🏷️ Basic Information

Make:

Harley-Davidson

Model:

FL 1200

Year:

1983

Model Designation:

FLH Electra Glide

Chassis Code:

FLH-80

👋 Introduction

Positioning:

The 1983 FL 1200 represents a significant transitional year for Harley-Davidson, moving towards the Evolution engine platform. This manual targets owners and independent mechanics seeking to maintain and repair these iconic touring motorcycles.

Competition:

In its era, the FL 1200 competed with large-displacement touring motorcycles from brands like Honda (Gold Wing) and Kawasaki (Vulcan/Voyager), though Harley-Davidson occupied a distinct cruiser/touring niche focused on V-twin performance and styling.

Manual Value:

Provides essential technical data, diagnostic procedures, and repair instructions crucial for preserving the originality and functionality of the 1983 FL 1200.

📋 Manual Details

Primary Coverage:

Mechanical, Electrical, Chassis, Bodywork

Specific Systems:

Engine, Transmission, Drivetrain, Brakes, Suspension, Fuel System, Ignition System, Electrical System, Lighting, Instruments, Frame, Body Panels, Wheels, Tires

Estimated Pages:

Approximately 500-700 pages (typical for factory service manuals of this era)

Type:

Factory Service Repair Manual

Language:

English

Format:

Printed

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, repair, and assembly of the Evolution engine.

Engine Tuning:

Carburetor adjustment, ignition timing, valve lash adjustment.

Transmission:

Four-speed constant mesh transmission service, clutch operation and adjustment.

Drivetrain:

Primary drive system, final drive belt, rear wheel sprocket, and associated components.

Brakes:

Hydraulic disc brake system maintenance, repair, and bleeding (front and rear).

Suspension:

Front fork assembly (Showa or similar), rear shock absorber service, and lubrication.

Electrical System:

Wiring diagrams, component testing, battery, charging system (alternator/generator), starter motor, ignition system (points and condenser or early electronic ignition), lighting circuits, switches, and instruments.

Fuel System:

Fuel tank removal/installation, fuel lines, fuel valve, and carburetor (e.g., Keihin butterfly or Bendix/Zenith).

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, chain adjustment (if applicable, though belt drive is common for this era), brake fluid changes, battery checks.

Troubleshooting:

Diagnostic charts and procedures for common starting, running, and electrical issues.

Repair:

Detailed step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.

Installation:

Guidance on installing new or replacement parts, including torques and clearances.

Engine Rebuild:

Detailed procedures for complete engine disassembly, component inspection, machining specifications, and reassembly.

Transmission Rebuild:

Steps for removing, disassembling, inspecting, and reassembling the 4-speed transmission, including gear inspection and synchromesh (if applicable).

Depth:

Comprehensive, covering everything from basic adjustments to complete engine and transmission rebuilds, electrical diagnostics, and frame alignment.

Diagnostic Charts:

Includes specific diagnostic flowcharts for electrical and mechanical issues.

Wiring Diagrams:

Comprehensive, factory-quality wiring diagrams are a critical component of this manual.

Completeness Level:

Full factory service manual coverage.

📊 Manual Specifications

Format:

Printed book

Quality:

Typically black and white line drawings, schematic diagrams, and text. Print quality may vary depending on original printing and subsequent handling.

Binding:

Often saddle-stitched or perfect bound for professional manuals.

Paper:

Durable paper stock suitable for workshop environments.

⚙️ Engine Specifications

Engine Type:

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

Engine Displacement:

73.7 cu in (1208 cc)

Bore X Stroke:

3.4375 in x 4.25 in (87.3 mm x 108.0 mm)

Compression Ratio:

Approx. 8.0:1

Engine Code:

FHC (for 1983 FLH-80)

Horsepower:

Approx. 60-65 HP @ 5000 RPM (estimated, varied by tuning and specific models)

Torque:

Approx. 75-80 lb-ft @ 3000-3500 RPM (estimated)

Carburetor:

Single Keihin Butterfly CV (Constant Velocity) or Bendix/Zenith (common for earlier models transitioning)

Fuel Type:

Unleaded gasoline, 87 octane (Octane Rating) minimum recommended.

🔧 Transmission

Transmission Type:

4-speed constant mesh manual

Clutch Type:

Dry, multi-plate

Final Drive:

Belt drive (570Q pattern)

Gear Ratios:

Refer to manual for specific ratios; typical for the era.

