1979 Harley-Davidson XLH-1000 / XLCH-1000 Service Manual (P/N 99484-79)

Harley-Davidson service manual P/N 99484-79 provides factory maintenance and repair information for the 1979 XLH-1000 and XLCH-1000. VIN model codes are 3A (XLH) and 4A (XLCH).

Text search and wiring detail: PDF text search and embedded bookmarks are not available. Small wire color codes and component labels in the XLH and XLCH wiring diagrams are readable when enlarged.

• Engine repair: Cylinder head overhaul, piston and cylinder inspection, valve seat refacing, connecting rod bearing work and flywheel truing.

• Lubrication and cam gears: Gerotor oil pump inspection, oil pressure testing, gearcase bushing replacement, cam gear end play checks and timing alignment.

• Fuel system: Keihin carburetor overhaul, float level checks, accelerator pump service, choke adjustment and troubleshooting by symptom.

• Clutch and transmission: Wet multiple disc clutch repair, release adjustment, shifter inspection, gearbox disassembly and shaft end play setup.

• Chassis and brakes: Telescopic front fork repair, steering head bearing service, wheel balancing, hydraulic disc brake caliper rebuilds and master cylinder service.

• Electrical diagnosis: Separate XLH/XLCH wiring diagrams, electronic ignition tests, charging system checks, starter relay testing and Prestolite/Hitachi starter motor service.

The manual supports basic maintenance and repair, with major repair methods written for professional Harley-Davidson mechanics.

Engine Repair and Build Differences

Top-end repairs are described with the crankcase still in the frame; lower-end bearing work requires engine removal. Cylinder and piston inspection includes bore measurement, ring fitting and connecting rod alignment, with wear limits, running clearances and torque data for individual components. Valve Seat Specifications and exploded views support cylinder head inspection and reassembly.

Push rod seals: Separate drawings show early 1979 push rod assemblies with cork washers and late 1979 assemblies with O-rings. This comparison helps identify the installed sealing arrangement before selecting replacement parts.

Flywheel and bearing work: Connecting rod race lapping and roller bearing selection lead into flywheel assembly and truing. Correcting Flywheel Alignment illustrations accompany the procedures. Named tools include the Connecting Rod Lapping Arbor, P/N 96740-36, and Flywheel Truing Device, P/N 96650-30.

Keihin Carburetor and Gerotor Oil Pump

The fuel chapter explains low-speed, mid-range and main-metering circuits, choke operation and accelerator pump behavior, backed by the Keihin Carburetor Trouble Chart. It also warns that wire or drills used to clean jet openings can damage their precisely sized passages.

The gerotor pump section distinguishes feed and scavenge components, with inspection and priming procedures. The Oiling System diagram traces oil supply and return, alongside oil pressure test specifications and fluid-capacity information.

Clutch, Gearbox and Starting Systems

The transmission can be serviced through its access cover; the manual also describes transmission work during crankcase disassembly. Shifter fork selection, gear engagement checks, mainshaft and countershaft end play, and factory gear-ratio specifications extend the coverage beyond clutch adjustment.

The XLCH kick starter and XLH electric starter have separate procedures. Electric starter coverage includes the Bendix drive, solenoid and both Prestolite and Hitachi motors.

Chassis and Hydraulic Brakes

The Wheel Service Chart connects handling complaints with wheel trueness, alignment, tire condition and bearing checks. The Frame with Basic Dimensions drawing supports alignment assessment.

Fork tube straightening procedures specify an arbor or hydraulic press and dial-indicator checks; sharply bent tubes are excluded because of metal fatigue.

Brake repair includes front and rear caliper teardown, master cylinder inspection, hydraulic bleeding and rear brake linkage adjustment. Rear fork bearing service and rear shock absorber inspection are also covered.

Support the motorcycle securely and disconnect the battery before engine, drivetrain or electrical service.

Ignition and Charging Diagnostics

Separate model wiring diagrams include component keys and wire color codes. Breakerless ignition coverage extends to sensor air-gap adjustment, mechanical advance inspection, coil testing and strobe timing.

The charging section covers generator field-coil and armature tests, commutator repair, polarization and the solid-state regulator's temperature-compensated voltage checks. These tests help distinguish generator output faults from regulator problems.

Incorrect coil wiring can permanently damage the electronic ignition module; the manual identifies that connection risk. The sealed module is tested as a unit and replaced if faulty.

PDF Edition and Included Pages

One printable English-language PDF contains 152 pages in total, including six original opening pages: the cover, important notice, title/section guide, foreword and two table-of-contents pages.