Harley-Davidson Electra Glide & Super Glide 1200 Service Manual, 1970–1978 (P/N 99482-78)

Factory Harley-Davidson Service Manual P/N 99482-78 covers Electra Glide FL/FLH 1200 and Super Glide FX/FXE/FXS 1200 models from 1970 through early 1978 production, up to January 1, 1978. The foreword directs users to applicable Service Bulletins for interim engineering changes; later 1978 production falls outside this edition’s stated coverage.

PDF Search, Diagram Detail and Page Count

Search and wiring detail: PDF text search and embedded bookmarks are not available. Small component numbers and wire-color codes in the wiring diagrams require zooming.

The ZIP contains one printable, 232-page PDF, including the front cover, foreword, title page, contents pages and back cover.

Engine Overhaul, Chassis Service and Electrical Diagnosis

The following selected coverage highlights outline the main workshop content. Additional topics include Comfort Flex seat adjustment and speedometer/tachometer cable service.

• Engine repair: Engine removal, cylinder-head overhaul, cylinder refinishing, piston and ring fitting, connecting-rod alignment, oil-pump service, hydraulic-tappet inspection, timing-gear setup and flywheel truing.

• Carburetor repair: Tillotson for 1970, Bendix for 1971–1975 and Keihin for 1976 and later, with adjustment, disassembly, inspection, cleaning, reassembly and troubleshooting.

• Drivetrain: Front and rear chain service, clutch-control adjustment, clutch overhaul, electric and kick starter mechanisms, shifter-cover timing and internal gearbox repair.

• Chassis and brakes: Fork rebuilding, steering-head alignment, wheel-hub service, spoke lacing and truing, rear suspension, drum and disc brake service, master cylinders and hydraulic bleeding.

• Electrical diagnosis: Fourteen year/model-specific wiring diagrams with separate keys, charging-system tests, ignition timing, switch checks, battery service and Prestolite/Hitachi starter-motor repair.

• Workshop reference: Locating Troubles charts, regular-service schedules, component torque tables, fluid and tire data, wear limits, clearance specifications, electrical test values and special-tool listings.

The manual introduces basic maintenance and also addresses professional Harley-Davidson mechanics performing major repairs; the overhaul sections call for specialist measuring, reaming and alignment equipment.

Engine Inspection and Internal Repair

Diagnosis and top-end work: Compression testing and valve-train noise diagnosis support decisions about top-end work versus crankcase repair. Step-by-step procedures cover rocker-arm bushings, valve guides, valve seats, valve lapping, cylinder inspection and refinishing, ring fitting, piston-pin bushings and cylinder installation.

Gearcase and bottom end: Internal repair extends to oil-pump gears and lines, hydraulic tappet units, cam and pinion timing gears, gearcase-cover bushings, flywheel disassembly, rod-bearing fitting, main-bearing lapping and end-play checks. The Gearcase - Exploded View supports component identification during this work.

The FL/FLH/FX Lubrication (1972 and Earlier) and FL/FLH/FX 1200 Lubrication System (1973 and Later) illustrations distinguish the oiling and breather layouts. Late-1977-and-later cam, pinion and breather gears also receive separate matching guidance because their pitch diameters changed.

Piston-pin lock-ring procedures distinguish early and later designs. The manual warns that an over-expanded, reused or improperly seated ring can escape and damage the piston and cylinder beyond repair.

Carburetor Testing and Production Differences

Tillotson coverage includes inlet-needle, main-nozzle check-valve and economizer leakage checks. Bendix material explains the fuel-supply, accelerating, idle and high-speed systems; Keihin coverage adds float and throttle adjustment, installation checks and dedicated trouble charts.

Fuel-system service also covers air-cleaner elements, fuel tanks and the different fuel-supply valves used on 1974-and-earlier versus 1975-and-later models.

These distinctions matter when a motorcycle has a mix of original and replacement parts and the correct procedure depends on production design rather than the model name alone. The specifications section also states that FL data applies to FLP unless otherwise noted.

Wheels, Forks and Brake Systems

Wheel coverage distinguishes 16-inch assemblies from the 19-inch FX front wheel, with rim centering, radial and lateral truing, tire mounting, wheel alignment and balancing. Sidecar wheel and brake service is included.

Fork information separates FL non-adjustable and adjustable designs from the FX fork. Procedures extend to slider-bushing removal, installation and reaming, tube straightening, bracket alignment and steering-head bearing adjustment. Rear shock and rear-fork inspection are covered; faulty shock-absorber units require replacement.

Brake sections distinguish early drum systems from the FL/FLH and FX/FXE/FXS disc arrangements, including later FXS/FX front calipers. The Disc Brake - Exploded View accompanies caliper service, while separate sections address front and rear master cylinders, fluid replacement and bleeding.

The caliper instructions identify bore scoring from a cocked piston, and the bleeding section explains that brake-fluid contamination of the pads cannot be reliably removed. Fiberglass body repair includes surface damage, holes, punctures and breaks.

Clutch, Shifting and Gearbox Repair

Transmission material covers hand- and foot-shift controls, main-drive-gear oil-seal replacement, shifter-fork centering, shaft and gear inspection, and four-speed reassembly. The Countershaft and Case Assembly - Exploded View identifies the internal parts and three-speed/reverse substitutions.

Three-speed/reverse compatibility: This transmission cannot be installed on a foot-shift motorcycle or assembled in a four-speed gearcase. Shifter-fork assemblies are not interchangeable; the manual warns that straightening a bent fork can weaken it and lead to gearbox damage.

Wiring, Charging and Workshop Equipment

The wiring section runs from the 1970 FL/FLH layout through the early-1978 FL/FLH, FX/FXE and FXS versions, including the 1978 FXS 1200 Wiring Diagram. Component keys accompany the diagrams, and switch coverage includes ignition-light, handlebar, neutral, solenoid, starter-relay and stop-lamp circuits.

Charging diagnosis separates the 1975-and-earlier system from the 1976-and-later alternator/Tympanium rectifier-regulator arrangement. Starter-motor sections cover troubleshooting, disassembly, armature service and brush replacement for Prestolite and Hitachi units.

Tool plates identify the Wheel Truing Stand P/N 95500-29A, FL Fork Slider Bushing Tools P/N 96254-50 and flywheel Truing Stand P/N 96650-30. The Fork Shifter Gauge P/N 96384-39 and Alternator Rotor Puller P/N 95960-52A show where dedicated setup and pulling equipment is required.

Support the motorcycle securely before wheel, fork, engine or transmission removal, and follow the manual’s fuel-system and hydraulic-brake precautions.

A Preview of Ignition-Coil Test Specifications

The ignition-coil troubleshooting section lists primary-winding resistance of 4.7–5.7 ohms and secondary-winding resistance of 16,000–20,000 ohms. These limits accompany ohmmeter checks for hard starting or misfiring.

The same section distinguishes replaceable spark-plug cables from a defective coil assembly, which requires replacement.