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Table Of Contents

Te AMF/Harley-Davidson Merger: 1969 to 1981
Evel Knievel
Elvis Presley
Te Wild One: Birthplace of the American Biker
1965 Panhead: Te Last Year
Comparing 1965 Panhead and 1966 Shovelhead Specifcations
1966 Shovelhead: Te First Year
Major Changes from the 1964 Panhead to the 1966 Shovelhead
1967 Shovelhead: Te Tillotson Carburetor
1968 Shovelhead: Te Aluminum Oil Pump
1969 Shovelhead: AMF Buys Harley-Davidson
1970 Shovelhead: Nosecone and Alternator
Big Twin Alternator Charging Amperage by Year
Big Twin Crankcase with Associated Parts
1971 Shovelhead: FX Super Glide
1972 Shovelhead: the Disc Brake
1966 to 1985 Shovelhead Brake Shoes/ Pads and Brake Drums/Rotors
1973 Shovelhead: Constant Crank Oil Delivery
Handlebar Electrical Switches: 1972 to 1981
1974 Shovelhead: the 74-74
1975 Shovelhead: Defcit of Distinction
1976 Shovelhead: Te Kehein Carburetor
1977 Shovelhead: FXS Low Rider
Japanese Front Forks
1978 Shovelhead: 1338cc/81.65c.i Engine
1979 Shovelhead: Market Share Plummets
1980 Shovelhead: FLT Rubbermount 5-speeds
1981 Shovelhead: Te Eagle Soars Alone
1982 Shovelhead: Te FXR Rubbermount 5-speed
1983 Shovelhead: Te Year of the HOG
1984 Shovelhead: Te Evolution Crossover
1985 Shovelhead: Belt Drives and Wet Clutches
Late-1966 to 1967 Shovelhead Engine Diagram
Power-to-weight and Weight-to-power Ratios
Comparing Power-to-weight Ratios
Comparing Weight-to-power Ratios
Horsepower: Are Ofcial Figures a Generalization?
1968 to 1969 Shovelhead Engine Bottom End Picture
Shovelhead 1979 Bottom End Picture
Pushrod Engines 101
Four Stroke Engine Reality
Overhead Valve (OHV), Sidevalve, and IOE Valves
Air Cooling
Combustion Air is Separate from Internal Engine Air
Air Cooling
Engine Compartments
Shovelhead Engine Description
Panhead and Shovelhead Engine Comparison
Comparing Panhead and Shovelhead Engine Components
Calculating Cubic Inch Displacement
Shovelhead Top End 1980 to 1985 Diagram
Shovel Heads
Shovel Cylinders
Shovelhead Engine, Heads Removed Picture
Shovelhead Valves, Valve Guides, Valve Springs, and Collars
Shovelhead Valve Guides and Valves Chart
Shovelhead Valve Spring Specifcations
Neway Valve Seat Cutter in Shovel Head Picture
Valve and Valve Seat Cutting
Te Crank and Crankcases
1966 to 1969 Shovelhead Bottom End Diagram
Flywheel Components and Torque Specifcations
1966 to 1969 Flywheel Assembly Diagram
Flywheel Assembly Locks: 1978
Loctite Flywheel Shafts: 1979
Flywheel Sprocket Shaft Contamination: Late-1984 to 1985
Early and Late, FL/FX 1200cc (74c.i) Connecting Rods
Shovelhead 1200cc Piston Set
Commonized Engine Shafts: Late-1981
Identifying Old and New Flywheel Shafts and Components
Ofset Connecting Rods: Late-1983
Pinion Flywheel Half with Ofset Connecting Rods and Crank Pin Picture
Straightening a Bent and/or Twisted Connecting Rod
Loose Roller Bearings: Running Fit versus a Plug Fit
Individual Bottom End Crank Roller Bearing Sizing
Bottom End Crank Bearing Set Sizing 1
Individual Engine Bottom End Roller Bearing Cages
Sideplay between Flywheels
Te Skinny on Bottom End Roller Bearing Cages
Sprocket Shaft Bearings
Sprocket Shaft Endplay Specifcations and Fitment: 1956 to 2002
Shovelhead Flywheel Support Bearing(s)
Truing Flywheels
Engine Flywheel Assembly in H-D Truing Stand Picture
Timing Chest
1980 to 1985 Shovelhead Gear Case Diagram
Servicing the Pinion Case Race
Big Twin Pinion Roller Bearing Sizing 1958 to 2000
Quiet Timing Gears
Shovelhead Pinion and Cam Gear Color Coding
Camshaft Endplay
Engine Breathing; Plastic and Steel Breather Gear Comparison Picture
Breather Valve Gear Trust Washer
Shovelhead Oil Pumps Diagram
Te Oil Pump
Shovelhead Ignition
Point’s Ignition & Advance Unit for Shovelhead: 1970 to early-1978 Picture
V-Fire II Electronic Ignition for Shovelhead: 1980 to 1983 Picture
How a Cam Works
Big Twin Camshafts: 1948 to 2006 Picture
Cam Lift and Valve Lift
Stock Cam Specifcations for H-D Big Twins
Cam Lobe, Rocker Arm Ratio, Valve Lift Formulae
Cam Duration
Valve Overlap
Calculating Valve Overlap (Cam Lobe Overlap)
Calculate the Lobe Centerline Angle (LC or LCA)
Calculate Lobe Centerline Angle (LCA)
Calculate Lobe Separation Angle (LSA)
Why are the Cam Lobe Angles (LCA and LSA) Important?
Valve Closing Delay, Overlap, and LCA
Cylinder Pressure (Compression) and Intake Valve Closing
Degreeing a Camshaft
Calculation of Intake Cam Timing Change
Generalized Cam Profle Efects on Engine Operation
Te Power Band
Connecting Rod Length to Engine Stroke Ratio
Choosing a Cam
Valve Spring Harmonics
Compression: Diferent Names and Measurements
Compression Test
Close Ratio versus Wide Ratio Gears
4-speed FL Transmission Kick Starter 1967-and-earlier Diagram
Kick Start
