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

Covers 1959–1969 Harley-Davidson Duo-Glide and Electra Glide models, identified in the factory specifications by the FL and FLH model letters. This is Harley-Davidson Service Manual P/N 99482-69, reprinted in October 1971.

PDF Search, Wiring Detail, and Page Count

Text search and diagram detail: Text search is not available, and there are no embedded PDF bookmarks. Small wiring labels require magnification; some fine lettering in dense areas remains blurred when enlarged.

One printable English PDF is supplied in a ZIP archive, with 240 pages total. This includes the original covers, 19 blank pages, and a one-page annotated handlebar-control illustration appended after the manual.

Chassis, Engine, Drivetrain, and Electrical Service

These selected topics preview the manual’s contents. Additional material includes speedometer and tachometer cable servicing.

• Drive and wheels: Primary and rear-chain service, wheel-hub overhaul, spoke replacement, wheel truing, tire runout checks, and wheel alignment.
• Suspension, brakes, and body: Hydra-Glide forks, steering-head bearings, rear-fork and shock-absorber service, seat-post suspension, brake repair, hydraulic bleeding, and fiberglass repairs.
• Engine overhaul: Cylinder heads, valve guides and seats, cylinders, pistons and rings, connecting rods, oil pump, breather system, timing gears, gearcase bushings, crankcases, flywheels, and main bearings.
• Fuel system: Model HD, M, and DC carburetor operation and service, fuel strainers, air cleaners, tanks, and fuel supply valves.
• Clutch and gearbox: Clutch adjustment and teardown, kick and electric starter drives, hand- and foot-shift controls, shifter timing, mainshafts, countershafts, and gearbox repair.
• Electrical diagnosis: Period-specific wiring diagrams, generator checks, circuit-breaker and ignition-coil diagnosis, regulator tests, battery service, lighting, horns, solenoids, and starter motors.
• Factory reference data: Service-interval and lubrication charts, torque and clearance data, bearing and bushing fits, fluid capacities, carburetor settings, ignition-timing information, and illustrated special-tool listings.

The manual supports basic maintenance and repair, while its major-repair material addresses professional Harley-Davidson mechanics and calls for the specified measuring equipment and special fixtures.

Coverage and Production Changes

The publication separates important running changes instead of treating the full decade as one build. Examples include 1966-and-earlier versus 1967-and-later wheel hubs, 1965-and-earlier versus 1966-and-later cylinder heads, early and later rear shock absorbers, the 1968-and-later oil pump, and a 1969 crankcase bearing-lock-ring detail.

These distinctions matter when selecting parts, tools, and the correct repair procedure.

Some shared-component pages also carry Sportster or Servi-Car headings, particularly in the carburetor, generator, regulator, horn, and starter-motor material. The Model MD carburetor section is specifically labeled for Servi-Car. This is not a complete Sportster or Servi-Car service manual.

Chassis and Suspension Repair

Step-by-step procedures cover sprocket replacement and riveting, spoke lacing, fork-slider rebushing, and fork-tube and bracket alignment. Frame-dimension checks and brake-drum refinishing extend the chassis coverage beyond routine adjustment.

The seat section explains the spring-loaded seat post. Fiberglass coverage includes surface finishing, touch-up, and structural patching of holes, punctures, and breaks.

Rear-shock instructions cover spring and associated hardware disassembly; faulty damper units themselves are replaced, not internally repaired.

For wheel, fork, rear-shock, engine, or transmission repair, the motorcycle should be secured on a stable stand and spring-loaded or hydraulic components controlled before disassembly.

Engine and Transmission Overhaul

Engine removal preparation leads into cylinder refinishing, piston-ring fitting, and connecting-rod alignment. Internal repair coverage includes crankcase separation, flywheel truing, bearing-race lapping, main-bearing fitting, and final assembly checks.

Transmission material adds starter-clutch work, main-drive-gear oil-seal service, shifter-fork inspection, shifter-gauge adjustment, and internal gearbox assembly. Separate instructions identify the component differences for the reverse-equipped hand-shift transmission.

The manual warns that a reused or overexpanded piston-pin lock ring can release in service and ruin both the piston and cylinder. Overtightening the oil-pump body can displace its plastic gaskets, eliminate gear side clearance, and seize the pump.

Carburetor and Electrical Troubleshooting

HD carburetor diagnosis includes accelerator-pump checks, inlet-needle pressure testing, and leakage tests for the main-nozzle and economizer check valves. These tests help distinguish fuel-metering faults before replacement parts are selected.

Keyed wiring diagrams cover the 1959, 1960, and 1961–1964 Duo-Glide and the 1965–1967 and 1968–1969 Electra Glide.

Charging-system chapters distinguish standard and fan-cooled generators. Regulator tests use separate meters or a VAT 26 tester, while starter sections cover Delco-Remy two-pole and four-pole motors and Prestolite four-pole units.

Illustrations and Factory Tools

Illustrations include the Lubrication and Service Chart, Electra-Glide Lubrication System, 1963 to 1965 Oil Feed Pressure System, Hydra-Glide Fork — Exploded View, and Model M Carburetor — Exploded View. These complement the electrical wiring diagrams and component section views.

Separate tool sections identify equipment for chassis, engine, transmission, and electrical work. Examples include the 96219-50 frame-head bearing adjusting cone and locknut wrench, 96254-50 fork-slider bushing tools, 97010-52A rear-shock absorber tool, and 96295-65 timing-mark view plug.

The listings identify where factory fixtures, reamers, pullers, gauges, or holding tools are expected beyond normal hand tools.

A Preview of Piston and Valve Clearances

Piston specifications list a .010–.020 in. ring end gap and .004–.005 in. compression-ring side clearance, alongside procedures for checking ring fit.

Cylinder-head data specify .002–.004 in. intake-valve guide clearance and .004–.006 in. exhaust-valve guide clearance. The repair section covers guide replacement and valve-seat work.