Target Audience:
Do-it-yourself owners and experienced mechanics.
Value Proposition:
Inexpensive way to keep the vehicle working properly; saves on professional labor costs.
Completeness:
COMPLETE official full factory service repair manual.
Accessibility:
Immediate PDF download, no shipping or waiting.
Usability:
Printable pages for on-demand reference in the workshop.
Engine:
Shovelhead V-Twin (Displacement details vary by specific FLHS sub-model, typically 74 cubic inch or 80 cubic inch variants).
Clutch:
Operation, Adjustment, and Repair
Primary Drive:
Chain Drive System Components and Maintenance
Transmission:
4-Speed Gearbox (Operation, Disassembly, Reassembly)
Kickstarter:
Mechanism and Repair
Fuel System:
Carburetor Tuning (e.g., Keihin Butterfly or CV), Fuel Lines, Tank
Exhaust Systems:
Pipe Removal, Installation, and Sealing
Electrical System:
Ignition, Lighting, Charging System (Alternator/Generator), Starter, Battery
Front Suspension:
Fork Assembly (Telescopic), Seals, Oil Changes
Steering:
Headset Bearings and Adjustment
Rear Suspension:
Shock Absorbers and Swingarm Bearings
Brakes:
Front and Rear Brake System Overhaul, Fluid Replacement
General Information:
Vehicle Identification, Specifications, Torque Values
Periodic Lubrication:
Grease Points, Fluid Change Intervals
Maintenance:
Routine Checks and Adjustments
Tune Up:
Ignition Timing, Carburetor Adjustment, Valve Clearance
Engine Rebuild:
Piston, Rings, Bearings, Seals, Cylinder Head
Transmission Overhaul:
Gear Inspection, Bearing Replacement, Shafts
Electrical Troubleshooting:
Component Testing, Circuit Diagnosis
Brake Bleeding:
Procedure for Hydraulic and Mechanical Systems
Fork Seal Replacement:
Step-by-step Guide
Carburetor Rebuild:
Jetting, Float Adjustment, Diaphragms
Wiring Diagram Interpretation:
Detailed Diagrams for Component Identification
Depth:
Complete Factory-Level Repair and Rebuild Procedures
Illustrations:
Hundreds of Photos and Illustrations
Instructions:
Step-by-step, Numbered Instructions
Critical Information:
Notes, Cautions, and Warnings Included
Diagnostic Focus:
Emphasis on Diagnosing and Repairing Problems
Type:
Shovelhead V-Twin, Air-Cooled
Displacement:
Typically 74 cu in (1213 cc) or 80 cu in (1310 cc) for this era, manual covers specific variant.
Cylinder Arrangement:
90-degree V-Twin
Horsepower:
Specifications within the manual are model-specific; typically around 50-60 HP for stock configurations.
Torque:
Specifications within the manual are model-specific; typically around 65-75 ft-lbs for stock configurations.
Carburetor:
Commonly Keihin butterfly or Constant Velocity (CV) carburetors. Manual details adjustment and rebuild.
Fuel Type:
Unleaded gasoline (Manual will specify octane requirements).
Oil Change:
Typically every 2,000-3,000 miles or annually. Manual will specify precise intervals and procedures.
Tune Up:
Recommended every 5,000-7,500 miles for ignition timing, carburetor adjustments, and spark plug replacement.
Engine Oil:
Manual will specify SAE viscosity grade (e.g., 20W-50) and type (e.g., V-twin specific or mineral oil).
Transmission Oil:
Manual will specify type and viscosity (e.g., Harley-Davidson transmission fluid or equivalent).
Primary Chain Case Oil:
Manual will specify type and viscosity (e.g., Harley-Davidson primary oil or equivalent).
Brake Fluid:
DOT 3 or DOT 4 brake fluid (Manual will specify). Note: Some older systems may have different specifications.
Shovelhead Characteristics:
Known for oil leaks from various seals, potential for valve guide wear, and ignition system tuning sensitivity. The manual addresses these common points.
Task List:
Spark plug replacement, air filter cleaning/replacement, battery maintenance, brake pad inspection, tire pressure checks.
Legacy:
Harley-Davidson's iconic American motorcycle brand, known for its V-twin engines and cruiser styling.
Shovelhead Era:
The Shovelhead engine, produced from 1966 to 1984, was an evolution of the Panhead and knucklehead designs, known for its distinctive cylinder head design.
Manufacturing Location:
Milwaukee, Wisconsin, USA
