Harley Davidson Electra Glide FL/FLH, Super Glide FX/FXE/FXEF/FXS (1978 1/2 to 1980). Service manual - page 1

IMPORTANT NUTICE

Harley-Davidson motorcycles produced after January 1, 1978, conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture.

To maintain the safety, dependability and emission control performance it is essential that the procedures, specifications and service instructions in this manual are followed.

Any substitution, alteration or adjustment of emission system components outside of factory specifications may be prohibited by law.
AMF Harlev-Davidson Motor Co.. Inc

FOREWORD

This service and repair manual has been prepared with two purposes in mind. First, it will acquaint the reader with the construction of the Harley-Davidson product and assist him in performing basic maintenance and repair. Secondly, il will introduce to the professional Harley-Davidson mechanic the latest field-tested and factory-approved major repaii methods. We sincerely believe that this manual will make your association with Harley-Davidson products more plea sant and profitable.
HOW TO USE YOUR SERVICE MANUAL

Your Service Manual is arranged for quick, easy reference. This manual is divided into numbered sections. Sections are then divided into sub-sections. Use this manual as follows:

1. Check the TABLE OF CONTENTS located in the front of each section to find subject desired.

2. Page number is listed across from subject. Page number consists of section number and page number.

3. Information is presented in a definite order as follows:

Minor adjustments Minor maintenance or repair Complete disassembly Cleaning

Major maintenance or repair Assembly

In figure legends, the number following a name of a part indicates the quantity necessary for one complete assembly.

All information for servicing a part should be read before repair work is started to avoid needless disassembly.

NOTE: All information, photographs and illustrations are based on the latest product information available at the time of publication.

SERVICE BULLETINS

In addition to the information given in this Service Manual, Service Bulletins are issued to Harley-Davidson
Dealers from time to time, which cover interim engineering changes and supplementary information. Service Bulletins should be consulted for complete information on the models covered by this manual.
USE GENUINE REPLACEMENT PARTS

To ensure a satisfactory and lasting repair job, follow the manual instructions carefully and use only genuine Harley-Davidson replacement parts.

WARNING — Gasoline is extremely flammable and

highly explosive under certain conditions. Always stop engine, and do not smoke or allow open flame or sparks when refueling or servicing the fuel system, or when using gasoline as a cleaning solvent where specified in this manual.
IMPORTANT NOTICE!

Statements in this manual preceded by the following words are of special significance:

WARNING — means there is the possibility of

personal injury to yourself or others.

CAUTION — means there is the possibility of damage to the vehicle.

Other information of particular importance has been placed in italic type.

We recommend you take special notice of these items.
Harley-Davidson products are manufactured under one or more of the following patents: U.S. Patents — 2986162, 2987934. 2998809. 3116089. 3144631. 3144860. 3226994. 3229792. 3434887. 3559773. 3673359. 3709317. Des. 225 626.

19781/2 to 1980 FL/FLH FX/FXE/FXEF/FXS

SERVICE

MANUAL
PRODUCT D

CHASSIS г

ENGINE 3

TRANSMISSION D

ELECTRICAL 5

MISCELLANEOUS 6

The information in this manual applies to the 1978% to 1980 FL/FLH/FX/FXE/FXEF/FXS Models manufactured after January 1,1978.
COPYRIGHT 1980 BY HARLEY-DAVIDSON MOTOR CO., INC., ALL RIGHTS RESERVED

PART NO. 99482-80

TABLE OF CONTENTS
SECTION 1 • PRODUCT
Specifications

Dimensions..................................1-1

Capacities...................................1-1

Engine.......................................1-1

Vehicle Identification..........................1-1

Transmission.................................1-2

Tire Data.....................................1-2

Service

Servicing a New Motorcycle......................1-3

Regular Service Intervals.......................1-4
Torque Requirements

Wheels..................

Brakes...................

Forks....................
Handlebar...

Engine......

Transmission Electrical ...
Fluid Requirements

Harley-Davidson Oil ...........................1-9

Harley-Davidson Chain Grease,

Chain Saver, Chain Spray.....................1-9

Gasoline.....................................1-9

Brake Fluid...................................1-9

Harley-Davidson/Loctite Products................1-9

Locating Troubles

Engine......................................1-11

Lubrication System...........................1-12

Electrical System ............................1-13

Carburetor..................................1-13

Transmission................................1-13

Clutch......................................1-13

Brake.......................................1-14

SECTION 2 CHASSIS

Drive

Chains.......................................2-1

Wheels

General......................................2-5

Check List ...................................2-5

Front Wheel..................................2-5

Rear Wheel...................................2-6

Wheel Hubs..................................2-6

Spoking Wheels -16 Inch.......................2-9

Spoking Wheels -19 Inch......................2-10

Truing Spoked Wheel .........................2-11

Checking Cast Rim Runout ....................2-13

Tires.......................................2-14

Handlebar Throttle Control

General.....................................2-15

Frame

General.....................................2-17
Forks Page No.

