70-80 lb-ft (varies with tuning)
Fuel Type:
Unleaded gasoline
Fuel Octane Rating:
Minimum 91 AKI (Octane Rating)
Safety Ratings:
N/A (Motorcycle safety not rated by traditional agencies)
Braking System:
Hydraulic front disc brake, rear mechanical drum brake
Lighting:
Headlight, taillight, brake light, turn signals
Frame Construction:
Steel tube frame
Rider Controls:
Handlebars, footpegs, hand levers
Oil Change Interval:
Every 2,000-3,000 miles or annually
Spark Plug Replacement:
Every 5,000-10,000 miles
Primary Chain Tensioner Check:
Check and adjust every 5,000 miles
Valve Adjustment:
Every 5,000-10,000 miles
Engine Oil Type:
Harley-Davidson 20W50 motorcycle oil or equivalent API SG/SH rated 20W-50
Engine Oil Capacity:
Approx. 3 quarts (2.8 liters) with filter change
Transmission Oil Type:
SAE 80W-90 gear oil
Primary Chain Case Oil Type:
Harley-Davidson Primary Chain Case Lubricant or SAE 90 gear oil
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Common Problems:
Oil leaks (especially from the Shovelhead top end), carburetor flooding/tuning issues, starter clutch failure, weak charging system, clutch drag.
Maintenance Tips:
Regularly check oil levels, keep ignition points clean and correctly gapped, ensure proper carburetor tuning, address any oil leaks promptly.
Brand History:
Harley-Davidson, founded in 1903, is one of the oldest motorcycle manufacturers in the world, renowned for its American V-twin motorcycles and custom cruiser culture.
Shovelhead Lineage:
The Shovelhead engine was introduced in 1966, replacing the Panhead. The FLHS (Electra Glide Sport) was a sportier variant of the touring FLH models, featuring a lower handlebar and solo seat.
Model Production Years:
Shovelhead engines produced from 1966 to 1984. FLHS specific variants existed throughout this period.
Manufacturing Location:
York, Pennsylvania, USA; Milwaukee, Wisconsin, USA
