1978 – 1980 FL FLH FX FXE FXEF Harley-Davidson SERVICE MANUAL – PDF DOWNLOAD
DESCRIPTION:
1978 – 1980 FL FLH FX FXE FXEF Harley-Davidson SERVICE MANUAL – PDF DOWNLOAD
IMPORT ANT NOTICI:
Harley-Davidson motorcycles produced after January 1, 1978, conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture. To maintain the safety, dependability and emission control performance it is essential that the procedures, specifications and service instructions in this manual are followed. Any substitution, alteration or adjustment of emission system components outside of factory Specifications may be prohibited by law.
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, ii will introduce to the professional Harley-Davidson mechanic the latest field-tested and factory-approved major repai1 methods. We sincerely believe that this manual will make your association with Harley-Davidson products more plea sant and profitable.
HOW TO USE YOUR SERVICE MANUAL
Your Service Manual is arranged for quick, easy reference. This manual is divided into numbered sections. Sections are then divided into sub-sections. 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. Page number consists of section number and page number. 3. 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.
NOTE:
All information, photographs and illustrations are based on the latest product information available at the time of publication
SERVICE BULLETINS
In addition to the information given in this Service Manual, Service Bulletins are issued to Harley-Davidson
TABLE OF CONTENTS:
1978 – 1980 FL FLH FX FXE FXEF Harley-Davidson SERVICE MANUAL – PDF DOWNLOAD
SECTION 1 · PRODUCT Page No
Specifications
D1mens1ons 1-1
Capacities 1-1
Engine 1-1
Vehicle Identification 1-1
Transmission 1-2
Tire Data 1-2
Service
Servicing a New Motorcycle 1-3
Regular Service Intervals 1-4
Torque Requirements
Wheels 1-7
Brakes 1-7
Forks 1-7
Handlebar 1-7
Engine 1-7
Transmission 1-8
Electrical 1-8
Fluid Requirements
Harley-Davidson Oil 1-9
Harley-Davidson Chain Grease
Chain Saver Chain Spray 1-9
Gasoline 1-9
Brake Fluid 1-9
Harley-Davidson/Loctite Products 1-9
Locating Troubles
Engine 1-11
Lubrication System 1-12
Electrical System 1-13
Carburetor 1-13
Transmission 1-13
Clutch 1-13
Brake 1-14
SECTION 2 · CHASSIS
Drive
Chains 2-1
Wheels
General 2-5
Check List 2-5
Front Wheel 2-5
Rear Wheel 2-6
Wheel Hubs 2-6
Spoking Wheels• 16 Inch 2-9
Spoking Wheels – 19 Inch_ 2-10
Truing Spoked Wheel 2-11
Checking Cast Rim Runout 2-13
Tires _- 2-14
Handlebar Throttle Control
General 2-15
Frame
General 2-17
· Forks Page No
General 2 -19
FL Front Fork : 2 -23
FX Front Fork 2-24
Straightening Fork Tubes 2-27
Rear Shock Absorber 2-29
Rear Fork 2 -30
Brakes
General 2-33
Rear Brake Pedal Adjustment 2-33
Disc Brake Calipers 2-34
Rear Brake Master Cylinder 2-38
Seat
Solo Saddle 2-39
Comfort Flex Seat 2-40
Tools 2-43
SECTION 3 · ENGINE
General
Specifications 3-1
Description 3-1
Lubrication 3-2
Repair and Diagnostic Procedure · 3-4
Cylinder Head
Removing 3-7
Disassembling 3-7
Cleaning and Inspection 3 7
Repairing Rocker Arms and Bushings 3-7
Replacing Valve Guides 3-9
