1959–1969 Harley-Davidson Electra Glide / Duo-Glide Service Manual (P/N 99482-69)

Covers 1959–1969 Harley-Davidson Duo-Glide and Electra-Glide motorcycles, with specifications and service data for FL and FLH models. This factory service manual is identified as P/N 99482-69; individual pages and sections carry revision dates extending through 3-69.

One 219-page PDF, organized into six major divisions covering Product, Chassis, Engine, Transmission, Electrical, and Miscellaneous service.

• Engine repair: Cylinder-head and valve repair, cylinder refinishing, piston and connecting-rod work, flywheel truing, crankcase bearing service, and oil-system testing.

• Chassis service: Wheel truing, hub-bearing service, frame alignment, Hydra-Glide fork repair, rear suspension work, mechanical brake service, and hydraulic brake bleeding.

• Transmission overhaul: Clutch and gearbox repair, foot- and hand-shift arrangements, kick-start mechanisms, electric-starter drives, and mainshaft and countershaft service.

• Fuel systems: Model HD, Model M, and Model DC carburetor repair, with exploded views, adjustment data, leakage checks, and fuel-supply service.

• Electrical diagnosis: Factory wiring diagrams support generator testing, ignition timing, regulator checks, and starter-motor repair across the documented electrical configurations.

• Factory specifications: Fits, clearances, spring loads, bearing dimensions, torque specifications, oil-tank and transmission-lubricant capacities, fuel capacities, and troubleshooting checklists support inspection and diagnosis.

The manual is written to help readers understand construction and perform basic maintenance and repair, while providing professional Harley-Davidson mechanics with factory-approved major repair methods.

Engine and Crankcase Repair

The engine section is built around the 45-degree, air-cooled overhead-valve V-twin. The specifications distinguish the FLH's 8:1 compression ratio from the FL's 7.25:1 ratio and provide ignition settings, oil-system data, and flywheel limits.

Top-end repair covers rocker arms, valves and guides, cylinders, pistons, and tappets. Lower-end chapters address the oil pump, cam and breather timing, crankcases, connecting rods, flywheels, main bearings, and pinion- and sprocket-shaft assemblies.

The 1969 sprocket-shaft bearing arrangement differs substantially from 1968-and-earlier construction, with its own races, spacers, and retaining components. Illustrations include “Engine Cutaway (1967 Model Shown)” and “Sprocket Shaft Bearing Assemblies - Section View.”

Engine assembly data covers cylinder-head bolts, flywheel gear-shaft and sprocket-shaft nuts, and crankpin nuts. Excessive tightening of the oil-pump fasteners can squeeze the plastic gaskets, remove pump-gear side clearance, and seize or damage the pump.

Wheels, Forks, Brakes, and Chains

The wheel-hub section separates the 1966-and-earlier roller-bearing design from the revised 1967-and-later hub. Solo and sidecar gearing and tire data are included.

Chassis coverage also includes handlebars and controls, seat components, and fiberglass body repair. “Hydra-Glide Fork - Exploded View” accompanies the fork procedures, which distinguish adjustable solo/sidecar and non-adjustable arrangements.

Brake service covers the mechanical front brake, hydraulic rear and sidecar brakes, master-cylinder repair, and bleeding.

“Determining Engine Sprocket Spacer Thickness to Secure Chain Alignment” accompanies chain and sprocket service. The adjustment data separates primary- and rear-chain requirements, including cold and hot primary-chain settings.

On models using the primary-chain tensioner, Harley-Davidson warns against repairing the chain with a repair link because a subsequent chain failure can damage the crankcase.

Transmission, Clutch, and Starter Drive

Transmission information covers the constant-mesh four-speed unit, foot- and hand-shift arrangements, and the optional three-forward/one-reverse configuration. The reverse arrangement requires the appropriate hand-shift gearcase; it cannot be installed in foot-shift models or a four-speed gearcase.

Clutch specifications, shifter linkage, shifter forks, main-drive-gear oil seal service, gearcase repair, and transmission adjustment data accompany “Mainshaft Assembly - Exploded View.”

The manual also documents the 1965-and-later electric-start system and its Bendix-type starter drive. The factory chain-case vacuum check provides a defined test point for locating air leakage after engine or starter-related repair.

Carburetors and Servi-Car Coverage

Fuel-system chapters cover the Model HD diaphragm carburetor with automatic economizer and accelerator pump as well as Model M and Model DC carburetors. Fuel-strainer, air-cleaner, tank, and valve service are also included.

Servi-Car material is limited to selected shared-component sections; the Model MD carburetor subsection is specifically identified for 1966-and-later Servi-Car models.

Wiring, Ignition, and Electrical Repair

Separate factory wiring diagrams cover the 1959 Duo-Glide, 1960 Duo-Glide, 1961–1964 Duo-Glide, 1965–1967 Electra-Glide, and 1968–1969 Electra-Glide electrical systems. These include the “1968-69 Electra-Glide Wiring Diagram.”

Electrical sections address switches, lamps, standard and fan-cooled generators, regulators, and batteries, with generator output and component tests. Circuit breakers, ignition coils, spark plugs, horns, and starter motors have separate service material.

Both Delco-Remy and Prestolite starter service appears in the later electric-start material.

On 1961 Duo-Glide engines prior to Engine No. 61FLH 7987, the manual specifies Spark Timing Gage P/N 95885-61 because the flywheel lacks a rear-cylinder timing mark.

The 1960-and-earlier and 1965-and-later ignition arrangements use a single set of breaker points and a double-lobe cam; the 1961–1964 system uses two sets of points and a single-lobe cam.

Returning a generator to service with incorrect polarity can burn relay points, discharge the battery, and damage the generator.

Dedicated Service Tools

The manual identifies P/N 96254-50 fork slider bushing tools, P/N 96740-36 connecting-rod lapping arbor, and P/N 96921-52 oil-pressure gauge. It also specifies P/N 96950-68 chain-case vacuum gauge and P/N 95960-41A clutch-hub and chain-housing puller.

Factory tolerances, test values, and safety procedures should be followed whenever these systems are dismantled, adjusted, tested, or returned to service.

PDF Contents and Navigation

The page total includes one added CD cover, one foreword page, one title page, and eight contents or section-divider pages. PDF text search and embedded bookmarks are not available; navigation uses the printed contents and section page numbers. Small wiring labels require zooming.