1970-1978 Harley Davidson Electra Glide FL/FLH-1200 Super Glide FX/FXE/FXS-1200 Service Manual 99482-78 – PDF DOWNLOAD
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1970-1978 Harley Davidson Electra Glide FL/FLH-1200 Super Glide FX/FXE/FXS-1200 Service Manual 99482-78 – PDF DOWNLOAD
Description
1970-1978 Harley Davidson Electra Glide FL/FLH-1200 Super Glide FX/FXE/FXS-1200 Service Manual 99482-78 – PDF DOWNLOAD
FILE DETAILS:
1970-1978 Harley Davidson Electra Glide FL/FLH-1200 Super Glide FX/FXE/FXS-1200 Service Manual 99482-78 – PDF DOWNLOAD
Language : English
Pages : 233
Downloadable : Yes
File Type : PDF
Size: 41.2 MB
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
1970-1978 Harley Davidson Electra Glide FL/FLH-1200 Super Glide FX/FXE/FXS-1200 Service Manual 99482-78 – PDF DOWNLOAD
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, it will introduce to the professional Harley-Davidson mechanic the latest fieldtested
and factory-approved major repair methods. We sincerely believe that this manual will make your
association with Harley-Davidson products more pleasant and profitaΠ«e.
HOW Π’Π USE YOUR SERVICE MANUAL;
Your Service Manual is arranged for quick, easy reference. This manual is divided into numbered sections entitled “Chassis,” ” Engine” and “Transmission.” Sections are then divided into sub-sections. The Engine Section, for example is comprised of “Cylinder” and “Crankcase” subsections.
Use this manual as follows:
1. Check the Π’Π°Π«Π΅ of Contents located in the front of each
section to find subject desired.
2. Page number is listed across from subject.
3. Each section is printed with section number for quick
general location of subject. Page number consists of section
number and page number.
4. Information is presented in Π° definite order as follows:
Minor adjustments
Minor maintenance or repair
Complete disassemΠ«y
Cleaning
Major maintenance or repair
AssemЬly
TABLE OF CONTENTS:
1970-1978 Harley Davidson Electra Glide FL/FLH-1200 Super Glide FX/FXE/FXS-1200 Service Manual 99482-78 – PDF DOWNLOAD
PRODUCT
TRANSM ISSION
SERVICE
MANUAL ELECTRICAL
MISCELLANEOUS
PRODUCT HANDLEBAR ENGINE
Spiral Π’ΡΡΠ΅ 2-19
SPECIFICATIONS DisassemΠ«ing and GENERAL
Dimensions 1 -1 AssemΠ«ing 2-19 Specifications 3-1
Capacities 1 -1 Drum Π’ΡΡΠ΅ 2-20 Descript,on 3-1
Engine 1 -1 DisassemΠ«ing and Lubrication 3-2
Transmission 1 -1 AssemΠ«ing 2-20 Repair and Oiagnostic
Sprockets and Gear Ratios 1 -1 Procedure 3.7
Tire Data 1-2 FRAME 2-21
SERVICE FORKS CYLINDER HEAD
Servicing Π° New Motorcycle 1-3 Changing Oil 2-23 Removing 3-11
TOROUE REOUIREMENTS FL Front Fork 2-24 DisassemΠ«ing 3-11
Chassis Components 1-5 lnspection Procedure 2-24 Cleaning and lnspection 3-11
Engine Components 1-5 Adjusting and Repairing Rocker Arms
Electrical Components 1-5 DisassemΠ«ing 2-27 and Bearings 3-11
Regular Service 1-6 Repairing 2-27 Valves, Valve Seats
Lubricants 1-15 AssemΠ«ing 2-29 and Guides 3-11
FX Front Fork 2-29 AssemΠ«ing Cylinder