Reconditioning or Replacing Vavle Seats 3-9
Grinding Valve Faces and Seats 3 9
Lapping Valve Faces and Seats 3 -10
Installing and Adjusting Push Rods 3-11
Checking Push Rod Adjustment 3-11
Cylinder and Piston
Disassembling Cylinder and Piston 3-13
Cleaning and Inspecting 3-13
Refinishing Cylinders 3-13
Fitting Pi ston Rings 3-14
Piston Pin Bushing 3-16
Assembling Cylinder and Piston 3-17
Gearcase
Oil Pump 3-19
Valve Tappets and Guides 3 -21
Gearcase Cover and Timing Gears 3 -22
Crankcase
General 3-27
Disassembling Crankcase 3 -27
Flywheels 3-28
Assembling Crankcase 3-34
Fuel System
Carburetor 3-37
Air Cleaner 3-43
Fuel Tank 3-45
Fuel Supply Valve 3-45
TABLE OF CONTENTS
SECTION 3 · ENGINE (cont’d ) Page No
Tools 3 47
SECTION 4 · TRANSMISSION
General
Specifications 4-1
Description 4-1
Clutch
General 4-3
Disassembling Clutch 4-3
Cleaning and Inspection _ _ 4-6
Assembling Clutch 4-6
Electric Starter
General 4-7
Disassembling Starter Shaft and Solenoid 4-7
Assembling Starter Shaft and Solenoid 4-7
Kick Starter
Disassembling Kick Starter 4 9
Cleaning Inspection and Repair 4-9
Assembling Kick Starter 4 9
Disassembling Starter Clutch 4-9
Cleaning Inspection and Repair 4-9
Assembling Starter Clutch 4-10
Transmission Case
Adjusting Shifter Linkage 4-11
Replacing Main Drive Gear Oil Seal 4-11
Shifter Cover Drum Shifter
Early 1979 and Earlier 4-13
Shifter Cover – Plate Shifter
Late 1979 and Later 4-16
Shifter Forks 4-17
Transmission Case 4-19
Tools 4-24
SECTION 5 · ELECTRICAL
General
Specifications 5-1
Wiring
1978½-1979 FUFLH Wiring Diagram 5-3
1978½-1979 FX/FXE Wiring Diagram 5 5
1978½-1979 FXS/FXEFWiring Diagram 5-7
1980 FUFLH Wiring Diagram 5-8A
1980 FXE Wiring Diagram 5-SC
1980 FXS/FXEF Wiring Diagram 5-SE
Switches
Ignition – Light Switch 5-9
Handlebar Switch Assembly 5-10
Stoplight Switch 5-10
Starter Relay Switch 5-10
Transmission Neutral Switch 5-10
Solenoid Switch 5-11
Lamps Page No
Headlamp 5-13
Charging System
Alternator 5-15
Rectifier – Regulator _ 5-15
Checking Charging System 5-16
Removing the Alternator 5-17
Installing the Alternator 5-18
Ignition System – 1979 and Earlier
Ignition Timer 5-19
Troubleshooting 5-20
Disassembling and Assembling 5-22
Ignition System – 1980 and Later
Description 5-24A
Troubleshooting 5-248
Check Advance Timing with
a Strobe Timing Light 5-24C
Setting Retarded Timing _ 5-24D
Removing Ignition Components 5-24D
Inspection and Replacing Parts 5-24D
Installing Ignition Components 5-24D
Ignition Coil
Description 5-25
Troubleshooting 5-25
Replacing Spark Plug Cable 5-25
Spark Plugs
General 5-27
Removing Spark Plugs 5-27
Inspecting Spark Plugs 5-27
Setting Spark Gap 5-27
Installing Spark Plugs _ 5-27
Battery
General 5-29
Battery Care 5-29
Testing Battery 5-29
Charging Battery 5-30
Horn 5-31
Starter Motor
Description 5-31
Troubleshooting 5-31
Starter Motor and Drive 5·32
Prestolyte Starter Motor 5-32
Hitachi Starter Motor 5-33
SECTION 6 · MISCELLANEOUS
Instruments 6-1
PRODUCT
TABLE OF CONTENTS
Page
General 1-1
Service 1-3
Torque Requirements 1-7
Fluid Requirements 1-9
Locating Troubles 1-11
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