Target Audience:
Harley-Davidson owners, mechanics, restoration enthusiasts
Value Proposition:
Essential resource for maintaining, repairing, and restoring the iconic FLH Shovelhead
Competitor Manuals:
Aftermarket manuals may lack the detail and accuracy of factory documentation
Authenticity:
Official Factory Service Manual ensuring correct procedures and specifications
Comprehensiveness:
Covers every aspect of the vehicle from routine maintenance to complete engine rebuilds
Usability:
Well-organized structure with clear diagrams and step-by-step instructions
Engine Mechanical:
Full rebuild, troubleshooting, tuning, component replacement
Engine Electrical:
Ignition system, charging system, lighting, wiring diagrams
Fuel System:
Carburetor (e.g., Keihin Butterfly), fuel lines, fuel tank, petcock
Transmission:
4-speed, clutch, primary drive, maintenance, repair
Drivetrain:
Final drive, chain maintenance, sprocket replacement
Suspension:
Front forks (e.g., FLH telescopic), rear shock absorbers, lubrication, seals
Brakes:
Front disc brake, rear drum brake, hydraulic system, pad/shoe replacement, bleeding
Electrical System Details:
Battery, starter motor, generator, regulators, switchgear, lighting circuits
Chassis And Frame:
Frame inspection, steering head bearing adjustment, wheel bearings
Bodywork And Trim:
Fenders, tank, seat, fairings (if applicable), trim pieces
Scheduled Maintenance:
Oil changes, filter replacements, lubrication points, adjustments
Troubleshooting:
Diagnostic charts, common problems, solutions
Engine Overhaul:
Top-end rebuild, bottom-end rebuild, component torque specifications
Transmission Repair:
Clutch adjustment, gear shifting mechanism service, bearing replacement
Brake System Service:
Pad replacement, caliper service, bleeding procedures
Electrical Diagnosis:
Circuit testing, component diagnosis, wiring repair
Fork Rebuild:
Seal replacement, oil changes, spring replacement
Diagnostic Capabilities:
Advanced diagnostic procedures and fault finding
Repair Detail:
Comprehensive step-by-step repair instructions for all major components
Specification Accuracy:
Precise torque values, clearances, and measurements
Wiring Diagrams:
Detailed and accurate electrical schematics for all circuits
Engine Configuration:
45-degree V-Twin
Bore Stroke In:
3.4375 x 4.00
Compression Ratio:
8.0:1 (approx.)
Valve Train:
Overhead Valve (OHV), Pushrod Actuated
Horsepower Hp:
Approximately 60-70 hp (estimated, varies with tuning)
Torque Lb Ft:
Approximately 70-80 lb-ft (estimated, varies with tuning)
Carburetor Type:
Keihin Butterfly (e.g., 36mm or 40mm) or Linkert
Fuel Type:
Unleaded gasoline (90 octane minimum recommended)
Oil Capacity Quarts:
3.0 (with filter)
Oil Type Specification:
Harley-Davidson Genuine Motor Oil SAE 20W50 or equivalent API SG/SH rated oil
Engine Oil Change Interval:
Every 2,500-3,000 miles or 6 months
Transmission Fluid Change Interval:
Every 5,000-7,500 miles or annually
Primary Chaincase Oil Change Interval:
Every 2,500-3,000 miles or 6 months
Spark Plug Replacement:
Every 5,000-10,000 miles (refer to manual for specific types)
Air Filter Cleaning Or Replacement:
Inspect every 2,500 miles, clean/replace as needed
Engine Oil Viscosity:
SAE 20W50
Transmission Oil Viscosity:
SAE 90
Brake Fluid Type:
DOT 3 or DOT 4 (check specific caliper requirements)
Carburetion:
Tuning and adjustment of the Keihin or Linkert carburetor can be sensitive
Oil Leaks:
Common across vintage motorcycles; requires diligent maintenance of seals and gaskets
Electrical Reliability:
Older wiring harnesses and components may require inspection and potential replacement
Engine Vibration:
Characteristic of the V-twin design; proper balancing and engine mounts are crucial
Kickstart Operation:
Requires proper technique; components like the clutch and transmission linkage need to be in good order
