Target Audience:
Harley-Davidson owners, independent repair shops, and mechanics specializing in vintage motorcycles.
Value Proposition:
Provides essential, detailed technical information for maintaining and repairing a classic Harley-Davidson model, crucial for preserving its value and functionality.
Documentation Type:
Official or factory-equivalent workshop manual, offering authentic repair procedures and specifications.
Diagnostic Focus:
Emphasis on practical, on-bike diagnostics for common issues encountered with Shovelhead engines and related systems.
Engine:
Shovelhead V-Twin, carburetor systems (e.g., Keihin Butterfly, Tillotson), ignition systems (points and electronic), oiling systems (dry sump, oil pump, oil filter)
Transmission:
4-speed constant mesh, clutch systems, shifter mechanisms, primary drive, final drive chain
Electrical:
Battery, charging system (generator/alternator), lighting, ignition switch, starter motor, horn, instrument cluster, wiring diagrams
Chassis:
Frame, front fork (telescopic), rear suspension (swingarm, shock absorbers), wheels, tires, bearings
Brakes:
Front disc brake, rear drum brake, hydraulic systems, brake fluid specifications
Fuel System:
Fuel tank, fuel lines, fuel filter, fuel delivery
Exhaust System:
Exhaust pipes, mufflers, heat shields
Bodywork And Trim:
Fenders, fuel tank, seat, fairing (if applicable), handlebars, controls
Maintenance:
Scheduled maintenance checks, oil changes, filter replacements, lubrication, spark plug service, tire pressure checks, brake adjustments
Troubleshooting:
Diagnostic charts for common starting, running, and electrical issues, symptom-based problem solving
Repair:
Engine disassembly and reassembly, transmission overhaul, carburetor tuning, brake system repairs, electrical component replacement, suspension servicing
Specifications:
Torque values, clearances, fluid capacities, electrical resistance values, timing settings
Depth Of Coverage:
Comprehensive, covering routine maintenance to major overhauls and diagnostics for all major systems.
Engine Type:
Air-cooled, 45-degree V-twin
Engine Displacement:
74 cubic inches (1200 cc) and 80 cubic inches (1310 cc)
Bore X Stroke:
Typically 3.4375 in. x 4.00 in. (74 CI) or 3.50 in. x 4.25 in. (80 CI)
Compression Ratio:
Varies by specific model and year, typically around 7.5:1 to 8.0:1
Horsepower:
Approximately 60-70 HP (estimated, highly dependent on tuning and specific engine build)
Torque:
Approximately 75-85 ft-lbs (estimated, highly dependent on tuning and specific engine build)
Carburetor Types:
Keihin Butterfly (e.g., CV) and possibly earlier Tillotson models depending on exact production run.
Fuel Type:
Unleaded gasoline (87 octane or higher recommended, depending on compression and tuning)
Ignition Type:
Dual spark plug per cylinder, either points-based breaker system or early electronic ignition systems (e.g., Boyer, Fairbanks-Morse).
Oiling Type:
Dry sump with a frame-mounted oil tank.
Oil Pump Type:
Internal engine-driven gear pump.
Transmission Type:
4-speed, constant mesh, foot-shift, hand-clutch operation.
Optional Transmission:
N/A for FLHS; 4-speed was standard across most Harley-Davidson big twins of this era.
Primary Drive Type:
Primary chain drive with a dry clutch assembly (multi-plate).
Final Drive Type:
Enclosed final drive chain.
Wheelbase:
Approximately 62 inches (1575 mm)
Overall Length:
Approximately 93 inches (2362 mm)
Dry Weight:
Approximately 620-650 lbs (281-295 kg), depending on equipment.
Gvwr:
Not typically specified for motorcycles in the same way as cars; refers to gross vehicle weight rating including rider and cargo.
Oil Change Interval:
Typically every 2,000-3,000 miles or annually, whichever comes first (refer to manual for precise recommendations).
Primary Chain Tensioner Check:
Frequent checks are recommended, especially on models with plastic hydraulic tensioners, which were prone to wear.
Spark Plug Replacement:
Every 5,000-10,000 miles, depending on plug type and engine conditions.
Engine Oil Type:
Harley-Davidson recommends specific V-Twin motorcycle oils, often 20W-50 or 20W-40. Consult manual for exact specification (e.g., HD 360).
Transmission Oil Type:
Harley-Davidson recommended transmission fluid or equivalent SAE 80W-90 gear oil.
Primary Chain Case Oil Type:
Harley-Davidson primary chain lubricant or SAE 20W-50 motorcycle oil.
Brake Fluid Type:
DOT 4 brake fluid.
Primary Chain Tensioner Wear:
The original plastic primary chain tensioner can wear quickly, leading to noise and potential chain damage. Upgraded hydraulic tensioners or manual adjusters are common upgrades.
Oil Leaks:
Common in Shovelhead engines due to aging seals, gaskets, and the nature of the dry-sump system. Regular inspection and maintenance are crucial.
Carburetor Tuning:
Requires regular tuning and adjustment to maintain optimal performance, especially with changes in altitude or fuel quality.
Electrical Reliability:
Older wiring harnesses and components can be prone to issues like loose connections or corroded terminals.
Pushrod Tube Seals:
Pushrod tube seals are a common source of oil leaks.
Brand Legacy:
Harley-Davidson, an iconic American motorcycle manufacturer with a long history of innovation and building powerful, distinctive motorcycles.
Shovelhead Era:
The Shovelhead engine (introduced in 1966) was the successor to the Panhead and Panhead. The FLHS Electra Glide Sport variant offered a touring-oriented platform with the Shovelhead powertrain.
Flhs Specifics:
The FLHS (Electra Glide Sport) was positioned as a more performance-oriented touring model compared to the standard Electra Glide, often featuring a slightly different fairing or accessory package.
Production Period:
Shovelhead engines were produced from 1966 through 1984. The FLHS model was produced during various years within this period, with 1980 being a specific year of interest.