Kick Starting the Beast
Tree-speed/Reverse Transmission
3-speed Sprockets and Overall Gear Ratios
Early Gear Ratios and Sprockets
Tree-speed Transmission
Transmission 3-speed, 3-speed/reverse, 4-speed Gears
Identifying 3-speed, Reverse, and 4-Speed Gears
4-speed Transmission + some 3-speed Gears Diagram
Four-speed Transmission
Late-1976 to 1979 Four Speed Transmission Gear Set Picture
How the 4-speed Transmission Works
Tree/Four Speed Transmission Mainshaft Identifcation
Mainshaft Final Drive Gear Oil Seal: 1965
Defective Transmission Case: 1975
Transmission Gear, Countershaft, and Bearing Changes: 1977
Upgrade Transmission Shaft/Primary Ball Bearing: 1979
1982 4-speed FL/FX Transmission Lockup Safety Recall
) Drive Gear Spline Oil Leaks: 1982 to 1986
H-D 3-speed, 4-speed, 5-speed Transmission Part Numbers
Locking the Transmission Chain Sprocket or Belt Pulley
Five-speed Transmission
1980 to 1984 5-speed Transmission Diagram
How the 5-speed Transmission Works
Transmission Shafts with Final Mainshaft Gears Picture
Rubbermount Transmission Dangling Oil Filters
Transmission Breather Vent Leakage: 1980
Transmission Breather Vent: 1980 to 1982
Transmission Shifter Shaft Spring Breakage
1980 to 1984 Five-speed Shifter Forks
Te Importance of Transmission Dowel Pins
Shifter Cam Drum Trust Washers
Shovelhead 5-speed Transmission Shifter Cam Drum Picture
Shifter Cam (Drum) End Spacing
Transmission Sprocket Heat Treatment
Five Speed Main Drive Gear Spacer and Seal Change
Comparing H-D Four, Five and Six-speed Shifting
Te 5-speed Transfers More Torque
Syn 3 Oil vs. Gear Oil in H-D Transmissions
Torque Multiplication and Reduction Ratio
Te Primary Reduction Ratio
Te Secondary Reduction Ratio
Historical Sprocket or Pulley Sizes
Te Final Drive Reduction Gear Ratio
Historical Sprocket or pulley Sizes
Shovelhead Gear Ratios
Primary, Secondary, and Final Ratio Chart
Internal Transmission Gear Ratios
Internal Gear Ratio Formula
Total Reduction or Overall Gear Ratios
1980 to 1984 5-speed Overall Gear Ratios + Internal Transmission Gear Ratios
Engine Sprocket Infuence on Overall Gear Ratios
Formulae: Engine RPM and Motorcycle Speed
Rear Belt Drive
Belts versus Chain Drives
Te Engine Compensating Sprocket
Engine Drive Compensating Sprockets Picture
1968 to 1982 Shovelhead Dry Clutch Picture
Clutch 101
Te Main Shovelhead Multi-plate Clutch Components
Locking (engaging) a Shovelhead Clutch
Shovelhead Dry and Wet Clutches
Clutch Plates
Clutch Springs
clutch spring
Automatic (Centrifugal, Hydraulic) and Manual Clutches
Clutch Release Mechanisms
Lever and Pivot Clutch Release
Ball and Ramp Clutch Release
Clutch Release Mechanism Adjustment
Te Clutch Package as a Vibration Source
Hand-Shift-Foot Clutch
Clutch Slipping or Dragging: 1941 to Early-1984
Footshift Linkage Adjustments: FL/FX/FLT/FXR
Footshift-Mousetrap Hand Clutch
Footshift-Hand Clutch Eliminator
How to Wreck a Clutch
Finding a Difcult Neutral
Clutch Specifcations: 1941 to 1985 Dry Multiple Disc Clutch
Clutch Release Forks
Te Perfectly Functioning 4-speed Clutch Release Fork
Te Breaking 5-speed Clutch Release Fork
Clutch Trowout Bearings
Late-1984 to 1989 Wet Clutch Diagram
Late-1984 to 1989 Wet Clutch Inspection and Installation
Clutch Specifcations: Late-1984 to 1989 Wet Clutch
Tolerance Fitment Specifcations
Te Science of a Bearing Plug Fit and a Bearing Running Fit
Te Art of a Loose or Tight Bearing Running Fit
Tools from another Era
Reamers, Lapping, and In-line Lapping Tools
A Selection of Tools Diagram
Race Lapping Fitment Process
Metallurgy, Plug Fit and Light Hand Press Fit
How Tight Should Bottom End Fitment Be?
Captured and Loose Roller Bearings
Pullers
Engine Installation & Removal Tools
Engine Top End Rebuild Tools
Cylinder Head Bolt/Nut Torque Specifcation
Valve Springs, Valves, and Valve Guides: Head Work
Measure Upper Valve Collar to Valve Guide Clearance
Piston, Piston Rings, Piston Pin, and Wrist Pin Bushings
Engine Bottom End Rebuild Tools
Endplay and Sideplay
Flywheel Assembly and Truing Tools
Transmission/Clutch Installation & Removal Tools
Chassis Tools
Measuring Tools
Electrical Tools
Carburetor Tools
Shovelhead 1966 to Early-1977 41mm (Wide Glide) Front Forks Diagram
Front Fork Tools
Wheel Tools
Tire Tools
Brake Tools
Miscellaneous Tools
Harley-Davidson, Kent-Moore + Other Shovelhead Tools
H-D/Kent-Moore Tool List Numerical Order
H-D/Kent-Moore Tool List by Year
Other Necessary Tools
Torque Specifcations
Deducing Correct Torque Specifcation Values
Torque Specifcation for Fastener Outer Diameter
Shovelhead Tolerance Fitment Specifcations
Specifcations Booklet
Acronyms
Author Biography Update
Contents Part II of Te Shovelhead: 1966 to 1985
P. 1
Donny’s Unauthorized Technical Guide to Harley-Davidson, 1936 to Present

