Category:
Classic American V-Twin Motorcycle
Segment:
Full-size touring cruiser
Competitors Era:
Other large displacement V-twins from American and European manufacturers of the early 1980s, though Harley-Davidson held a dominant position in its segment.
Engine Architecture:
Iconic Shovelhead V-twin engine, known for its distinctive sound and torque.
Model Purpose:
Designed for comfortable long-distance touring, with a relaxed riding position and ample luggage capacity.
Manual Value Proposition:
Essential resource for preserving, maintaining, and repairing a classic Harley-Davidson, ensuring longevity and optimal performance.
Engine:
Complete engine service, overhaul, tuning, diagnostics, component replacement (pistons, rings, valves, camshafts, timing, oil pump).
Transmission:
Service and repair of the 4-speed constant mesh transmission, including clutch, primary drive, and shifting mechanisms.
Drivetrain:
Rear drive, chain maintenance, belt drive systems (if applicable for FLHS), final drive unit.
Electrical System:
Ignition system (points, coils, spark plugs), charging system (generator/alternator, regulator), lighting, starter motor, battery, wiring diagrams, troubleshooting electrical faults.
Fuel System:
Carburetor service and tuning (likely Keihin Butterfly or CV), fuel tank, fuel lines, fuel pump (if applicable).
Brakes:
Front and rear brake systems (likely disc brakes), hydraulic components, pad replacement, bleeding procedures.
Suspension:
Front fork (leading axle or similar), rear shock absorbers, bushings, bearing maintenance.
Chassis And Frame:
Frame inspection, steering head bearings, wheel bearings, swingarm service.
Bodywork And Trim:
Fenders, tank, seat mounting, fairings (if any), saddlebag mounting and repair.
Maintenance:
Regular service intervals, oil changes, filter replacement, lubrication points, tune-ups, battery care, tire pressure.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault diagnosis charts.
Repair:
Detailed step-by-step repair procedures for all major and minor components, including engine rebuilds and transmission overhauls.
Disassembly And Assembly:
Comprehensive instructions for removing and reinstalling components.
Adjustments:
Carburetor adjustments, ignition timing, clutch and brake lever adjustments, suspension settings.
Specifications And Tolerances:
Torque specifications, clearances, wear limits for all major components.
Depth:
Comprehensive, covering everything from basic owner maintenance to complete engine and transmission rebuilds. Suitable for professional mechanics and experienced DIY enthusiasts.
Diagnostic Capabilities:
Advanced diagnostic procedures for electrical and mechanical systems, including troubleshooting common starting and running issues.
Component Level Detail:
Detailed diagrams and instructions for individual component servicing and replacement.
Engine Type:
Air-cooled, 45-degree V-twin
Engine Family:
Shovelhead
Displacement:
73.7 cubic inches (1207 cc) for the standard Shovelhead, though 80 cubic inch (1310 cc) versions were also prevalent.
Bore X Stroke:
Typically 3.4375 in. x 4.25 in. (87.3 mm x 108 mm) for 74ci; 3.5 in. x 4.25 in. (88.9 mm x 108 mm) for 80ci.
Compression Ratio:
Varied, but often around 7.5:1 to 8.0:1 depending on model and year.
Cylinder Heads:
Cast iron (earlier) or aluminum (later Shovelheads, though 1982 likely cast iron).
Valvetrain:
Overhead valves (OHV), two valves per cylinder, pushrod actuated.
Horsepower:
Estimated 60-65 HP at the crankshaft (exact figures often not officially published).
Torque:
Strong low-end torque, crucial for cruiser feel. Estimated 75-85 ft-lbs.
Carburetor:
Likely a Keihin Butterfly or a Keihin Constant Velocity (CV) carburetor, depending on specific FLHS configuration.
Fuel Type:
Unleaded gasoline
Oil Capacity:
Approximately 3 quarts (2.8 liters) of engine oil.
Oil Type:
Specific Harley-Davidson motorcycle oil recommended (e.g., 20W50).
Transmission Type:
4-speed constant mesh
Clutch:
Wet multi-plate clutch, cable operated.
Primary Drive:
Primary chain drive within a sealed primary cover.
Final Drive:
Belt drive on many touring models, but chain drive also possible for FLHS variants of this era. Manual will cover applicable system.
Gear Ratios:
Specific gear ratios will be detailed in the manual. Generally optimized for cruising.
Transmission Fluid:
Specialized Harley-Davidson transmission oil or equivalent (e.g., SAE 80W-90 gear oil, or primary case oil).
Wheelbase:
Typically around 62-63 inches (1575-1600 mm).
Length:
Approx. 90-94 inches (2286-2388 mm).
Height:
Variable based on seat and handlebars, but typically around 50-55 inches (1270-1397 mm).
Dry Weight:
Around 600-650 lbs (272-295 kg) depending on configuration.
Gross Vehicle Weight Rating:
Will be specified in the manual, considering rider, passenger, and luggage.
Crash Test Ratings:
Not applicable in the modern sense for motorcycles of this era.
Braking System:
Hydraulic disc brakes front and rear. Manual will cover proper function and maintenance.
Lighting:
Headlight, taillight, brake light, turn signals. Manual covers troubleshooting and maintenance.
Frame Integrity:
Robust steel frame designed for stability.
Tire Design:
Bias-ply tires common for the era, with specifications in manual.
Oil Change Interval:
Typically every 2,000-3,000 miles or annually. Manual will provide precise intervals.
Primary Chain Adjustment:
Recommended every 1,000-2,000 miles. Manual will detail procedure.
Spark Plug Replacement:
As per manual recommendation, typically every 5,000-10,000 miles.
Drive Belt Inspection:
If belt drive equipped, inspect for wear and tension at regular intervals (see manual).
Engine Oil:
Harley-Davidson 20W-50 Motorcycle Oil or equivalent.
Transmission Oil:
Harley-Davidson Transmission Lubricant or SAE 80W-90 Gear Oil.
Primary Chain Case Oil:
Harley-Davidson Primary Chain Lubricant or specific motorcycle primary fluid.
Brake Fluid:
DOT 3 or DOT 4 brake fluid, depending on system.
Oil Leaks:
Common for Shovelheads due to older seal technology and engine vibration. Manual addresses sealing and gasket replacement.
Kick Starter Engagement:
Potential issues with kick start mechanism. Manual provides repair details.
Carburetor Tuning:
Carburetors of this era require periodic tuning for optimal performance. Manual covers adjustments.
Electrical Gremlins:
Older wiring can degrade. Comprehensive wiring diagrams in the manual are essential for diagnosis.
Brand Establishment:
Harley-Davidson, founded in 1903, is the quintessential American motorcycle manufacturer.
Brand Philosophy:
Known for V-twin engines, distinct styling, and a strong rider community.
Shovelhead Era:
The Shovelhead engine replaced the Panhead in 1966 and was produced until 1984. It represented a significant evolution in Harley-Davidson's engine technology.
Flhs Designation:
FLHS typically denoted a 'Electra Glide Sport' or similar touring variant, often with stripped-down fairings or saddlebags compared to the full dresser FLHT.
Manufacturing Location:
Milwaukee, Wisconsin, USA (Harley-Davidson's primary manufacturing site).
Production Period:
The Shovelhead engine was produced from 1966 to 1984. 1982 models are towards the later end of this influential period.