Era:
Iconic late 1970s and early 1980s Harley-Davidson cruisers.
Target Audience:
Harley-Davidson owners and mechanics seeking detailed repair and maintenance information.
Competitors:
Other aftermarket service manuals of the era (e.g., Clymer, Haynes), though factory manuals are generally considered the most authoritative.
Authenticity:
Provides factory-level information essential for maintaining these classic motorcycles accurately.
Longevity Support:
Crucial for owners of these vintage models to keep them running reliably.
Engine:
Shovelhead V-Twin engine overhaul, tuning, and component diagnosis.
Transmission:
4-speed Cruise Drive transmission inspection, repair, and adjustment.
Clutch:
Clutch assembly service, adjustments, and replacement procedures.
Frame And Body:
Frame inspection, fork assembly, swingarm, fenders, and fuel tank service.
Suspension:
Front fork (leading axle) and rear shock absorber service and adjustment.
Brakes:
Front and rear brake system maintenance, caliper, master cylinder, and hydraulic line service.
Electrical System:
Wiring diagrams, ignition system (points and electronic), charging system, lighting, and starter motor troubleshooting.
Fuel System:
Carburetor (e.g., Keihin butterfly and Linkert) service, tuning, and fuel pump operation.
Exhaust System:
Exhaust pipe and muffler inspection and replacement.
Wheels And Tires:
Wheel bearing service, tire replacement, and spoke tension checks.
Maintenance:
Scheduled maintenance tasks, lubrication points, and fluid level checks.
Troubleshooting:
Diagnostic charts and common problem identification for engine, electrical, and mechanical systems.
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly.
Overhaul:
Complete engine and transmission rebuild procedures.
Wiring Diagrams:
Detailed electrical schematics for all model variants.
Torque Specifications:
Essential torque values for critical fasteners.
Depth:
Comprehensive coverage from basic rider maintenance to full engine and transmission rebuilds.
Diagnostic Capability:
Advanced diagnostic procedures for identifying and resolving complex issues.
Detail Level:
Detailed illustrations, diagrams, and exploded views for component identification and assembly.
Engine Type:
Air-cooled, 45-degree V-twin, OHV (Overhead Valve)
Engine Family:
Shovelhead
Displacement:
74 cubic inches (1200cc) for most models; some FX models may have 80 cubic inches (1340cc) in later years of this range.
Bore X Stroke:
Typically 3.4375 in. x 4.000 in. (74 ci) or 3.4375 in. x 4.250 in. (80 ci)
Compression Ratio:
Varies by model and year, generally around 7.0:1 to 8.0:1
Horsepower:
Approx. 60-70 HP (estimated, varies by tune and model)
Torque:
Approx. 70-80 ft-lbs (estimated, varies by tune and model)
Carburetor:
Keihin butterfly carburetor (e.g., Keihin BD or similar) and some earlier models or variations might retain the Linkert carburetor.
Fuel Type:
Unleaded gasoline (low octane, typically 87-89 RON/AKI, depending on compression and ignition timing)
Ignition Type:
Breaker-point ignition system (standard on most), with options or later upgrades to electronic ignition (e.g., Boyer Bransden).
Oil System:
Dry sump lubrication with a remote oil tank.
Type:
4-speed constant mesh, foot-shifted, hand-clutched.
Gear Ratios:
Specific ratios vary by model year but are detailed in the manual. Example: 1st gear ~9.15:1, 2nd ~6.42:1, 3rd ~4.70:1, 4th ~3.33:1 (ratios are approximate and representative).
Options:
Primarily 4-speed manual; 5-speed transmissions were not standard for these models.
Primary Drive:
Primary chain drive enclosed in a primary case, wet clutch operation.
Final Drive:
Belt drive, typically 132-tooth rear pulley and 32-tooth front pulley.
Transmission Fluid:
Harley-Davidson recommends specific transmission fluids (e.g., Harley-Davidson Gear Oil, SAE 80W-90 API GL-5).
Wheelbase:
Approximately 60.5 - 62 inches, depending on model and front fork configuration.
Length:
Approximately 90-94 inches.
Seat Height:
Approximately 27-29 inches (unladen).
Dry Weight:
Approximately 600-650 lbs (1978-1980 Electra Glide models).
Gross Vehicle Weight Rating:
Typically around 900-950 lbs.
Crash Safety:
Motorcycles of this era were not subjected to standardized crash testing in the same way as automobiles. Safety is primarily derived from rider skill and adherence to road laws.
Braking:
Dual disc front brake (most models) and single disc rear brake (most models).
Lighting:
Headlight, tail light, brake light, turn signals, and dashboard illumination.
Frame Design:
Robust steel frame designed for stability.
Rider Controls:
Handlebar controls for throttle, brakes, clutch, and turn signals; foot controls for shifting and rear brake.
Audio System:
Most models did not feature integrated audio systems. Aftermarket radios and speaker kits were available.
Gauges:
Analog speedometer, tachometer (on some models), ammeter, and indicator lights.
Rider Aids:
None. This era predates modern electronic rider aids.
Connectivity Features:
None.
Oil Change:
Recommended every 2,000-3,000 miles or annually. Manual will specify exact intervals.
Transmission Fluid Change:
Recommended every 5,000-10,000 miles or annually. Manual will specify exact intervals.
Primary Chain Tension:
Check and adjust as needed, typically every 5,000 miles.
Spark Plugs:
Inspect and gap every 5,000 miles, replace as needed.
Engine Oil:
Harley-Davidson recommends specific viscosity grades (e.g., 20W-50 or 50W) for air-cooled V-twins, often with specific additives. Refer to the manual for exact part numbers or specifications (e.g., Harley-Davidson SAE 50 or 20W-50 Motorcycle Oil).
Transmission Oil:
Harley-Davidson Gear Oil SAE 80W-90 API GL-5 or equivalent.
Primary Chain Case Fluid:
Typically 1 quart of SAE 50 motorcycle oil (e.g., Harley-Davidson SAE 50 Motorcycle Oil) or specific primary chain case lubricant.
Brake Fluid:
DOT 3 or DOT 4 brake fluid (verify with manual for exact specification).
Engine Oil Leaks:
Common with Shovelheads due to older seal designs and materials. Crankshaft seal and pushrod tube seals are frequent culprits.
Carburetor Tuning:
Shovelhead carburetors (especially early butterfly types) can be finicky and require regular adjustment for optimal performance and fuel economy.
Electrical Reliability:
While improved over earlier models, the electrical systems of this era can still be prone to issues with wiring insulation, regulators, and points. The manual is essential for diagnosis.
Transmission Shifting:
The 4-speed transmission can sometimes be stiff or clunky, especially when cold. Clutch adjustment is critical.
Vibration:
Vibrations are characteristic of Shovelhead engines; proper engine mounts and balance are key.
Heritage:
Harley-Davidson has a rich history dating back to 1903, known for its iconic V-twin engines and cruiser motorcycles.
Electra Glide Lineage:
The Electra Glide, introduced in 1965 as the first electric-start Harley-Davidson, evolved significantly through the decades. The 1978-1980 models represent the Shovelhead era, known for its distinct styling and sound.
Shovelhead Era:
The Shovelhead engine, produced from 1966 to 1984, succeeded the Panhead and Knucklehead engines. The 1978-1980 models feature refined Shovelhead versions.
Manufacturing Location:
Milwaukee, Wisconsin, USA.
Key Innovations During Period:
Introduction of electronic ignition on some models, improvements in braking systems, and refinement of the Shovelhead engine.
