Model:
FL/FX Series (4-Speed)
Applicable Models:
FLH, FLHS, FXB, FXSB, FXE, FXEF, FXS, FXWG, FXST
Generation:
4-Speed Era (Pre-Evolution Big Twin)
Engine Configuration:
45-Degree V-Twin
Market Niche:
Essential reference for owners and technicians of classic Harley-Davidson Big Twin motorcycles from a pivotal era of their development.
Comparative Value:
Offers factory-level detail often exceeding aftermarket manuals, crucial for maintaining these iconic machines.
Diagnostic Tools:
Provides the specific procedures and specifications needed to diagnose issues unique to the 4-speed era Big Twins.
Restoration Support:
Indispensable for restoration projects, ensuring accuracy in assembly and tuning.
Primary Coverage:
Comprehensive repair and maintenance for 1978-1984 Harley-Davidson FL/FX series motorcycles equipped with 4-speed transmissions and 1200/1340cc V-twin engines.
Estimated Page Count:
400-600 Pages (typical for comprehensive factory-style manuals of this era)
Manual Type:
Factory-Style Service/Repair Manual
Format:
Printed (likely softcover or spiral-bound for workshop use)
Engine:
Full engine overhaul, including cylinder head, piston, crankshaft, camshaft, oil pump, and timing components.
Transmission:
Disassembly, inspection, repair, and reassembly of the 4-speed constant mesh transmission, including gear sets, shifting mechanisms, and primary drive.
Fuel System:
Carburetor (e.g., Keihin, Linkert) service, adjustment, and troubleshooting; fuel tank and line maintenance.
Ignition System:
Points and condenser ignition system maintenance, timing, and troubleshooting.
Electrical System:
Wiring diagrams, charging system (generator/alternator), lighting, starter motor, and battery service.
Wheel Brakes:
Front and rear brake system maintenance, adjustment, and repair (likely drum brakes and early disc brakes).
Forks Shock ABSorber:
Front fork (e.g., FL style or Sportster style depending on model) and rear shock absorber service, including fluid changes and seal replacement.
Body Accessories:
Bodywork, fenders, seat, handlebars, controls, and accessory installation/maintenance.
Maintenance:
Scheduled maintenance, lubrication, fluid changes, filter replacement, cable adjustments, and general upkeep.
Troubleshooting:
Systematic diagnostic procedures for common problems, with symptom-based fault finding.
Repair:
Step-by-step instructions for component disassembly, repair, reassembly, and testing.
Rebuilds:
Detailed guidance for complete engine and transmission rebuilds.
Adjustments:
Carburetor, ignition timing, clutch, and brake adjustments.
Depth:
Comprehensive, covering routine maintenance to full engine and transmission overhauls. Suitable for experienced home mechanics and professional technicians.
Print Quality:
Good to Excellent (typical for factory-issue or reputable aftermarket manuals of the period, with clear diagrams and text).
Binding Type:
Likely perfect bound or saddle-stitched for softer covers, or spiral-bound for easier workshop use and lay-flat capability.
Paper Type:
Durable paper stock, often with glossy pages for diagrams and illustrations.
Engine Displacement Options:
1200cc (74 cubic inch) and 1340cc (80 cubic inch) Shovelhead variants.
Cylinder Arrangement:
45-degree V-twin
Typical Horsepower Range:
Approx. 60-70 HP (depending on specific model, tuning, and displacement)
Typical Torque Range:
Approx. 70-80 ft-lbs (depending on specific model, tuning, and displacement)
Carburetor Examples:
Keihin Butterfly, Linkert (earlier variations), or others fitted by the factory/dealers.
Fuel Type:
Unleaded Gasoline (transition period, manual will specify octane and lead content requirements based on the year).
Oil Type Specification:
Specific Harley-Davidson recommended oil viscosity (e.g., SAE 20W-50, HD 360) and type (e.g., mineral-based).
Ignition Type:
Mechanical Breaker Point Ignition System.
Transmission Type:
4-Speed Constant Mesh Manual Transmission.
Optional Transmissions:
None for this specific manual's coverage period and models.
Clutch Type:
Wet multi-plate clutch.
Primary Drive:
Chain Drive (to transmission) from the engine, often enclosed in a primary chaincase.
Final Drive:
Belt Drive or Chain Drive (depending on specific model/year).
Transmission Oil Type:
Specific Harley-Davidson transmission oil or equivalent (e.g., SAE 75W-90 GL-4 gear oil is common for later models, manual will specify for this era).
Safety Standard Era:
Reflects safety standards and equipment typical of the late 1970s and early 1980s.
Braking System:
Dual-acting front and rear brakes. Early models may have drum brakes; later models in this range introduced disc brakes for front and sometimes rear.
Lighting:
Headlight, taillight, brake light, turn signals (where equipped).
Oil Change Interval:
Typically every 2,000-3,000 miles or annually, whichever comes first. Manual will provide specific factory recommendations.
Transmission Oil Change Interval:
Typically every 5,000-10,000 miles or annually. Manual will provide specific interval.
Primary Chain Tensioner:
Regular checks and adjustment are crucial, often before every long ride and periodically at service intervals.
Engine Oil Capacity:
Approximately 3.5 quarts (3.3 liters) for 1200cc/1340cc Shovelhead engines. Manual will confirm exact capacity.
Transmission Oil Capacity:
Approximately 1 quart (0.95 liters). Manual will confirm exact capacity.
Fork Oil Type Capacity:
Specific weight fork oil (e.g., 10W or 15W) and capacity per fork leg. Manual will list precise specifications.
Shovelhead Engine Quirks:
Potential for oil leaks (especially from head gaskets and pushrod tubes), oil pump drive issues, and stator/rotor failure. Ignition timing can be sensitive.
Transmission Wear:
Common wear on shift forks, drum bearings, and dog teeth on gears. Primary chain tensioner wear is also frequent.
Electrical Reliability:
Early electrical systems can be prone to issues with stator, regulator, and wiring harness degradation.
Common Filter Part Numbers:
While specific part numbers are best found in the manual or parts catalog, common oil filter types from this era include Fram, Wix, or Harley-Davidson branded filters fitting the appropriate thread and size.
Brand Legacy:
Harley-Davidson's Big Twin line is legendary, representing American motorcycling culture and engineering prowess.
Shovelhead Era:
This period (1978-1984) represents the final years of the iconic Shovelhead engine before the introduction of the Evolution (Evo) engine in 1984.
Manufacturing Location:
Milwaukee, Wisconsin, USA.
Transitional Period:
These models mark a significant transition as Harley-Davidson navigated economic challenges and evolving market demands, leading up to the significant engine change.
