🏷️ Basic Information

Make:

Harley-Davidson

Model:

Shovelhead

Year:

1968

Engine Code:

Shovelhead (Designation varies by specific model/variant, but the core engine architecture is consistent for 1968)

👋 Introduction

Target Audience:

Owners and enthusiasts of 1968 Harley-Davidson Shovelhead motorcycles seeking to perform their own maintenance and repairs, aiming for authenticity and quality.

Manual Value Proposition:

Provides essential, factory-level technical data for a classic and highly sought-after motorcycle, enabling owners to maintain its performance and longevity effectively.

Accessibility:

Digital download format offers instant access for immediate use, without waiting for physical delivery.

Comprehensiveness:

Covers a wide range of service and repair topics, empowering users to tackle most maintenance tasks.

📋 Manual Details

Primary Coverage:

Service, Repair, Maintenance, Troubleshooting

Estimated Page Count:

Likely 200-400 pages (typical for comprehensive service manuals of this era)

Type:

Service and Repair Manual

Language:

English

Format:

Downloadable Digital Format (likely PDF)

📖 Manual Coverage

Engine:

Engine disassembly, assembly, tuning, top-end repairs (cylinders, heads, pistons), bottom-end repairs (crankshaft, connecting rods, bearings), valve train, lubrication system, cooling system (air-cooled), ignition system (points, coils, spark plugs), carburetor systems (e.g., Linkert, Keihin) and fuel delivery.

Transmission:

4-speed constant mesh gearbox service, clutch operation and adjustment, primary drive system (chain, compensator sprocket), shifter mechanism, transmission oil maintenance.

Chassis:

Frame inspection and repair, front fork (leading link or telescopic, depending on model variant) overhaul and adjustments, rear suspension (swingarm, shocks) service, wheel and tire maintenance, brake system service (drum brakes typically), steering head bearing service.

Electrical:

Wiring diagrams for the 1968 model year, lighting system, horn, starter system, battery charging system (generator or early alternator), ignition switch, basic troubleshooting of electrical faults.

Bodywork:

Fender removal and installation, fuel tank servicing, seat mounting, exhaust system maintenance, basic trim and component removal/installation.

Routine Maintenance:

Oil changes, filter replacement, chain adjustment, spark plug inspection and replacement, battery care, brake adjustment, lubrication points.

Troubleshooting:

Diagnostic procedures for common starting issues, engine running problems, electrical faults, and transmission performance issues, with symptom-based fault finding guides.

Repair Procedures:

Step-by-step instructions for major component overhauls, including engine rebuilds, transmission repairs, fork rebuilding, and brake system servicing.

Adjustments:

Carburetor tuning, ignition timing adjustment (points), clutch and brake lever adjustments, suspension preload adjustments (if applicable).

Level:

Comprehensive. Suitable for both home mechanics and professional technicians. Covers detailed disassembly, measurement specifications, tolerances, and assembly procedures.

📊 Manual Specifications

Digital Format:

PDF

Quality:

High-resolution scans of original factory documentation, ensuring clarity of diagrams and text.

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Air-cooled, 45-degree V-twin

Displacement:

74 cubic inches (1213 cc) for FL/FLH, 80 cubic inches (1310 cc) for FX/FXR variants (note: 1968 marked the introduction of the Shovelhead, often starting with 74ci, but engine options could vary.)

Bore X Stroke:

Approx. 3.4375 in. x 4.25 in. (74ci) / 3.5 in. x 4.25 in. (80ci) - *Exact figures to be confirmed by manual's specific data.*

Horsepower:

Estimated 55-65 hp (dependent on specific model and tuning) - *Manual will provide precise ratings.*

Torque:

Estimated 60-70 ft-lbs (dependent on specific model and tuning) - *Manual will provide precise ratings.*

Carburetion:

Single carburetor, typically a Linkert M74B or early Keihin butterfly type, or a S&S Super B aftermarket option (though factory spec is key).

Fuel Type:

Gasoline (Leaded or Ethyl)

Ignition Type:

Battery and Coil, with Mechanical Breaker Points and Condenser

Oil System:

Dry Sump with Oil Tank (separate from crankcase)

🔧 Transmission

Transmission Type:

4-speed Constant Mesh Manual

Optional Transmissions:

N/A for factory 1968 models; aftermarket options exist but are outside scope of a stock manual.

Clutch Type:

Wet, multi-plate diaphragm spring clutch

Primary Drive:

Duplex chain drive from crankshaft to transmission input shaft, enclosed in primary cover.

