Engine:
Detailed disassembly, assembly, inspection, and repair of the 1340cc Shovelhead engine, including cylinders, pistons, crankshaft, camshaft, valve train, oil pump, and lubrication system.
Fuel System:
Carburetor (e.g., Keihin butterfly or Bendix Zenith) overhaul, adjustment, and troubleshooting; fuel tank, fuel lines, and fuel filter service.
Ignition System:
Ignition timing, spark plugs, ignition coils, breaker points, condenser, and electronic ignition systems (if applicable to specific models of 1982 FL).
Transmission:
4-speed constant mesh gearbox service, including clutch operation, primary drive, gear engagement, shifting mechanisms, and final drive (chain or belt).
Electrical System:
Wiring diagrams, charging system (alternator, regulator), starting system (starter motor, solenoid), lighting, battery service, fuses, and instrumentation.
Brakes:
Hydraulic disc brake system service (front and rear), including master cylinder, caliper, brake lines, pads, and rotors; parking brake (if equipped).
Suspension:
Front fork service (hydraulics, seals, springs), rear shock absorber replacement and adjustment, swingarm and pivot bearing maintenance.
Frame And Bodywork:
Frame inspection, handlebars, controls, seat mounting, fender installation and removal, exhaust system service, and accessory mounting.
Wheels And Tires:
Wheel bearing maintenance, tire replacement, tube service, and spoke tension adjustment.
Maintenance Procedures:
Scheduled maintenance tasks, fluid changes (engine oil, primary oil, transmission oil), filter replacements, lubrication points, and tune-up procedures.
Repair Procedures:
Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation of all major systems.
Troubleshooting:
Diagnostic charts and procedures to identify and resolve common operational problems and failures.
Adjustment Procedures:
Carburetor tuning, ignition timing setting, clutch and brake lever adjustments, suspension sag settings.
Special Tool Requirements:
Identification and usage of specific Harley-Davidson or aftermarket tools required for certain procedures.
Depth Of Coverage:
Comprehensive, covering everything from basic routine maintenance to complete engine and transmission overhauls.
Diagnostic Capability:
Advanced diagnostic procedures for electrical and mechanical systems, including component testing and fault finding.
Rebuild Instructions:
Detailed instructions for complete engine and transmission rebuilds, including specifications for wear limits and clearances.
Engine Type:
Air-cooled V-twin, OHV (Overhead Valve)
Bore X Stroke:
Typically 3.4375 in x 4.25 in (87.31 mm x 107.95 mm) for the 1340cc (80 cubic inch) Shovelhead.
Compression Ratio:
Varied by model and tune, often around 8.0:1 to 8.5:1 for stock configurations.
Horsepower:
Approximately 65-70 hp at 5000-5500 RPM (estimated, varies by specific tune and model variant).
Torque:
Approximately 80-85 ft-lbs at 3000-4000 RPM (estimated).
Carburetor Type:
Commonly Keihin butterfly (e.g., CV) or Bendix Zenith Stromberg, depending on the specific FL variant.
Fuel Type:
Unleaded gasoline, 87 octane (Octane rating may vary based on regional availability and specific engine tuning).
Oil Capacity:
Approximately 3 quarts (2.8 Liters) for the engine and primary chaincase combined (dry fill).
Oil Type:
Harley-Davidson specified 20W50 motorcycle oil, often a blend or full synthetic meeting H-D specifications. Check manual for exact spec.
Engine Oil Change:
Typically every 2,500 - 5,000 miles (4,000 - 8,000 km) or as recommended by Harley-Davidson for the era. Check manual for exact interval.
Primary Chain Tension Check:
Regular checks, often at oil change intervals or every 1,000-2,500 miles.
Spark Plug Replacement:
Typically every 5,000 - 10,000 miles, depending on plug type and condition.
Tune Up Schedule:
Carburetor and ignition timing adjustments usually recommended annually or every 5,000 miles.
Engine Oil Specification:
Harley-Davidson 20W50 motorcycle oil (or equivalent meeting H-D specification).
Primary Oil Specification:
Typically the same as engine oil (20W50) or a dedicated primary chain lubricant.
Transmission Oil Specification:
Harley-Davidson 80W90 gear oil (or equivalent meeting H-D specification).
Brake Fluid Specification:
DOT 3 or DOT 4 hydraulic brake fluid. Always verify with the manual.
Shovelhead Reliability:
Known for being robust but requiring diligent maintenance. Common issues can include oil leaks (especially from the crankcase), pushrod tube seal leaks, and carburetor tuning sensitivity. Vibrations are inherent, requiring periodic checks of fasteners and mounts.
Electrical Components:
Aging wiring, voltage regulator failures, and starter solenoid issues can occur on older Shovelheads.
Clutch Adjustment:
Requires periodic adjustment to ensure proper engagement and disengagement.
