🏷️ Basic Information

Make:

Harley-Davidson

Model:

Electra Glide

Model Variant:

FLH

Year:

1978

Chassis Code:

FLH

👋 Introduction

Positioning:

The 1978 Electra Glide FLH represented the pinnacle of Harley-Davidson's touring motorcycle offerings, aimed at riders seeking comfort and capability for long-distance travel and cruising. It was a premium offering in its class.

Lifestyle Appeal:

The Electra Glide FLH in 1978 was synonymous with the American motorcycle lifestyle, embodying freedom, open roads, and a distinct sense of individuality.

Competitors:

Primary competitors included other large-displacement V-twin cruisers and touring motorcycles from manufacturers like Indian (though their market presence was diminished by this era) and potentially some European offerings, though the Electra Glide held a strong niche.

Features:

Flagship touring model, comfortable ergonomics for long rides, large V-twin engine, ample storage (panniers, tour-pak options), iconic styling, robust construction, often considered a 'gentleman's express'.

📋 Manual Details

Systems Covered:

Engine, Transmission, Drivetrain, Chassis, Suspension, Brakes, Electrical System, Fuel System, Ignition System, Cooling System, Bodywork, Lubrication System, Troubleshooting, Maintenance

Page Count:

Detailed page count not specified in product description, but factory service manuals are typically extensive, often exceeding 400 pages.

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Likely a printed book, consistent with factory service manuals of the era. Digital formats (PDF) may also be available from resellers.

📖 Manual Coverage

Engine Mechanical:

Detailed overhaul procedures, component diagnostics, timing, valve adjustments, carburetor tuning, cylinder head service, piston and ring replacement, crankshaft and connecting rod service.

Transmission Drivetrain:

4-speed constant mesh transmission service, clutch operation and adjustment, primary drive chain inspection and adjustment, final drive belt/chain maintenance (depending on specific FLH configuration), Jiffy stand service.

Electrical System:

Wiring diagrams, ignition system troubleshooting (points, condenser, coil), lighting circuits, starter system, battery service, charging system (generator/alternator).

Brakes:

Front and rear brake system service, hydraulic system bleeding, pad/shoe replacement, caliper/wheel cylinder service.

Suspension Steering:

Front fork service (oil changes, seal replacement), rear shock absorber inspection and replacement, steering head bearing adjustment and service.

Fuel System:

Carburetor disassembly, cleaning, and adjustment (likely for Linkert or early Keihin CV carburetors), fuel tank and petcock service, fuel line maintenance.

Wheels Tires:

Wheel bearing service, tire pressure specifications, rim and spoke inspection.

Bodywork Fittings:

Fairing removal and installation (if equipped), fender service, seat mounting, handlebar adjustments, dashboard and instrument cluster service.

Cooling System:

While air-cooled, the manual will cover pre-ride checks of cooling fins and general advice on maintaining airflow for optimal heat dissipation.

Routine Maintenance:

Oil and filter changes, chain lubrication and adjustment, tire pressure checks, brake adjustments, spark plug replacement, air filter cleaning/replacement.

Troubleshooting:

Diagnostic charts and procedures for common starting, running, and electrical issues. Symptom-based troubleshooting guides.

Major Repairs:

Engine rebuilds, transmission overhauls, complete brake system overhauls, suspension rebuilds, electrical system diagnostics and repair.

Technical Specifications:

Torque specifications for all fasteners, engine tolerances, fluid capacities, ignition timing settings, valve clearances.

Diagnostics:

Comprehensive diagnostic procedures for engine performance, ignition timing, charging system, fuel delivery, and electrical faults.

Assembly Disassembly:

Detailed, step-by-step instructions for disassembling and reassembling major components and sub-assemblies.

Safety Precautions:

Extensive safety warnings and precautions relevant to working on motorcycles, including handling of fuels, oils, electrical components, and safe lifting procedures.

Depth:

Comprehensive, covering from basic owner maintenance to full factory-level mechanical and electrical repairs. Expected to include detailed exploded diagrams and step-by-step instructions.

Special Tools:

Likely lists specific Harley-Davidson special tools required for certain procedures, such as primary chain alignment tools, bearing pullers, or engine timing tools.

📊 Manual Specifications

Digital Format Notes:

If digital, expect searchable PDF with high-resolution diagrams. Original factory manuals were printed and may have been scanned.

Print Quality Notes:

Original manuals typically featured high-quality paper with clear, detailed diagrams and text. Reproduction quality can vary.

Binding Type Notes:

Original factory manuals were often perfect-bound or spiral-bound for lay-flat usability. Some reproductions might vary.

Paper Type Notes:

Durable paper stock suitable for workshop environments.

Manual Completeness:

This is a factory service repair manual, intended to be a complete guide for maintaining, troubleshooting, and repairing all aspects of the 1978 Harley-Davidson Electra Glide FLH.

⚙️ Engine Specifications

Engine Type:

Air-cooled, 45-degree V-twin

Engine Displacement:

74 cubic inches (1200cc)

Bore X Stroke:

3.4375 in. x 4.00 in. (87.3 mm x 101.6 mm)

Compression Ratio:

Typically around 7.0:1 to 7.5:1 for Shovelhead engines of this era.

