Harley Davidson FLH Shovelhead 1981 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLH Shovelhead Year: 1981 Codes Engine Family Code: Shovelhead Generation Platform Generation: Fourth Generation (Shovelhead Evolution) 👋 Introduction Market Position Target Audience: Harley-Davidson FLH Shovelhead 1981 owners, mechanics, restorers, and enthusiasts. Competitive Analysis Manual Authenticity: Genuine Factory Service Manual, not a third-party reproduction, ensuring accuracy and completeness. Key Features Usability: Easy to use, printable format, searchable text for quick information retrieval. Cost Effectiveness: Enables DIY servicing, saving an estimated $50-$60 per hour in shop labor costs. Content Highlight: Detailed substeps, notes, cautions, warnings, numbered instructions, bold figure numbers, detailed illustrations, and enlarged insets. Content Structure: Numbered instructions, notes, cautions, warnings, detailed illustrations, and enlarged insets guide users through procedures. 📋 Manual Details Coverage Areas Primary Coverage: FLH Shovelhead models Style Coverage: All Styles Covered Page Count Estimated Page Count: Hundreds of pages Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download Delivery Method: Digital download link provided after payment confirmation. 📖 Manual Coverage Systems Covered Engine Systems: Engine assembly, disassembly, troubleshooting, maintenance, tune-up, lubrication, fuel system, exhaust systems, engine management systems. Drivetrain Systems: Clutch, primary drive, transmission, Kickstarter. Chassis Systems: Front suspension, steering, rear suspension, brakes. Electrical Systems: Electrical system diagnosis, wiring diagrams, troubleshooting. Indexing: Index included for quick reference. Wiring Diagrams: Detailed wiring diagrams provided for electrical system troubleshooting and tracing. Index Availability: Yes, an index is provided. Procedures Included Maintenance Procedures: Periodic lubrication, routine maintenance, tune-ups, fluid checks and changes. Repair Procedures: Step-by-step repair instructions for all covered systems, including component replacement and adjustments. Diagnostic Procedures: Fault symptom diagnosis, part testing using specialized techniques, advanced troubleshooting guide. Troubleshooting Guide: Advanced troubleshooting guide included to help diagnose and correct any problem, with specific fault symptom analysis. Owner Empowerment: Enables owners to make informed decisions about maintenance and repairs, and to effectively communicate with mechanics. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete rebuilds and restoration. Includes factory-trained technician knowledge. Diagnostic Techniques: Includes techniques used by top mechanics for testing suspected parts. Completeness: Covers everything needed to repair, maintain, rebuild, refurbish, or restore the vehicle. 📊 Manual Specifications File Format Format: PDF Compatibility: Compatible with Windows and Mac operating systems, requires Adobe PDF Reader. Searchability: Search function available within the PDF for locating specific information quickly. Print Quality Printability: Printable without restriction; individual pages, chapters, or the entire manual can be printed. Binding Type Binding: N/A (Digital Download - Printable) Paper Type Paper Type: N/A (Digital Download - Printable) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, OHV, V-twin Engine Family: Shovelhead Performance Displacement Liters: 1.34 L (82 cu in) Bore X Stroke Inches: 3.4375 in x 4.25 in Fuel System Carburetion: Typically a Keihin butterfly or Linkert carburetor (specific model dependent, covered in manual). Fuel Type: Unleaded gasoline (manual will specify octane rating and fuel system adjustments for unleaded). Engine Management Systems Ignition System: Breaker point ignition or early electronic ignition (details covered in manual). Carburetor Information: Detailed information on carburetor identification, disassembly, cleaning, and adjustment is covered. 🔧 Transmission Standard Transmission Type: 4-speed constant mesh, foot shift, hand clutch (typical for FLH). Optional Optional Transmission: N/A for factory manual coverage of 1981 FLH. Features Clutch Type: Wet multi-plate, cable-actuated. Primary Drive Type: Duplex chain in a primary chaincase with chain oil. 📐 Dimensions Exterior Wheelbase Inches: Approximately 61.5 - 63.5 inches (varies by specific FLH model, manual will detail). Weights Dry Weight Lbs: Approximately 700-750 lbs (varies by specific FLH model, manual will detail). Gross Vehicle Weight Rating Lbs: Typically around 1160 lbs (manual will specify exact GVWR). 🛡️ Safety Features Ratings Safety Certification: Not applicable in the modern sense of crash test ratings for motorcycles of this era; focus is on mechanical integrity and operational safety. Active Features Braking System: Hydraulic disc brakes front and rear (e.g., front disc brake, rear drum brake or dual disc depending on specific FLH variant covered). Passive Features Lighting System: Headlight, tail light, brake light, turn signals (all covered in electrical section). 💡 Technology Features Infotainment Infotainment Features: Basic analog instrumentation: speedometer, tachometer (optional), oil pressure light, neutral indicator, turn signal indicators. Driver Assistance Driver Assistance Features: None (pre-dates modern driver assistance systems). Connectivity Connectivity Features: None. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 2,000-3,000 miles or as per manual recommendations for primary oil, engine oil, and transmission oil. Spark Plug Replacement: As recommended, often around 10,000 miles, but checking condition is key. Fluid Specifications Engine Oil Type: Viscosity grades such as 20W-50 or 50W are common for air-cooled V-twins of this era. Manual will specify exact grade and API service classification. Primary Chaincase Oil Type: Dedicated primary oil or specific motorcycle transmission fluid. Manual will specify exact type and quantity. Transmission Oil Type: Typically heavier gear oil or specific transmission lubricant. Manual will...
Basic analog instrumentation: speedometer, tachometer (optional), oil pressure light, neutral indicator, turn signal indicators.
Driver Assistance
Driver Assistance Features:
None (pre-dates modern driver assistance systems).
Connectivity
Connectivity Features:
None.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 2,000-3,000 miles or as per manual recommendations for primary oil, engine oil, and transmission oil.
Spark Plug Replacement:
As recommended, often around 10,000 miles, but checking condition is key.
Fluid Specifications
Engine Oil Type:
Viscosity grades such as 20W-50 or 50W are common for air-cooled V-twins of this era. Manual will specify exact grade and API service classification.
Primary Chaincase Oil Type:
Dedicated primary oil or specific motorcycle transmission fluid. Manual will specify exact type and quantity.
Transmission Oil Type:
Typically heavier gear oil or specific transmission lubricant. Manual will specify exact grade and quantity.
Brake Fluid Type:
DOT 3 or DOT 4, depending on system configuration. Manual will specify.
Fork Oil Type:
Specific viscosity fork oil (e.g., 10W). Manual will specify type and quantity per fork leg.
Known Issues
Common Shovelhead Issues:
Oil leaks from rocker boxes and crankcase seals, valve guide wear, oil pump drive wear, transmission shifting issues, electrical connector corrosion. Manual provides troubleshooting for these.
Tune Up Procedures
Tune Up Components:
Carburetor adjustment, ignition timing setting, spark plug inspection/replacement, air filter service, checking for vacuum leaks.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Harley-Davidson, founded in 1903, renowned for its iconic V-twin engines and cruiser motorcycles.
Model Evolution
Shovelhead Era:
The Shovelhead engine, introduced in 1966, was the successor to the Panhead and was produced until 1984, evolving through various iterations. The FLH designation represents the full dresser touring models.
Production
Production Period For Shovelhead:
1966-1984
🏆 Awards & Recognition
Recognitions
Model Recognition:
The Shovelhead engine and FLH models are considered iconic and historically significant within the motorcycle industry, representing a key era for Harley-Davidson.