General.....................................2-19

FL Front Fork................................2-23

FX Front Fork................................2-24

Straightening Fork Tubes......................2-27

Rear Shock Absorber .........................2-29

Rear Fork...................................2-30

Brakes

General.....................................2-33

Rear Brake Pedal Adjustment ..................2-33

Disc Brake Calipers...........................2-34

Rear Brake Master Cylinder....................2-38

Seat

Solo Saddle.................................2-39

Comfort Flex Seat............................2-40

Tools.....................................2-43

SECTION 3 - ENGINE

General

Specifications................................3-1

Description...................................3-1

Lubrication...................................3-2

Repair and Diagnostic Procedure................3-4

Cylinder Head

Removing....................................3-7

Disassembling................................3-7

Cleaning and Inspection........................3-7

Repairing Rocker Arms and Bushings.............3-7

Replacing Valve Guides........................3-9

Reconditioning or Replacing Vavle Seats..........3-9

Grinding Valve Faces and Seats.................3-9

Lapping Valve Faces and Seats.................3-10

Installing and Adjusting Push Rods .............3-11

Checking Push Rod Adjustment................3-11

Cylinder and Piston

Disassembling Cylinder and Piston .............3-13

Cleaning and Inspecting.......................3-13

Refinishing Cylinders.........................3-13

Fitting Piston Rings ..........................3-14

Piston Pin Bushing...........................3-16

Assembling Cylinder and Piston................3-17

Gearcase

Oil Pump....................................3-19

Valve Tappets and Guides.....................3-21

Gearcase Cover and Timing Gears ..............3-22

Crankcase

General.....................................3-27

Disassembling Crankcase.....................3-27

Flywheels...................................3-28

Assembling Crankcase........................3-34

Fuel System

Carburetor..................................3-37

Air Cleaner..................................3-43

Fuel Tank...................................3-45

Fuel Supply Valve............................3-45
Page No.
-8

-8

SECTION 3 - ENGINE (cont’d.) Page No.
Tools.....................................3-47

SECTION 4 • TRANSMISSION

General

Specifications................................4-1

Description...................................4-1

Clutch

General......................................4-3

Disassembling Clutch..........................4-3

Cleaning and Inspection........................4-6

Assembling Clutch............................4-6

Electric Starter

General......................................4-7

Disassembling Starter Shaft and Solenoid.........4-7

Assembling Starter Shaft and Solenoid...........4-7

Kick Starter

Disassembling Kick Starter.....................4-9

Cleaning, Inspection and Repair.................4-9

Assembling Kick Starter........................4-9

Disassembling Starter Clutch...................4-9

Cleaning, Inspection and Repair.................4-9

Assembling Starter Clutch.....................4-10

Transmission Case

Adjusting Shifter Linkage......................4-11

Replacing Main Drive Gear Oil Seal..............4-11

Shifter Cover - Drum Shifter

Early 1979 and Earlier.......................4-13

Shifter Cover - Plate Shifter

Late 1979 and Later.........................4-16

Shifter Forks................................4-17

Transmission Case...........................4-19

Tools.....................................4-24

SECTION 5 ■ ELECTRICAL

General

Specifications................................5-1

Wiring

1978 Va-1979 FUFLH Wiring Diagram .............5-3

1978V*-1979 FX/FXE Wiring Diagram .............5-5

1978У2-1979 FXS/FXEF Wiring Diagram...........5-7

1980 FL/FLH Wiring Diagram...................5-8A

1980 FXE Wiring Diagram .....................5-8C

1980 FXS/FXEF Wiring Diagram................5-8E

Switches

Ignition - Light Switch..........................5-9

Handlebar Switch Assembly...................5-10

Stoplight Switch.............................5-10

Starter Relay Switch..........................5-10

Transmission Neutral Switch...................5-10

Solenoid Switch..............................5-11
Lamps Page No.

Headlamp...................................5-13

Charging System

Alternator...................................5-15

Rectifier-Regulator..........................5-15

Checking Charging System....................5-16

Removing the Alternator.......................5-17

Installing the Alternator.......................5-18

Ignition System -1979 and Earlier

Ignition Timer................................5-19

Troubleshooting .............................5-20

Disassembling and Assembling ................5-22

Ignition System -1980 and Later

Description................................5-24A

Troubleshooting............................5-24B

Check Advance Timing with

a Strobe Timing Light......................5-24C

Setting Retarded Timing.....................5-24D

Removing Ignition Components...............5-24D

Inspection and Replacing Parts...............5-24D

Installing Ignition Components................5-24D

Ignition Coil

Description..................................5-25

Troubleshooting .............................5-25

Replacing Spark Plug Cable............5-25

Spark Plugs

General.....................................5-27

Removing Spark Plugs........................5-27

Inspecting Spark Plugs........................5-27

Setting Spark Gap............................5-27

Installing Spark Plugs.........................5-27

Battery

General.....................................5-29

Battery Care.................................5-29

Testing Battery..............................5-29

Charging Battery.............................5-30

Hom......................................5-31

Starter Motor

Description..................................5-31

Troubleshooting .............................5-31

Starter Motor and Drive........................5-32

Prestolyte Starter Motor.......................5-32

Hitachi Starter Motor.........................5-33
SECTION 6 - MISCELLANEOUS

Instruments...............................6-1

PRODUCT
TABLE OF CONTENTS

Page

General..............................................................................1-1

Service..............................................................................1-3

Torque Requirements........................................................1-7

Fluid Requirements..........................................................1-9

Locating Troubles..............................................................1-11

Content .. 1 2 ..

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