Category:
Cruiser Motorcycle
Segment:
Touring / Full-size Cruiser
Competitors 1980:
Indian Chief (historically), custom choppers, other large-displacement motorcycles.
Design Philosophy:
Classic American motorcycle styling, emphasis on rider comfort and long-distance cruising, robust V-twin engine.
Engine System:
Shovelhead engine service, troubleshooting, overhaul, performance tuning, ignition system, carburetion, lubrication.
Transmission System:
4-speed constant mesh transmission service, clutch assembly, primary drive, gear ratios, lubrication, troubleshooting.
Chassis System:
Frame, suspension (front forks, rear shocks), steering, wheels, brakes (front and rear drum/disc), electrical system (wiring diagrams, charging, lighting, starting).
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug service, chain/belt adjustment, brake inspections.
Repair Overhaul:
Engine rebuild procedures, transmission overhauls, carburetor rebuild, brake caliper service, fork seal replacement, electrical component repair.
Troubleshooting:
Diagnostic flowcharts for common problems, ignition issues, fuel delivery problems, starting difficulties, electrical faults.
Depth:
Comprehensive, covering from basic user maintenance to advanced engine and transmission rebuilding, including detailed torque specifications and clearances.
Engine Configuration:
Air-cooled, 45-degree V-twin
Engine Displacement:
74 cubic inches (1200cc) and later 80 cubic inches (1340cc) for Shovelhead.
Bore X Stroke:
3.4375 in x 4.00 in (87.3 mm x 101.6 mm)
Compression Ratio:
Approximately 8.0:1
Engine Build:
Cast iron cylinders, aluminum heads
Horsepower Estimated:
60-70 HP (est. at crank, depending on tuning)
Torque Estimated:
75-85 lb-ft (est. at crank)
Carburetor:
Keihin Butterfly (e.g., CV carb), Linkert, or S&S Super E/G (optional/aftermarket)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Ignition Type:
Battery and Coil / Electronic Ignition (often upgraded from stock points)
Type:
4-speed, constant mesh, foot-shift, hand-clutch
Drive System:
Primary chain drive to 4-speed transmission, belt drive to rear wheel.
Clutch Type:
Wet, multi-plate, cable-actuated
Gear Ratios:
Specific ratios provided in manual for each gear.
Wheelbase:
Approximately 63.5 inches (1613 mm)
Length:
Approximately 93 inches (2362 mm)
Dry Weight:
Approximately 600-650 lbs (272-295 kg)
Gross Vehicle Weight Rating:
Not typically published as a strict GVWR, but payload capacity is a consideration.
Safety Certification:
DOT (Department of Transportation) compliance for road use.
Braking System:
Dual-action front brake (often disc) and rear brake (disc or drum depending on specific FLH variant). Dual-action system means lever and pedal operate both pistons to some degree.
Lighting:
Headlight, taillight, brake light, turn signals.
Frame Construction:
Steel tube frame for stability and rider support.
Oil Change Interval:
Every 2,500 - 3,000 miles or annually, whichever comes first (refer to manual for exact specification based on oil type).
Primary Chain Adjust:
Every 1,000-2,000 miles
Spark Plug Service:
Every 5,000 - 7,500 miles
Engine Oil Type:
Viscosity: SAE 20W50 motorcycle-specific oil. API Service Classification: SG or higher. (e.g., Harley-Davidson Genuine V-Twin Oil, Mobil 1 V-Twin 20W-50).
Primary Chain Case Oil:
Type E Primary Chain Lubricant or Harley-Davidson Primary Chaincase Lube.
Transmission Oil:
GL-5 Gear Lubricant (e.g., SAE 80W-90 or 85W-140, refer to manual for specific viscosity).
Brake Fluid:
DOT 4 brake fluid (for disc brake systems).
Shifter Lever Wear:
Common wear on the shifter lever pivot and pawl mechanism, leading to sloppy shifting.
Oil Leaks:
Shovelhead engines are prone to minor oil leaks from various seals and gaskets, often considered 'character' by enthusiasts, but significant leaks require attention.
Carburetor Tuning:
Early models may require frequent adjustment or tuning, especially if modified or not properly maintained.
Kickstand Pivot Wear:
Wear at the kickstand mounting point can lead to the stand not retracting fully or being loose.
Electrical Reliability:
Older wiring harnesses and components can degrade over time, leading to intermittent electrical issues.
Founding:
Founded in 1903, Milwaukee, Wisconsin.
Legacy:
Iconic American motorcycle manufacturer known for its V-twin engines and cruiser/touring motorcycles.
Shovelhead Introduction:
Introduced in 1966 as an evolution of the Panhead engine, evolving through the 70s and ending production in 1984.
Flh Designation:
FLH denotes the 'Electra Glide' model, Harley-Davidson's premier full-dress touring motorcycle, offering comfort and amenities for long rides.
Manufacturing Location:
York, Pennsylvania, USA (primary assembly location for this era).
Production Run Shovelhead:
1966-1984