LOCATING TROUBLES lnspection Procedure 2-29 Head 3-14
Engine 1-17 DisassemΠ«ing 2-31 Adjusting Tappets 3-14
Lubrication System 1-18 Repair 2-31
Electrical System 1-18 AssemЬling 2-34
Carburetor 1 -18 Rear Shock CYLINDER AND PISTON
Transmission 1-18 Absorbers 2-36 OisassemΠ«ing 3-15
Clutch 1-19 Rear Fork 2-38 Cleaning and lnspecting 3-15
Brakes 1-19 Refinishing Cylinders 3-16
BRAKES Fitting Piston Rings 3-17
CHASSIS Front Drum Brake 2-39 Connecting Rod Bushing 3 -1 8
Adjusting 2-39 Straightening Connecting
DRIVE DisassemΠ«ing 2-39 Rods 3-18
Chains 2-1 Servicing 2-40 AssemΠ«ing Cylinder
Front and Rear AssemΠ«ing 2-40 and Piston 3-19
Chain Adjustment 2-1 Rear Drum Brake 2-41
Rear Chain Lubrication 2-2 Adjusting 2-41
Cleaning Chain Oiler 2-2 DisassemΠ«ing 2-42 GEARCASE
Removing and lnstalling Servicing 2-42 Oil Pump 3-21
Rear Chain 2-3 AssemΠ«ing 2-43 DisassemΠ«ing 3-21
Removing and lnstalling Sidecar Wheel Brake 2-43 AssemΠ«ing 3-22
Front Chain 2-3 Disc Brake 2-43 Valve Tappets and
Check List 2-43 Guides 3-23
WHEELS DisassemΠ«y and DisassemΠ«ing Π-23
Removing Π°ΠΏd lnstalling ReassemΠ«y 2-43 Cleaning and lnspecting Π-23
Front Wheels 2-5 Front Disc Brake Hydraulic Units 3-23
Rear Wheel 2-7 Master Cylinder 2-48 As~emΠ«ing 3-23
Sidecar Wheel 2-8 DisassemΠ«ing and Gearcase Timing Gears Π -24
Wheel Hub and Brake AssemΠ¬ling 2-48 DisassemΠ¬ling Π-24
Drum or Disc 2-9 Rear Brake Master Cleaning and lnspecting 3-24
Sprocket Replacement 2-13 Cylinder 2-49 Replacing Cover
Spoking Wheels – DisassemΠ¬ling and Bushings Π-26
16 lnch 2-13 AssemΠ«ing 2-49 AssemΠ«ing Π-26
Spoking Front Wheel – Hydraulic System 2-49
19 lnch 2-14
Truing Wheels 2-15 SEAT 2-51 CRANKCASE
Removing and Mounting
FIBERGLASS 2-55
General Π-29
Tire ΠΎΠΏ Rim 2-16
Body Π‘Π°Π³Π΅ and Repairs 2-55 DisassemΠ«ing Crankcase 3-29
Checking Tire Trueness 2-17 Flywheels 3-30
Wheel Alionment 2-18 Π’OOLS 2-61 AssemΠ¬ling Crankcase Π – 36
TABLE OF CONTENTS (cont’d)
Page Page Page
Number Number Number
FUEL SYSTEM ΠIΠ‘Π ST ARTER 1974 FX/ FXE 1200
Tillotson Carburetor – DisassemΠ«ing and Wiring Diagram ΠΠ΅Ρ 5-14
1970 Models 3.39 AssemΠ«ing 4.9 1974 FX/ FXE 1 200
Descr Ipt ion 3.39 Wiring Diagram 5-15
Operation – 3-40 GEAR ΠΠΠ₯ 1975 FL/ FLH 1200
Adjusting ——3-42 Adjusting Shifting Wiring Diagram ΠΠ΅Ρ 5-16
lnspecting and Testing 3-43 Linkage 4-11 1975 FL/FLH 1200
DisassemЬling 3-45 Main Drive Gear Wiring Diagram 5-17
Cleaning and Repairing 3.45 Oil Seal 4-11 1975 FX/ FXE 1200
AssemΠ¬ling 3-47 Shifter Cover 4-12 Wiring Diagram ΠΠ΅Ρ 5-18
TrouЬleshooting 3-47 Shifter Cover (Hand 1975 FX/ FXE 1200
Bendi>( Carburetor – Shift) 4-13 Wiring Diagram 5-19
1971-1975 Models 3-48 Shifter Cover (Foot 1976 to 1977
Description 3-48 Shift) 4-13 FL/ FLH 1200
Operation 3-48 Shifter Forks 4-16 Wiring Diagram ΠΠ΅Ρ 5-20
Adjusting 3-49 Gear ΠΠΎΡ
(Four Speed) 1976 to 1977
DisassemΠ«ing 3-50 DisassemΠ«ing 4-17 FL/FLH 1200
Cleaning and tnspection 3-50 Cleaning and Repair 4-20 Wiring Diagram 5-21
