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's Unauthorized Technical Guide to Harley-Davidson, 1936 to Present Volume V: Part I of II—The Shovelhead: 1966 to 1985 By Donny Petersen iUniverse, Inc. Copyright © 2012 Donny Petersen All right reserved. ISBN: 978-1-4759-4282-8 Contents Acknowledgements.....................................................xviiPreface..............................................................xixIntroduction.........................................................xxiiiPreamble.............................................................xxvChapter I You Meet the Nicest People on a Honda......................1Chapter II The Shovelhead Models: Year-by-Year.......................31Chapter III The Shovelhead Engine: 1966 to 1985......................131Chapter IV The Shovelhead Engine: Top End............................165Chapter V The Shovelhead Engine: Bottom End..........................249Chapter VI The Shovelhead Engine: The Gear Case......................305Chapter VII The Shovelhead Engine: The Camshaft......................349Chapter VIII The Shovelhead Engine: Compression......................379Chapter IX Shovelhead Transmissions..................................389Chapter X Torque Multiplication: Gear Ratios.........................501Chapter XI The Drive Train...........................................527Chapter XII Shovelhead Clutches......................................547Chapter XIII Tools, Fitment, and Specifications......................597Chapter XIV Shovelhead Summary.......................................717Acronyms.............................................................723Author Biography Update..............................................735Contents Part II of The Shovelhead: 1966 to 1985.....................741 Chapter One You Meet the Nicest People on a Honda In 1959, Harley-Davidson's nemesis Honda comes to America to meet "the nicest people." Their enduring and effective slogan, "You meet the nicest people on a Honda," provides the competition that almost destroys the already declining Harley Davidson. This very effective mainstream catchphrase said it all to the Harley riders of the day. We were not that bad but this nice stuff was pure baby Pablum to us. We were tough, hardy individualists. Even if we were nice, we all had some of the old west outlaw free spirit in our soul. The problem with individualism, if there is one, is that some separation is required from the mainstream. Honda also provides the rivalry to drive Harley-Davidson to the pinnacle of excellence as both companies eventually thrive in the North American motorcycle marketplace. However, Honda did not miss a beat in its continual success whereas H-D had to get up to speed before accelerating onto triumph. My earliest memories of Honda was around 1969 when riders on the 450cc Honda CB450 whose name if memory serves me correct was the Hellcat (Canada) or the Black Bomber (USA) beat all our Triumphs, Norton's, Harley's and Indians with no trouble whatsoever. This was sacrilege. We socially ostracised anyone on a Japanese motorcycle. Of course, these riders would abhor the thought of associating with us. However, Harley-Davidson did not need Honda to put the nails in its coffin, as their sales 10-years earlier in 1959 were only about $17,000,000.00 with approximately 12,300 units. Compare this to sales of $5,726,848,000.00 with a staggering 349,200 motorcycle production in 2007. By 1968, Harley-Davidson was in the midst of a financial crisis. This venerable company was in dire need of help from outside resources. The requirement for financial help was immediate with structural reorganization an ongoing