Positioning Statement:
The definitive factory service manual for owners and technicians working on 1978-1980 Harley-Davidson Electra Glide and Super Glide models, providing authoritative repair and maintenance data.
Comparison To Aftermarket:
Outperforms aftermarket manuals in accuracy, detail, and comprehensiveness, as it's produced by the manufacturer's own technical documentation department. Often includes specific tools and procedures not found elsewhere.
Manual Strengths:
Unrivaled accuracy, detailed exploded views, clear step-by-step instructions, comprehensive wiring diagrams, and factory-specified torque values. Essential for preserving the originality and functionality of these classic V-twin motorcycles.
Engine Systems:
Engine removal/installation, cylinder head assembly, piston/ring replacement, crankshaft/connecting rod service, valve train (lifters, pushrods, rocker arms), timing/ignition system, carburetor(s) overhaul and adjustment, oil pump operation, cooling system (if applicable, though primarily air-cooled), exhaust system.
Transmission Systems:
Transmission removal/installation, gear set inspection and replacement, clutch operation and adjustment, shift mechanism, primary drive system, transmission fluid specifications and service.
Electrical Systems:
Ignition system (points, condenser, coils), charging system (alternator/generator, regulator), lighting (headlight, taillight, turn signals), starting system (starter motor, solenoid, battery), wiring diagrams, component testing and troubleshooting, fuse box, switches, instruments (speedometer, tachometer, indicators).
Chassis Systems:
Frame inspection and repair, front fork (fork tubes, seals, oil), steering head bearings, rear suspension (shock absorbers, swingarm, bushings), wheels and tires (spoke tension, bearing service), brake system (master cylinders, calipers, pads/shoes, lines, fluid), control cables (throttle, clutch, brake), seat and bodywork mounting.
Fuel System:
Fuel tank inspection, fuel petcock service, fuel lines, fuel filter, carburetor(s) (e.g., Keihin, Mikuni depending on specific model variant) disassembly, cleaning, and adjustment.
Maintenance Procedures:
Routine servicing, oil changes, filter replacements, spark plug replacement, chain adjustment (if applicable), brake adjustments, lubrication points, tire pressure checks.
Repair Procedures:
Component disassembly, cleaning, inspection, reassembly, and adjustment for all major systems. Includes detailed steps for engine rebuilds, transmission overhauls, suspension repairs, brake caliper rebuilding, and electrical component replacement.
Troubleshooting Guidelines:
Diagnostic trees and flowcharts for common and uncommon issues related to starting, running, braking, and electrical systems. Includes symptom-based problem identification.
Technical Specifications:
Torque values for all fasteners, clearance specifications (e.g., valve lash, piston ring gap), ignition timing settings, carburetor jetting specifications, fluid capacities, electrical resistance values, diagnostic test parameters.
Depth Of Information:
Comprehensive (factory level). Covers everything from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostics and troubleshooting. Suitable for experienced mechanics and determined enthusiasts.
Engine Family:
Shovelhead V-Twin
Engine Displacement Cu In:
74 cu in (1200cc) - Standard for most models in this era. Some later models/variants might have 80 cu in (1340cc) 'Evolution' which is less likely for this specific range.
Engine Configuration:
Air-cooled, OHV, 45-degree V-twin
Bore X Stroke:
Typically 3.4375 in x 4.25 in (87.31 mm x 107.95 mm) for 74 ci Shovelhead
Horsepower Estimated:
Approx. 60-65 HP (This is a general estimate, factory figures were often conservative and not widely publicized in the same way as modern vehicles)
Torque Estimated:
Approx. 70-75 ft-lbs (Again, an estimate for context)
Carburetor Type:
Typically single Keihin Butterfly Carburetor (e.g., BD-26, BD-28) or sometimes a Stromberg/Zenith for earlier models/specific configurations. Manual will detail specific types and tuning.
Fuel Type:
Unleaded gasoline, Octane rating typically 90-93 RON (equivalent to 87-89 AKI US)
Fuel Capacity:
Typically 4-5 US gallons (15-19 liters) depending on the fuel tank installed.
Transmission Type:
4-speed constant mesh manual gearbox
Optional Transmissions:
N/A for this specific model/era; 4-speed was standard.
Clutch Type:
Wet multi-plate clutch, operated by cable.
Final Drive:
Chain drive (primary drive within the transmission housing, final drive via a separate chain)
Transmission Fluid Type:
Harley-Davidson specified gear oil, often a proprietary blend. Manual will specify viscosity and API rating (e.g., GL-4 or GL-5).
Transmission Fluid Capacity:
Approx. 1 US pint (0.47 liters), specific amount detailed in manual.
Safety Ratings:
N/A (Motorcycles of this era were not subjected to formal crash testing and rating systems like modern cars).
Braking System:
Front: Single disc brake with hydraulic caliper. Rear: Drum brake with mechanical actuation. Manual will detail fluid type (DOT 3 or DOT 4 typically), bleeding procedures, and pad/shoe specifications.
Suspension System:
Front: Telescopic fork with hydraulic damping. Rear: Dual shock absorbers with adjustable pre-load. Manual will specify fork oil type and quantity, and shock absorber servicing.
Lighting:
Halogen headlight, taillight, brake light, front and rear turn signals.
Oil Change Interval:
Typically every 2,000-3,000 miles (3,200-4,800 km) or 6 months, whichever comes first. Manual will provide exact intervals.
Primary Chain Case Oil Change:
Often coinciding with engine oil changes, or as specified in the manual.
Transmission Oil Change:
Typically every 5,000-10,000 miles (8,000-16,000 km) or annually. Manual will detail specific interval.
Spark Plug Replacement:
Every 5,000-7,500 miles (8,000-12,000 km). Manual will specify plug type and gap.
Air Filter Cleaning/Replacement:
Regular inspection and cleaning/replacement based on operating conditions, usually every 5,000 miles.
Engine Oil Type:
Harley-Davidson recommends its own proprietary V-twin specific oil (e.g., Harley-Davidson 360 or similar viscosity like 20W-50). Manual will specify API rating and viscosity.
Engine Oil Capacity:
Approx. 3 US quarts (2.8 liters) for Shovelhead engines. Manual provides exact figure.
Primary Chain Case Oil Type:
Typically the same engine oil or a specific primary chain lubricant. Manual specifies.
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for definitive spec, as systems evolved).
Common Shovelhead Issues:
Oil leaks (especially from rocker boxes and pushrod tubes), tappet noise, valve adjustment requirements, potential for starter motor issues, carburetor tuning sensitivity, brake system maintenance (especially drum brake on rear).
Clutch Adjustment:
Requires periodic adjustment to maintain proper engagement and disengagement.
Carburetor Tuning:
Sensitivity to altitude, temperature, and wear, often requiring periodic re-jetting or adjustment.
Harley Davidson Legacy:
Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer renowned for its V-twin engines and distinctive styling, representing freedom and the open road.
Electra Glide Super Glide Lineage:
The Electra Glide and Super Glide models represent Harley-Davidson's foray into large-displacement touring and cruiser motorcycles. The Shovelhead engine platform was in production from 1966 to 1984, with continuous evolution. The late 70s models saw improvements in handling and braking compared to earlier Shovelheads.
Manufacturing Era:
These models were produced during a period of transition for Harley-Davidson, leading up to the introduction of the Evolution engine. The Shovelhead engine was known for its character and distinctive sound, though it also presented maintenance challenges.