Transmission Fluid:

Refer to manual for specific type and capacity, often proprietary Harley-Davidson transmission lubricant or equivalent.

📐 Dimensions

Wheelbase:

Approx. 62.5 inches (1588 mm)

Length:

Approx. 93 inches (2362 mm)

Dry Weight:

Approx. 650-700 lbs (295-318 kg)

Gross Vehicle Weight Rating Gvwr:

Refer to frame decal; typically around 950-1000 lbs (431-454 kg)

Storage:

Integrated saddlebags and often a rear tour pak (optional or standard depending on trim).

🛡️ Safety Features

Crash Test Data:

Motorcycle crash testing standards for this era are not comparable to modern automotive standards. Focus is on rider protection and vehicle stability.

Braking System:

Dual hydraulic disc brakes (front), Single hydraulic disc brake (rear).

Lighting:

Headlight, taillight, brake light, turn signals, auxiliary lighting (often on FLHT/FLTC models).

Frame Construction:

Heavy-duty steel frame designed for stability and load carrying.

Rider Comfort:

Comfortable seating, wind protection (fairing on FLHT/FLTC models).

💡 Technology Features

Audio System:

Factory audio systems were not standard on most FL models in 1983; aftermarket or dealer-installed options were common. This manual would not cover aftermarket systems.

Rider Aids:

No electronic rider assistance systems (e.g., ABS, traction control) were present on this model.

Communication Features:

No integrated connectivity or communication features.

🔧 Maintenance

Oil Change:

Every 2,000-3,000 miles or 6 months. Refer to manual for exact specifications.

Spark Plug Replacement:

Every 6,000-10,000 miles. Refer to manual for recommended plug type (e.g., Champion, NGK).

Drive Belt Inspection:

Inspect for wear and tension at every service interval; replace as needed based on wear indicators. Belt life typically 30,000-50,000 miles.

Brake Fluid Flush:

Every 12-24 months to prevent contamination and maintain braking performance.

Engine Oil Type:

Refer to manual for specific viscosity and API classification. Historically, Harley-Davidson recommended their own proprietary oil or equivalent such as SAE 20W50 or 25W60 for air-cooled V-twins. Check for mineral or synthetic recommendations.

Engine Oil Capacity:

Approx. 3 quarts (2.8 liters) with filter change. Refer to manual for exact capacity.

Primary Chain Case Oil:

Harley-Davidson primary lubricant or suitable equivalent. Capacity approx. 1 quart (0.95 liters).

Transmission Oil Type:

Harley-Davidson transmission lubricant or equivalent. Manual will specify viscosity.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid, as specified by the manual.

Carburetor Tuning:

CV carburetors can be sensitive to altitude and wear, requiring periodic adjustment. Older Bendix/Zenith carbs may require more frequent attention.

Electrical Connections:

Corrosion and loose connections in wiring harness are common on older bikes, leading to intermittent electrical faults.

Primary Drive Tension:

Maintaining proper primary drive belt tension is crucial to prevent premature bearing wear.

Fork Seals:

Leaking fork seals are a common maintenance item on older telescopic forks.

📚 Vehicle History

Brand Legacy:

Harley-Davidson, established in 1903, is synonymous with American motorcycle culture, known for its V-twin engines and distinctive styling.

Evolution Engine Introduction:

The 1983 model year marked the introduction of the 80 cubic inch (1338 cc) Evolution engine, a significant development replacing the Shovelhead engine. This manual specifically covers the early '80'/'80 Evolution.

Fl Series Heritage:

The FL designation has historically represented Harley-Davidson's large displacement touring and cruiser motorcycles, evolving through various engine configurations over decades.

Manufacturing Location:

York, Pennsylvania, USA

Production Period For Flh 80:

The '80ci Evolution engine debuted in late 1983 for the 1984 model year, making the 1983 model year a very early transition and potentially including both Shovelhead and early Evolution variants. This manual is specifically for the 1983 FL 1200 equipped with the 80 cubic inch engine, likely the precursor to the full '84 Evolution launch.

🏆 Awards & Recognition

Industry Impact:

The 1983 FL 1200, and the Evolution engine it pioneered, is a landmark in Harley-Davidson's history, setting the stage for decades of successful models and solidifying the brand's market position.