AssemЫing 3-50 AssemЬling 4-21 1976 to 1977
Ke1h1n Carburetor – 1976 DisassemΠ«ing and FX/ FXE 1200
and Later Models 3-52 AssemΠ«ing Gear ΠΠΎΡ
Wiring Diagram ΠΠ΅Ρ 5-22
Description 3-52 (Three Speed and 1976 to 1977
Operation 3-52 Reverse) 4-21 FX/ FXE-1200
Adjusting Carburetor 3.54 Wiring Diagram 5-23
DisassemΠ«ing 3.54 TOOLS 4-23 1978 FL/ FLH 1200
Cleaning & lnspection 3.54 Wiring Diagram ΠΠ΅Ρ 5-24
AssemΠ«ing Carburetor 3-56 1978 FL/FLH 1200
lnstalling Carburetor ELECTRICAL Wiring Diagram 5-25
ΠΎΠΏ Motorcycle 3-56 1978 FX/ FXE 1200
Keihin Carburetor GENERAL Wiring Diagram ΠΠ΅Ρ β’ 5-26
TrouΠ«eshooting 3-57 Specifications 5-1 1978 FX/ FXE 1200
Air Cleaner 3-59 Wiring Diagram 5-27
Fuel Tank 3-59 WIRING 1978 FXS 1 200
Fuel Supply Valve 3-59 1970 FL/ FLH Wiring Diagram ΠΠ΅Ρ 5-28
Diagram ΠΠ΅Ρ 5-2 1978 FXS 1 200
Π’OOLS 3-61 1970 FL/ FLH Wiring Diagram 5-29
Diagram 5.3
1971 FL/ FLH
Diagram SWITCHES ΠΠ΅Ρ 5.4
TRANSMISSION 1971 FL/ FLH lgnition-Light Switch 5-30
Diagram 5-5 Handlebar Switch
GENERAL 1971 FX/ FXE 1970-1971 5-31
Specifications 4-1 Diagram ΠΠ΅Ρ 5-6 Handlebar Switch
~
Description 4-1 1971 FX/ FXE 1972 and Later 5-31
Stripping Motorcycte for Diagram 5-7 Transmission Neutral
Transmission Repair 4-1 1972 FL/FLH Switch 5-32
Diagram ΠΠ΅Ρ 5-8 Solenoid Switch 5-32
ΡΡΡΡΠ½ 1972 FL/FLH Staner Relay Switch 5.33
General 4.3 Diagram 5.9 Stop Lamp Front
Controls 4-3 1973-74 FL/ FLH 1200 Brake Switch 5-33
DisassemΠ«ing 4-3 Wiring Diagram ΠΠ΅Ρ 5-10 Stop Lamp Rear
Cleaning and lnspection 4-6 1973-74 FL/FLH 1200 Brake Switch 5-33
AssemΠ«ing 4 -6 Wiring Diagram 5-11
ELECTRIC STARTER 1973 FX 1 200 Wiring LAMPS
General 4-7 Diagram ΠΠ΅Ρ 5-12 Headlamp 5-35
DisassemΠ«ing and 1973 FX 1200 Wiring Adjusting Beam 5-35
AssemΠ«inQ 4-7 DiaQram 5-13 Bulb Chart 5-35
TABLE OF CONTENTS (cont’ d)
Page / Page Page
Number ( Number Number ‘ CHARGING SYSTEM CHECKING CHARGING ΠΠΠ’Π’ΠRΠ£
1975 & EARLIER 5-37 SYSTEM 5-44 General 5-55
Alternator 5-37 DisassemΠ«ing, Cleaning Π‘Π°Π³Π΅ 5-55
Rotor 5-37 and lnspecting and Charging 5-56
Stator 5-37 AssemΠ«ing Alternator 5-45
Rectifier-Regulator 5-37 CIRCUIT BREAKER HORN 5-57
Description 5-47
0peration 5-47
CHECKING CHARGING TrouΠ«eshooting 5-47 STARTER M0T0R
SYSTEM 5-38 Adjusting Points 5-48 TrouΠ«eshooting 5.59
DisassemΠ«ing Alternator 5-40 lgnition Timing 5-48 Prestolite 5-59
Cleaning and lnspecting DisassemΠ«ing 5-49 DisassemΠ«ing and
Alternator S:40 AssemЬling 5-50 AssemЬling 5-59
AssemΠ«ing Alternator 5-40 Hitachi
IGNITION COIL DisassemΠ«ing and
Description 5-51 AssemΠ«ing 5-61
TrouΠ«eshooting 5-51
CHARGING SYSTEM Replacing Π‘Π°Π«Π΅s 5-51
1976 & LATER 5-43
SPARK PLUGS
T00LS 5-63
Alternator 5-43
Rotor 5-43 General 5-53
Stator 5-43 Removing Plugs 5-53
Cleaning, lnspection MISCELLANEOUS
and Repair 5.53
Setting Spark Gap 5-54 INSTRUMENTS
TYMPANIUM RECTIFIER- Testing Spark Plugs 5.54 Speedometer 6-1
REGULAΠ’OR 5-43 lnstalling Spark Plugs 5-54 Tachometer 6-1
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