Engine Family:

Shovelhead

Horsepower:

Estimated 60-65 hp at 5000 rpm (actual figures can vary based on tuning and specific configuration).

Torque:

Estimated 75-80 lb-ft at 3500 rpm.

Carburetor:

Likely a Linkert M-series or early Keihin Butterfly (CV) carburetor, depending on the specific production run and market. Manual will detail specific type.

Fuel Type:

Unleaded gasoline (91 octane or higher recommended for optimal performance and to prevent pinging).

Fuel Tank Capacity:

Approximately 4.0 U.S. gallons (15.1 liters).

Oil Capacity:

Approximately 4 U.S. quarts (3.8 liters) including the oil filter.

Oil Type:

Motorcycle-specific engine oil, typically SAE 20W-50 or SAE 50 was common for these engines. The manual will specify the exact grade and type.

🔧 Transmission

Transmission Type:

4-speed constant mesh, manual foot shift with left-hand clutch operation.

Optional Gearbox:

No automatic or alternative manual transmission options were standard for this model in 1978.

Clutch Type:

Wet multi-plate clutch.

Primary Drive:

Primary drive chain (usually 1" pitch) within a sealed primary case.

Final Drive:

Belt drive (common for Electra Glide models of this era) or potentially chain drive depending on specific FLH sub-model. Manual will confirm.

📐 Dimensions

Wheelbase:

Approximately 61.5 inches (1562 mm).

Length:

Approximately 93 inches (2362 mm).

Width:

Approximately 36 inches (914 mm).

Height:

Approximately 55 inches (1397 mm) to the top of the windshield.

Dry Weight:

Approximately 685 lbs (311 kg).

Gross Vehicle Weight Rating:

Not typically specified in the same way as cars, but rider and cargo capacity would be detailed in the manual.

🛡️ Safety Features

Safety Ratings:

Motorcycles of this era did not undergo standardized crash testing or receive formal safety ratings like modern automobiles.

Active Safety Features:

Effective braking system (dual disc front, drum rear), stable chassis, good rider visibility.

Passive Safety Features:

Sturdy frame construction, rider protection via fairing and bodywork to some extent. Rider skill is the primary safety factor.

💡 Technology Features

Infotainment System:

The 1978 Electra Glide was a relatively analog machine. Infotainment would typically be limited to a speedometer, tachometer (optional), odometer, and basic indicator lights. Some models might have had aftermarket radios installed, but not factory-integrated.

Driver Assistance Features:

None in the modern sense. Rider input and skill were the primary 'assist' features.

Connectivity Options:

No factory connectivity options. Communication would be via rider interaction or aftermarket communication systems.

🔧 Maintenance

Oil Change Interval:

Typically every 2,000-3,000 miles or 6 months, whichever comes first. The manual will provide the definitive schedule.

Primary Chain Adjustment:

Every 1,000-2,000 miles or as needed. Manual will detail correct tension.

Spark Plug Replacement:

Every 5,000-10,000 miles, or as recommended based on spark plug type. Manual will specify appropriate plugs (e.g., Champion, NGK).

Front Fork Service:

Fork oil changes typically every 10,000-15,000 miles. Manual will specify fork oil type and quantity.

Engine Oil:

SAE 20W-50 or SAE 50 motorcycle-specific oil. Harley-Davidson branded oil or equivalent quality oil meeting API SG or higher specification. Manual will confirm.

Transmission Oil:

Gear oil, typically SAE 90 or SAE 75W-90 GL-5 synthetic gear oil. Manual will specify type and capacity.

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid for disc brake systems. Manual will specify the exact type and bleeding procedure.

Fork Oil Type:

The manual will specify the correct weight (e.g., SAE 10W) and type of fork oil, along with the precise volume for each fork leg.

Common Wear Items:

Pushrod tube seals (leaks), generator/alternator drive issues, carburetor tuning (Linkert can be finicky), primary chain tensioner wear, clutch adjustment, front fork leaks, ignition points and condenser wear.

Shakedown Procedures:

Post-rebuild break-in procedures, initial fluid checks, and adjustment intervals are critical for Shovelhead engines.

📚 Vehicle History

Brand Origin:

Harley-Davidson Motor Company, founded in Milwaukee, Wisconsin in 1903.

Evolution Path:

The Electra Glide lineage began in 1965 with the Electra-Glide FL, which replaced the Hydra-Glide and Duo-Glide models. It marked the introduction of the electric starter (hence the name) and the iconic 'batwing' fairing. The 1978 model represents a mature stage of the Shovelhead engine era, incorporating refinements from previous years.

Production Period:

The Shovelhead engine (1966-1984) powered the Electra Glide FLH. 1978 falls within this significant period for the model.

🏆 Awards & Recognition

Industry Recognition:

While specific awards for the 1978 model year aren't typically documented in the same way as modern vehicles, the Electra Glide FLH consistently received recognition as a premier American touring motorcycle, earning a reputation for its comfort, durability, and iconic status in motorcycling culture.

Customer Satisfaction:

Owner satisfaction was generally high for riders who appreciated the classic V-twin experience, though the Shovelhead engine required diligent maintenance. It became a beloved platform for customization and long-distance riding.