Harley-Davidson Shovelhead FL/FX Electra Glide & Super Glide (1966–1984) Repair Manual (P/N 94557-71)

• A 425-page PDF covering Harley-Davidson Shovelhead FL/FX Electra Glide and Super Glide (1966–1984).
• Engine removal, cylinder head disassembly, piston and ring inspection, oil pump repair, and cam timing.
• Clutch rebuilding, primary chain and belt alignment, transmission disassembly, and kickstarter repair.
• Carburetor overhaul, float-level checks, fuel valve service, and intake and exhaust removal and installation.
• Electrical troubleshooting combines charging tests, ignition flowcharts, and starter motor diagnosis.
• Chassis work covers front fork overhaul, steering head and swingarm bearings, wheel truing, and shock spring removal.
• Brake repair includes drum brake service, disc caliper and master cylinder overhaul, and hydraulic bleeding.

Written for owners with some mechanical ability as well as experienced mechanics, this service manual has ten technical chapters, followed by an index and a separate wiring diagram section.

Model Coverage and Service Data

Both 1200 cc and 1340 cc Shovelhead engines are covered, with separate specification tables for 1966–early 1978 and late 1978–1984 configurations. Serial-number decoding helps identify the original model, while the introduction addresses parts interchanged between models.

Maintenance schedules grouped by model year accompany cylinder head torque tables, transmission oil capacity, compression test specifications, and wear limits. Chassis specifications include fork oil capacities, bearing clearances, and drive belt adjustment data.

Engine, Primary Drive and Transmission

The Oil Hose Routing and Gear Timing Mark Alignment (1966–1969) drawings support lubrication and gearcase work. Hydraulic lifter service appears alongside adjustment procedures for solid-lifter conversions. Rocker arm bushing replacement calls out reamer HD-94804-57.

The oil pump section explains how incorrect gasket thickness can cause loss of oil pressure and severe engine damage. Crankcase separation and end-play checks are covered; crankshaft press work and bearing line reaming are referred to a dealer.

The Belt Drive System illustration covers the primary and rear drives, with procedures distinguishing adjustable and nonadjustable primary belts. For chain primaries, a housing vacuum check uses gauge HD96950-68. The transmission section also describes replacement of the main drive gear oil seal with the transmission still installed.

Carburetor Variants and Fuel Diagnosis

Carburetor procedures distinguish the 1966 DC, 1967–1970 HD, 1971–1975 Bendix Model 16P12, and Keihin designs from 1976 on. Early and late Keihin assemblies receive separate treatment, including accelerator pump and float valve inspection.

The HD Carburetor Troubleshooting chart links starting, idling, and acceleration symptoms to fuel-system checks. Throttle-control coverage distinguishes single-cable arrangements from the 1981–1984 push-pull setup.

Charging, Ignition and Wiring Diagrams

Charging system diagnosis separates 1966–1969 generators from 1970–1984 alternators. Ignition sections distinguish breaker points, late 1978–1979 breakerless systems with mechanical advance, and 1980-on Magnavox electronic advance. The ignition section explains why installing an earlier coil on 1980-on models can damage electronic ignition components.

Prestolite and Hitachi starter sections cover brush service and electrical checks. Wiring examples include 1966–1967 Electra-Glide and 1980–1984 FXWG diagrams, with component labels and wire color keys. Printed pages 390–391 are absent from this scan’s wiring section.

Forks, Wheels and Brake Variations

FL fork coverage distinguishes adjustable and nonadjustable assemblies, including solo/sidecar trail settings. Wheel service covers cast and wire-spoke designs, while rear-suspension work includes swingarm bearing preload.

Brake procedures distinguish seven disc caliper types, including the 1984 FX front caliper and 1981–1984 FLH rear caliper. Earlier hydraulic rear drums receive wheel cylinder overhaul procedures. Front master cylinder instructions also identify the 1984 FL/FX piston change that eliminated the earlier back-up disc.

Working on vintage motorcycles carries inherent risks. For engine lifting and brake or fuel-system repair, always rely on the complete service procedures and proper workshop protocols before executing hands-on mechanical work.