Harley Davidson (1970 to early 1978) Electra Glide FL/FLH-1200, Super Glide FX/FXE/FXS-1200. Service manual - page 1

 

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Harley Davidson (1970 to early 1978) Electra Glide FL/FLH-1200, Super Glide FX/FXE/FXS-1200. Service manual - page 1

 

 

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 field-tested and factory-approved major repair methods. We sincerely believe that this manual will make your association with Harley-Davidson products more pleasant and profitable.
HOW TO 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 Table 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 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.
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 insure a satisfactory and lasting repair job, follow the manual instructions carefully and use only genuine Harley-Davidson replacement parts. Behind the emblem bearing the words "Genuine Harley-Davidson" is more than half a century of designing, research, manufacturing, testing and inspecting experience.

This is your insurance that the parts you are using will fit right, operate properly and last longer. When you use genuine Harley-Davidson parts, you use the best.

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.
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
 

 

1970 to Early 1978 PRODUCT I
ELECTRA GLIDE FL/FLH 1200
CHASSIS 2

SUPER GLIDE ENGINE 3
FX/FXE/FXS 1200
TRANSMISSION
SERVICE

MANUAL ELECTRICAL 5
.j
MISCELLANEOUS 6

The maintenance and repair information in this manual applies to the 1970 through early 1978 (up to January 1. 1978 production) Electra Glide/Super Glide Models FL/FLH/FX/FXE/FXS-1200.
COPYRIGHT 1978 BY HARLEY-DAVIDSON MOTOR CO., INC. ALL RIGHTS RESERVED

PART NO. 99482-78

HG-5M 4/82-R
 

 

TABLE OF CONTENTS

 

Page

Number

PRODUCT
SPECIFICATIONS Dimensions 1-1

Capacities Ы

Engine 1-1

Transmission 1-1

Sprockets and Gear Ratios 1 -1 Tire Data 1-2

SERVICE Servicing a New Motorcycle 1-3

TORQUE REQUIREMENTS Chassis Components 1 -5

Engine Components 1 -5

Electrical Components 1 -5

Regular Service 1 -6

Lubricants 1-15

LOCATING TROUBLES Engine 1-17

Lubrication System 1-18

Electrical System 1-18

Carburetor 1-18

Transmission 1-18

Clutch 1-19

Brakes 1-19

CHASSIS

DRIVE

Chains 2-1

Front and Rear

Chain Adjustment 2-1

Rear Chain Lubrication 2-2

Cleaning Cham Oiler 2-2

Removing and Installing Rear Chain 2-3

Removing and Installing Front Cham 2-3

WHEELS

Removing and Installing Front Wheels 2-5

Rear Wheel 2-7

Sidecar Wheel 2-8

Wheel Hub and Brake Drum or Disc 2-9

Sprocket Replacement 2-13

Spoking Wheels -16 Inch 2-13

Spoking Front Wheel -19 Inch 2-14

Truing Wheels 2-15

Removing and Mounting Tire on Rim 2-16

Checking Tire Trueness 2-17

Wheel Alignment 2-18
Page

Number
HANDLEBAR Spiral Type 2-19

Disassembling and Assembling 2-19

Drum Type 2-20

Disassembling and Assembling 2-20

FRAME 2-21

FORKS

Changing Oil 2-23

FL Front Fork 2-24

Inspection Procedure 2-24

Adjusting and Disassembling 2-27

Repairing 2-27

Assembling 2-29

FX Front Fork 2-29

Inspection Procedure 2-29

Disassembling 2-31

Repair 2-31

Assembling 2-34

Rear Shock

Absorbers 2-36

Rear Fork 2-38

BRAKES

Front Drum Brake 2-39

Adjusting 2-39

Disassembling 2-39

Servicing 2-40

Assembling 2-40

Rear Drum Brake 2-41

Adjusting 2-41

Disassembling 2-42

Servicing 2-42

Assembling 2-43

Sidecar Wheel Brake 2-43

Disc Brake 2-43

Check List 2-43

Disassembly and Reassembly 2-43

Front Disc Brake

Master Cylinder 2-48

Disassembling and Assembling 2-48

Rear Brake Master Cylinder 2-49

Disassembling and Assembling 2-49

Hydraulic System 2-49

SEAT 2-51

FIBERGLASS 2-55

Body Care and Repairs 2-55

TOOLS 2-61
Page

Number

ENGINE
GENERAL Specifications 3-1

Description 3-1

Lubrication 3-2

Repair and Diagnostic Procedure 3-7

CYLINDER HEAD Removing 3-11

Disassembling 3-11

Cleaning and Inspection 3-11

Repairing Rocker Arms and Bearings 3-11

Valves, Valve Seats and Guides 3-11

Assembling Cylinder Head 3-14

Adjusting Tappets 3-14

CYLINDER AND PISTON Disassembling 3-15

Cleaning and Inspecting 3-15

Refmishmg Cylinders 3-16

Fitting Piston Rings 3-17

Connecting Rod Bushing 3-18

Straightening Connecting Rods 3-18

Assembling Cylinder and Piston 3-19

GEARCASE Oil Pump 3-21

Disassembling 3-21

Assembling 3-22

Valve Tappets and Guides 3-23

Disassembling 3-23

Cleaning and Inspecting 3-23

Hydraulic Units 3-23

Assembling 3-23

• _

Gearcase Timing Gears 3-24

Disassembling 3-24

Cleaning and Inspecting 3-24

Replacing Cover Bushings 3-26

Assembling 3-26

CRANKCASE General 3-29

Disassembling Crankcase 3-29

Flywheels 3-30

Assembling Crankcase 3-36

FUEL SYSTEM Tillotson Carburetor -

1970 Models Description Operation Adjusting Inspecting and Testing Disassembling Cleaning and Repairing Assembling Troubleshooting Bendix Carburetor -1971-1975 Models Description Operation Adjusting Disassembling Cleaning and Inspection Assembling Keihin Carburetor - 1976 and Later Models Description Operation

