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

The 1978 Harley-Davidson Motor Co. service manual, P/N 99482-78, covers Electra Glide FL/FLH 1200 and Super Glide FX/FXE/FXS 1200, including Low Rider. This edition applies to 1970 through early 1978 production, up to January 1, 1978.

• Engine repair: Cylinder-head, valve-guide, piston, crankcase, and flywheel work, plus oil-pump overhaul and hydraulic-tappet diagnosis.

• Fuel systems: Tillotson, Bendix, and Keihin carburetor disassembly, inspection, reassembly, and adjustment, with fuel-system troubleshooting.

• Transmission and clutch: Dry multiple-disc clutch service, hand- and foot-shifter adjustment, and four-speed or three-speed/reverse gearbox repair.

• Wheels and brakes: Wheel-bearing service, spoke lacing and truing, drum and disc brake overhaul, master-cylinder repair, and hydraulic bleeding.

• Forks and chassis: FL and FX fork disassembly, slider-bushing service, steering-head bearing adjustment, rear-fork service, and fiberglass body repair.

• Electrical diagnosis: Charging, ignition, solenoid, and starter tests, with model-specific wiring diagrams and Prestolite and Hitachi starter-motor service.

Major repair sections are written for professional Harley-Davidson mechanics; the basic maintenance material introduces routine work, while overhaul procedures require the specified measuring equipment and special tools.

Engine Overhaul and Lubrication

The Regular Service Intervals Chart and model-specific lubrication/service charts organize routine maintenance.

Engine coverage includes valve-seat reconditioning, cylinder refinishing, connecting-rod alignment, bearing fitting, flywheel truing, and timed gearcase assembly. The compression diagnostic chart links test patterns to ring trouble, valve trouble, and head-gasket leakage, helping narrow the likely repair before disassembly.

Lubrication drawings distinguish earlier and later oiling and breather layouts. The oil-pump section warns that overtightening can displace its plastic gaskets, eliminate gear side clearance, and seize or damage the pump.

For oil-pump parts changed during the 1973 model season, the identification note refers to separate Service Bulletin No. 647.

Carburetor Variants and Fault Charts

Separate procedures cover Tillotson for 1970, Bendix for 1971–1975, and Keihin for 1976 and later models within this edition. The Keihin Carburetor Trouble Chart addresses overflow, starting, idle, and road-performance problems. Air-cleaner, fuel-tank, and fuel-supply-valve service are also covered.

Gearbox Setup and Primary Drive

Shifter-clutch spacing checks use Fork Shifter Gauge P/N 96384-39. The three-speed/reverse transmission cannot be installed on a foot-shift model or assembled in a four-speed gearcase.

The Engine Sprocket Spacer Table relates rotor-recess and clutch-surface measurements to primary-chain alignment. A chain-housing vacuum test using Gauge P/N 96950-68 checks for air leaks after assembly.

Chassis Service and Component Limits

The wheel section covers lacing and truing 16-inch and 19-inch spoked wheels and includes a Wheel Alignment Diagram. Early FL hubs use a left-hand bearing locknut; the locking arrangement changes from hub staking to a separate retainer on late 1970 and later models.

Front Fork Exploded Views accompany the fork procedures. Early FX slider bushings are replaceable, while 1973 and later sliders have nonremovable bushings. Rear shock assemblies can be dismantled for spring and hardware service, but faulty hydraulic units are replaced rather than rebuilt.

Front-brake procedures distinguish the 1974–1977 FX/FXE caliper from the 1977–1978 FXS and 1978 FX/FXE design.

Fiberglass coverage extends from surface finishing and gel-coat repairs to reinforced structural patches.

Always adhere to standard workshop safety protocols when lifting the heavy chassis or handling high-amperage electrical systems.

Charging, Starting, and Ignition Tests

Charging-system sections separate 1975-and-earlier from 1976-and-later components, which are not directly interchangeable. The Tympanium Rectifier-Regulator Schematic Diagram supports the related test-circuit drawings and output checks.

Year- and model-specific wiring includes separate diagrams for the 1978 FL/FLH, FX/FXE, and FXS. The Bulb Chart, spark-plug heat-range data, and circuit-breaker point and ignition-timing sections support lighting and ignition service.

Starter procedures include armature repair and brush replacement. On Prestolite and Hitachi units, field-coil replacement requires the frame-and-field assembly.

A Preview of Engine Fits, Fastener Torques, and Oil Capacity

Fastener torques: The torque chart specifies 12–15 ft-lb for crankcase stud nuts and 18–22 ft-lb for primary chaincase bolts, with separate entries for clutch, wheel, brake, and electrical fasteners.

Engine fits and lubrication: Intake valve stem-to-guide fit is listed at 0.0018–0.0038 in., alongside separate exhaust-guide and rocker-arm fits. The oil-tank capacity is 4 U.S. quarts.

PDF Search, Diagram Detail, and Included Pages

Text navigation and wiring detail: PDF text search and embedded bookmarks are not available. Small wiring-diagram labels require zooming.

Supplied as one printable, English-language PDF with 251 pages total, including the cover, five front-matter pages, and 20 blank pages.