1966-1984 Shovelheads Clymer aftermarket Service Manual – PDF DOWNLOAD
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1966-1984 Shovelheads Clymer aftermarket Service Manual – PDF DOWNLOAD
- Troubleshooting, tune-up, maintenance and repair are not difficult, if you know what tools and equipment to use and what to do. Anyone of average intelligence and with some mechanical ability can perform most of the procedures in this manual.
- The manual is written simply and clearly enough for owners who have never worked on a motorcycle, but is complete enough for use by experienced mechanics. It is important to note that because of the parts interchangeability between different models of Harley- Davidson motorcycles, your model, if purchased second hand, may be equipped with parts different from its original equipment.
- Some of the procedures require the use of special tools. Using an inferior substitute tool for a special tool is not recommended, as it can be dangerous to you and may damage the part.
- Where possible, this manual shows suitable special tools that can be fabricated in your garage or by a machinist or purchased at motorcycle or tool stores. General specifications are listed in Table 1. Metric to U.S. conversion is given in Table 2. Thbles 1-5 are listed at the end of the chapter. MANUAL ORGANIZATION This chapter provides general information and discusses equipment and tools useful both for preventive maintenance and troubleshooting.
- Chapter Two provides methods and suggestions for quick and accurate diagnosis and repair of problems. Troubleshooting procedures discuss typical symptoms and logical methods to pinpoint the trouble.
- Chapter Three explains all periodic lubrication and routine maintenance necessary to keep your Harley-Davidson operating well. Chapter Three also includes recommended tune-up procedures, eliminating the constant need to consult other chapters on the various assemblies.
- Subsequent chapters describe specific systems such as the engine, clutch, primary drive, transmission, fuel, exhaust, suspension, steering and brakes. Each chapter provides disassembly, repair, and assembly procedures in simple step-by-step form.
- If a repair is impractical for a home mechanic, it is so indicated. It is usually faster and less expensive to take such repairs to a dealer or competent repair shop. Specifications concerning a particular system are included at the end of the appropriate chapter.
TABLE OF CONTENTS:
1966-1984 Shovelheads Clymer aftermarket Service Manual – PDF DOWNLOAD
QUICK REFERENCE DATA ……………………………………………. IX
CHAPTER ONE
GENERAL INFORMATION ……………………………………………… 1
Manual organization
Notes, cautions and warnings
Safety first
Service hints
Torque specifications
Fasteners
CHAPTER TWO
Lubricants
Serial numbers
Parts replacement
Basic hand tools
Test equipment
Mechanic’s tips
TROUBLESHOOTING ……………………………………………….. 20
Operating requirements
Troubleshooting instruments
Emergency troubleshooting
Engine starting
Engine performance
Engine noises
Engine lubrication
Clutch
Transmission
Charging system
CHAPTER THREE
Starting system
Electrical problems
Ignition system
Breaker point ignition troubleshooting
Breakerless ignition troubleshooting
Excessive vibration
Carburetor troubleshooting
Front suspension and steering
Brake problems
PERIODIC LUBRICATION, MAINTENANCE AND TUNE-UP …………………….. 41
Routine checks
Maintenance intervals
Tires and wheels
Battery
Periodic lubrication
Periodic maintenance
Suspension adjustment
Tune-up
Breaker point ignition service
Breakerless ignition service (late 1978-1979)
Breaker less ignition service ( 1980-on)
Carburetor adjustments
CHAPTER FOUR
ENGINE ………………………………………………………….. 96
Engine principles
Servicing engine in frame
Engine
Rocker arm cover/cylinder head
Pushrods
Valves and valve components
CHAPTER FIVE
Cylinder
Pistons and piston rings
Oil pump
Gearcase cover and timing gears
Crankcase
CLUTCH, PRIMARY DRIVE, TRANSMISSION AND KICKSTARTER …………….. 1 47
Clutch
Primary chain
Primary belt
Compensating sprocket
Primary chain/belt case
Transmission
Hand shifter cover ( 1966-early 1978)
CHAPTER SIX
Foot shifter (1966-early 1979)
Shifter cover (late 1979-1984)
Shift forks
Kickstarter and starter clutch
Side cover (electric start)
Electric starter drive
Shifter adjustment
FUEL AND EXHAUST SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Air cleaner
Carburetors
Throttle cable replacement
CHAPTER SEVEN
Fuel tank
Fuel supply valve
Exhaust system
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Charging system ( 1966-1969)
Voltage regulator (1966-1969)
Charging system (1970-1984)
Circuit breaker
Ignition system (late 1978-1979)
Ignition system (1980-on)
Ignition coil
CHAPTER EIGHT
Starter
Starter solenoid
Lighting system
Switches
Hom
Fuses and circuit breakers
FRONT SUSPENSION AND STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Front wheel
Front hub
Wheel balance
Tire changing
Tire repairs (tube-type tires)
Tire repairs ( tubeless type)
Handlebar and throttle control
Steering head
Front forks
CHAPTER NINE
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3
Rear wheel
Rear hub
Driven sprocket assembly
Drive chain
Drive belt
CHAPTER TEN
Wheel balancing
Tire changing
Rear swing arm
Shock absorbers
BRAKES ………………………………………………………. 329
Rear drum brake (1966-1972)
Disc brakes
Disc brake pad replacement
Brake caliper
Brake disc
Rear master cylinder
Brake hose replacement
Bleeding the system
INDEX …………………………………………………………. 369
WIRING DIAGRAMS ………………………………………. END OF BOOK
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]