1978–1980 Harley-Davidson Electra Glide / Super Glide Service & Repair Manual (P/N 99482-80)

• Coverage: Covers 1978½–1980 Harley-Davidson Electra Glide FL/FLH and Super Glide FX/FXE/FXEF/FXS, for models manufactured after January 1, 1978, with service data for the 1200cc and 1340cc engine configurations used across these model families.
• Engine repair: Covers cylinder-head removal and reconditioning, valve-guide and valve-seat work, pushrod adjustment, cylinder and piston inspection/refinishing, piston-pin bushings, oil-pump service, tappets and guides, gearcase timing gears, crankcase and flywheel work, carburetor service, and fuel-system repair.
• Chassis repair: Details chain service, wheel removal and hub work, 16- and 19-inch spoke lacing and truing, cast-rim runout checks, frame-alignment checks, FL and FX fork overhaul/straightening, adjustable FL fork setup for solo or sidecar use, rear shock service, rear-fork work, and hydraulic disc-brake service.
• Transmission and starting systems: Includes clutch disassembly/inspection/assembly, electric starter shaft and solenoid work, kick-starter and starter-clutch repair, main-drive-gear oil-seal replacement, shifter linkage adjustment, early/late shifter-cover procedures, shifter-fork setup, and mainshaft/countershaft service.
• Electrical diagnosis: Provides separate wiring diagrams for 1978½–1979 FL/FLH, FX/FXE, and FXS/FXEF models, plus 1980 FL/FLH, FXE, and FXS/FXEF diagrams; also covers switches, charging-system testing, alternator removal/installation, both ignition-system generations, battery testing, and Prestolite and Hitachi starter motors.
• Workshop reference material: Includes a general fastener-tightening chart, component-specific torque requirements, fluid and lubricant requirements, locating-trouble charts, factory special-tool references, and named exploded views such as the FL Adjustable Fork, Disc Brake, Cylinder Head, Crankcase, and Countershaft and Case Assembly.

Factory Repair Coverage

This 184-page PDF contains the 1980 Harley-Davidson Service Manual, P/N 99482-80. The foreword explains that the book was prepared both to help readers perform basic maintenance and repair and to give professional Harley-Davidson mechanics the latest factory-approved major repair methods. Routine service material is usable by mechanics familiar with these motorcycles, while crankcase, flywheel, valve-seat, fork-straightening, and transmission setup work assumes proper measuring tools and workshop equipment.

The manual goes well beyond tune-up information. Chassis chapters show how the factory approaches wheel alignment and truing, fork inspection and straightening, rear shock disassembly, brake master-cylinder work, caliper service, and hydraulic bleeding. Engine coverage moves from diagnostic checks into cylinder-head repair, piston and cylinder fitting, oil-pump and tappet work, timing-gear installation, flywheel inspection/truing, crankcase assembly, and carburetor repair. Transmission chapters carry the same depth through clutch, starter, shifter, shaft, bearing, seal, and case work.

Production Changes and Repair Traps

Late-production differences are handled directly instead of treating every covered motorcycle as mechanically identical. The piston section identifies the change to taper-face second compression rings in 1340cc engines beginning with crankcase No. 1479-345-165 and in 1200cc engines beginning with crankcase No. 179-023-001. Other sections separate early-1979-and-earlier drum-shifter hardware from the late-1979-and-later plate-shifter arrangement, 1979-and-earlier carburetor procedures from the 1980 design, and the 1979-and-earlier ignition system from the 1980 electronic-advance system.

The brake chapter also identifies a specific late-1980 change: motorcycles above VIN 26625-J0 use the later square-seal calipers in the applicable FL and FX brake positions. The manual warns that the marked front and rear calipers are not interchangeable because their piston retraction differs; installing the wrong unit can affect braking. In the electrical section, it similarly warns against interchanging the earlier ignition coil with the 1980 electronic-advance coil because the wrong type can damage electronic components.

Tools, Diagrams, and Scope

Factory-tool pages identify equipment such as the 95500-80 Wheel Truing Stand, 96245-51 Fork Stem and Cross Member Aligning Gage, 96384-39 Fork Shifter Gage, and 95952-33 Connecting Rod Clamping Tool. These references matter when evaluating whether a repair can be carried out with the equipment already in the shop.

Illustration coverage includes model- and system-specific exploded views, section drawings, setup diagrams, test circuits, and wiring schematics. Particularly useful examples include the FL Adjustable Fork exploded view, Disc Brake exploded view for FL front/rear and FX rear applications, Cylinder Head and Crankcase exploded views, Countershaft and Case Assembly exploded view, charging-system test arrangements, and the six model-year wiring diagrams listed above.

One scope point is worth noting: the manual’s stated coverage line does not list FXWG, even though the vehicle-identification table contains an FXWG-80 model code. The foreword also directs technicians to Harley-Davidson Service Bulletins for interim engineering changes and supplementary information. Mechanical repair carries inherent risk; follow the manual’s warnings and use proper workshop equipment, especially for brake hydraulic work, fuel-system service, spring-loaded assemblies, and major engine or chassis repair.