📐 Dimensions

Wheelbase:

Approximately 60-62 inches (1524-1575 mm), depending on specific model (e.g., FLH vs. FX).

Overall Length:

Approximately 88-92 inches (2235-2337 mm).

Dry Weight:

Approximately 550-650 lbs (250-295 kg), depending on model and accessories.

Gross Vehicle Weight Rating:

Not typically specified for motorcycles in the same way as cars; user should refer to manual for load limits.

Front Tire Size:

Typically 3.25-19 or 3.50-19.

Rear Tire Size:

Typically 4.00-18 or 4.25-18.

Wheel Bolt Pattern:

N/A (Spoked wheels with hub mounting)

🛡️ Safety Features

Crash Test Results:

N/A (Motorcycles are not subject to the same standardized crash testing as automobiles).

Braking System:

Typically front and rear drum brakes. The manual will detail their adjustment and service procedures.

Frame Construction:

Steel frame designed for stability and handling characteristics of the era.

Lighting:

Headlight, taillight, brake light, turn signals (depending on market and specific model). Manual covers bulb replacement and wiring.

💡 Technology Features

Infotainment System:

N/A (Basic motorcycle technology for the era - no electronic infotainment systems).

Driver Assistance Features:

N/A (No electronic driver assistance features).

Connectivity Options:

N/A (No electronic connectivity).

Charging System:

Generator (typical for early models) or possibly an early alternator system. Manual details service for this.

Starter System:

Electric starter motor (on FLH models), with related solenoid and battery system. Manual covers troubleshooting and repair.

🔧 Maintenance

Oil Change:

Typically every 1,000 - 2,000 miles or annually. Manual will provide exact recommendation.

Major Service:

Annual or every 5,000-10,000 miles, including valve adjustments, spark plug replacement, and thorough inspection. Manual specifies detailed schedule.

Engine Oil:

Typically Harley-Davidson SAE 50 or SAE 60 motorcycle-specific oil. The manual will confirm the precise viscosity and type, including any additive requirements.

Transmission Oil:

Typically Harley-Davidson Transmission Oil or equivalent SAE 80W-90 gear oil. Manual will confirm.

Primary Chain Case Oil:

Typically Harley-Davidson Primary Chaincase Lubricant or SAE 20W-50 motorcycle oil. Manual will confirm.

Brake Fluid:

N/A (Drum brakes do not use hydraulic fluid).

Valve Adjustment:

Requires periodic adjustment due to lifter wear. Manual details procedure.

Oil Leaks:

Common due to aging seals and gaskets; manual guides replacement.

Carburetor Tuning:

Linkert carburetors can be finicky and require precise adjustments. Manual provides tuning guides.

Points Ignition:

Requires periodic inspection, cleaning, and adjustment of points gap and timing. Manual details this.

Filter Part Numbers:

Manual will list OEM part numbers for common service items like oil filters, air filters, and spark plugs (e.g., spark plug gap spec will be provided).

Engine Torque Specifications:

Detailed torque values for critical fasteners (e.g., cylinder head bolts, crankcase bolts, manifold nuts) are a key feature of this manual.

📚 Vehicle History

Brand Founding:

Harley-Davidson Motor Company, founded in 1903.

Shovelhead Introduction:

The Shovelhead engine design, characterized by its distinctive rocker boxes, began replacing the Panhead engine in 1966. The 1968 model year represents an early production year for this iconic engine architecture.

1968 Key Features:

1968 saw the Shovelhead engine firmly established, offering increased performance and refined (though still robust) engineering over its predecessors. This year also saw stylistic variations and model-specific features across the FL (Electra Glide, Duo-Glide) and FX (Super Glide) lines.

Production Period:

Shovelhead engines were produced from 1966 to 1984.

Manufacturing Location:

Milwaukee, Wisconsin, USA (Harley-Davidson's primary manufacturing base).

🏆 Awards & Recognition

Historical Significance:

The Shovelhead engine is a landmark in Harley-Davidson history, representing a transitionary period and a robust, albeit sometimes maintenance-intensive, power plant that defined an era of American motorcycling.

Owner Satisfaction:

Highly regarded by enthusiasts for its sound, torque, and classic aesthetic, despite its mechanical demands.

Manual Accuracy:

Assumed to be based on original Harley-Davidson factory service documentation, providing the highest level of accuracy for repair procedures.