Adjusting Carburetor Disassembling Cleaning & Inspection Assembling Carburetor Installing Carburetor on Motorcycle Keihin Carburetor Troubleshooting Air Cleaner Fuel Tank Fuel Supply Valve

TOOLS
TRANSMISSION

GENERAL

Specifications

Description

Stripping Motorcycle for Transmission Repair

CLUTCH General Controls Disassembling Cleaning and Inspection Assembling

ELECTRIC STARTER General

Disassembling and Assembling
KICK STARTER Disassembling and Assembling

GEAR BOX Adjusting Shifting Linkage

Main Drive Gear Oil Seal Shifter Cover

Shifter Cover (Hand Shift)

Shifter Cover (Foot Shift)

Shifter Forks Gear Box (Four Speed) Disassembling Cleaning and Repair Assembling Disassembling and Assembling Gear Box (Three Speed and Reverse)

TOOLS
ELECTRICAL

GENERAL

Specifications

WIRING

1970 FL/FLH Diagram Key

1970 FL/FLH Diagram

1971 FL/FLH Diagram Key

1971 FL/FLH Diagram

1971 FX/FXE Diagram Key

1971 FX/FXE Diagram

1972 FL/FLH Diagram Key

1972 FL/FLH Diagram

1973-74 FL/FLH 1200 Wiring Diagram Key

1973-74 FL/FLH 1200 Wiring Diagram

1973 FX 1200 Wiring Diagram Key

1973 FX 1200 Wiring Diagram
Page Page
Number Number
1974 FX/FXE 1200 Wiring Diagram Key 5-14
4-9 1974 FX/FXE 1200
Wiring Diagram 5-15
1975 FL/FLH 1200 Wiring Diagram Key 5-16
4-11 1975 FL/FLH 1200
Wiring Diagram 5-17
4-11 1975 FX/FXE 1200
4-12 Wiring Diagram Key 5-18
4-13 1975 FX/FXE 1200 Wiring Diagram 5-19
4-13 1976 to 1977 FL/FLH 1200
4-16 Wiring Diagram Key 5-20
4-17 1976 to 1977 FL/FLH 1200
4-20 Wiring Diagram 5-21
4-21 1976 to 1977
FX/FXE 1200 Wiring Diagram Key 5-22
4-21 1976 to 1977 FX/FXE-1200
Wiring Diagram 5-23
4-23 1978 FL/FLH 1200
Wiring Diagram Key 5-24
1978 FL/FLH 1200 Wiring Diagram 5-25
1978 FX/FXE 1200 Wiring Diagram Key 5-26
5-1 1978 FX/FXE 1200
Wiring Diagram 5-27
5-2 1978 FXS 1200 Wiring Diagram Key 5-28
1978 FXS 1200
Wiring Diagram 5-29
5-3 5-4 SWITCHES
Ignition-Light Switch 5-30
5-5 Handlebar Switch
1970-1971 5-31
5-6 Handlebar Switch
1972 and Later 5-31
5-7 Transmission Neutral
Switch 5-32
5-8 Solenoid Switch 5-32
Starter Relay Switch 5-33
5-9 Stop Lamp Front
Brake Switch 5-33
5-10 Stop Lamp Rear
Brake Switch 5-33
5-11 5-12 LAMPS Headlamp 5-35
Adjusting Beam 5-35
5-13 Bulb Chart 5-35


 

CHARGING SYSTEM

1975 & EARLIER 5-37

Alternator 537

Rotor 5-37

Stator 5-37

Rectifier-Regulator 5-37

CHECKING CHARGING SYSTEM 5-38

Disassembling Alternator 5-40 Cleaning and Inspecting Alternator 5-40

Assembling Alternator 5-40

CHARGING SYSTEM

1976 & LATER 5-43

Alternator 5-43

Rotor 5-43

Stator 5-43
TYMPANIUM RECTIFIER-REGULATOR
5-43
 

CHECKING CHARGING
SYSTEM 5-44
Disassembling, Cleaning and Inspecting and
Assembling Alternator 5-45
CIRCUIT BREAKER
Description 5-47
Operation 5-47
Troubleshooting 5-47
Adjusting Points 5-48
Ignition Timing 5-48
Disassembling 5-49
Assembling 5-50
IGNITION COIL
Description 5-51
Troubleshooting 5-51
Replacing Cables 5-51
SPARK PLUGS
General 5-53
Removing Plugs 5-53
Cleaning, Inspection
and Repair 5-53
Setting Spark Gap 5-54
Testing Spark Plugs 5-54
Installing Spark Plugs 5-54

BATTERY General 5-55

Care 5-55

Charging 5-56

HORN 5-57

STARTER MOTOR Troubleshooting 5-59

Prestolite 5-59

Disassembling and Assembling 5-59

Hitachi Disassembling and Assembling 5-61

TOOLS 5-63

MISCELLANEOUS

INSTRUMENTS Speedometer 6-1

Tachometer 6-1
 

 

TABLE OF CONTENTS
PAGE

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

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

Torque Requirements .................................................1-5

Fluid Requirements ................................................. 1-15

Locating Troubles................................................... 1-17

 

 

 

GENERAL

SPECIFICATIONS
NOTE

Model FL specifications also apply to model FLP unless otherwise stated.

DIMENSIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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