Donny’s Unauthorized Technical Guide to Harley-Davidson, 1936 to Present

Ratings:

3.0

(1)
|Views: 2,492|Likes:
Published by iUniverseBooks
Donny Petersen, who studied privately with Harley-Davidson engineers, shares practical knowledge and street-wise tips in the fifth volume of his unauthorized guide on the best motorcycle maker in the world.

Written in straightforward language, this guide can help even a motorcycle novice to become an expert mechanic by following Donny’s step-by-step instructions. Whether you’re looking for detailed service procedures such as fitting engine bearings or simple tips on maintenance, Donny is eager to share the expertise he’s stockpiled on the Shovelhead over the last forty years.

Donny shares real stories so you can find solutions to whatever is ailing your Shovelhead. Resolve teething problems, troubleshoot problematic aspects of the engine, and fix whatever comes up with various models.

Gear ratios, torque multiplication, and H-D and aftermarket tools of the day are prominent in the guide, which even includes information on tools Donny invented himself to make your life easier. Get the specifications for tightening all the Shovelhead fasteners and adjustments to mechanisms on various models.

In his usual forthright manner, Donny makes technical issues understandable, interspersing explanations with entertaining stories about the hard core lifestyle that comes with being a Harley rider.
Donny Petersen, who studied privately with Harley-Davidson engineers, shares practical knowledge and street-wise tips in the fifth volume of his unauthorized guide on the best motorcycle maker in the world.

Written in straightforward language, this guide can help even a motorcycle novice to become an expert mechanic by following Donny’s step-by-step instructions. Whether you’re looking for detailed service procedures such as fitting engine bearings or simple tips on maintenance, Donny is eager to share the expertise he’s stockpiled on the Shovelhead over the last forty years.

Donny shares real stories so you can find solutions to whatever is ailing your Shovelhead. Resolve teething problems, troubleshoot problematic aspects of the engine, and fix whatever comes up with various models.

Gear ratios, torque multiplication, and H-D and aftermarket tools of the day are prominent in the guide, which even includes information on tools Donny invented himself to make your life easier. Get the specifications for tightening all the Shovelhead fasteners and adjustments to mechanisms on various models.

In his usual forthright manner, Donny makes technical issues understandable, interspersing explanations with entertaining stories about the hard core lifestyle that comes with being a Harley rider.

More info:

Publish date: Aug 31, 2012
Added to Scribd: Sep 07, 2012
Copyright:Traditional Copyright: All rights reservedISBN:9781475942835
List Price: $9.99 Buy Now

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