Positioning:
Essential resource for owners and technicians working on the iconic Harley-Davidson FXS Shovelhead model from 1978, known for its distinctive styling and robust performance.
Analysis:
This manual provides detailed, manufacturer-specific information, surpassing generic repair guides in accuracy and completeness for the FXS Shovelhead.
Features:
Focuses on the specific mechanical and electrical systems of the 1978 FXS Shovelhead, offering step-by-step procedures and critical torque specifications.
Engine:
Complete overhaul, diagnosis, tuning, carburetion, ignition, lubrication
Transmission:
Disassembly, assembly, adjustment, lubrication, troubleshooting
Chassis:
Frame, forks, swingarm, suspension, wheels, brakes
Electrical:
Wiring diagrams, lighting, ignition system, charging system, starter
Bodywork And Trim:
Fenders, fuel tank, seat, handlebars, controls
Frame And Suspension:
Inspection and maintenance of frame components, steering head bearings, front fork assembly (including oil changes and seal replacement), and rear shock absorbers.
Type:
Service and Repair Manual
Primary Systems:
Engine, Fuel, Ignition, Lubrication, Transmission, Clutch, Brakes, Suspension, Electrical System, Frame, Bodywork
Maintenance:
Oil changes, filter replacements, chain adjustment, brake adjustments, tune-ups
Repair:
Engine rebuild, transmission overhaul, carburetor repair, brake system service, electrical diagnostics, suspension component replacement
Troubleshooting:
Diagnostic charts, common problems and solutions, performance issues
Electrical System Repair:
Detailed wiring diagrams, troubleshooting steps for common electrical faults, charging system checks, and starter motor service.
Depth:
Comprehensive from basic maintenance to complete engine and transmission overhauls, including detailed electrical troubleshooting and wiring diagrams.
Diagnostic Procedures:
Detailed diagnostic charts and procedures for identifying and resolving engine, electrical, and drivetrain issues.
File Type:
PDF (Portable Document Format)
Quality:
High-resolution scans suitable for printing, clear text and diagrams.
Binding:
N/A (Digital Format)
Paper:
N/A (Digital Format)
Completeness:
Complete service and repair manual covering all aspects of maintenance, troubleshooting, and repair for the 1978 FXS Shovelhead.
Engine Type:
Air-cooled, 45-degree V-twin
Engine Family:
Shovelhead
Displacement:
74 cubic inches (1215cc)
Bore X Stroke:
3.4375 in. x 4.25 in. (87.31 mm x 107.95 mm)
Compression Ratio:
8.0:1 (Typical)
Valve Train:
Overhead valves, pushrod-actuated
Horsepower Estimate:
Approximately 60-65 HP @ 5500 RPM
Torque Estimate:
Approximately 70-75 ft-lbs @ 3500 RPM
Carburetor:
Keihin Butterfly (often CV) or Linkert (earlier models), specific to FXS configuration. Manual will detail tuning and rebuild.
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Oil Type:
Harley-Davidson High Performance 20W50 or equivalent V-twin specific oil
Oil Capacity:
Approximately 3 quarts (2.8 liters) for crankcase and oil tank combined.
Ignition Type:
Contact point ignition (points and condenser) or early electronic ignition (e.g., Fairbanks Morse or aftermarket). Manual details setup and timing.
Carburetor Tuning:
Comprehensive instructions for adjusting fuel mixture, idle speed, and float levels for optimal performance and emissions compliance for the era.
Type:
4-speed constant mesh, foot-shifted
Clutch:
Wet, multi-plate, cable-operated
Primary Drive:
Duplex chain
Transmission Fluid:
Harley-Davidson Formula+ Transmission Oil or a high-quality 75W-90 GL-1 gear oil
Gear Ratios:
Specific gear ratios for each of the 4 speeds are detailed in the manual for inspection and troubleshooting.
Ratings:
N/A (Motorcycle safety ratings are not directly comparable to automobiles and were not standardized as they are today).
Braking System:
Front: Disc brake; Rear: Drum brake. Manual covers inspection, pad replacement, fluid flush.
Lighting:
Headlight, tail light, brake light, turn signals. Manual includes troubleshooting for electrical circuits.
Oil Change Interval:
Every 2,000-3,000 miles or annually, whichever comes first. Manual details procedure for engine oil and oil filter.
Transmission Service:
Inspect and top-up transmission fluid at regular intervals. Full flush and refill recommended every 10,000-15,000 miles. Manual details procedure and fluid type.
Chain Adjustment:
Check and adjust final drive belt tension every 2,000-3,000 miles. Manual provides specifications for belt tension.
Spark Plug Replacement:
Recommended replacement every 5,000-10,000 miles or as needed based on inspection. Manual provides correct spark plug type and gap.
Engine Oil Type:
Harley-Davidson High Performance 20W50 Motorcycle Oil (or equivalent API SG rated oil).
Transmission Fluid Type:
Harley-Davidson Formula+ Transmission Oil (or equivalent 75W-90 GL-1 gear oil).
Primary Chain Case Oil:
Harley-Davidson Primary Chaincase Lubricant (or equivalent Type 'F' ATF for specific applications, check manual).
Brake Fluid Type:
DOT 4 or DOT 5 silicone fluid (depending on original specification, verify with manual or existing system).
Common Problems:
Oil leaks (especially from generator or primary), valve adjustments, primary chain adjustment, carburetor tuning, ignition system maintenance. Manual addresses these with diagnostic and repair procedures.
Heritage:
Harley-Davidson, founded in 1903, has a rich history of American motorcycle manufacturing, evolving from small, utilitarian bikes to iconic V-twins.
Fxs Evolution:
The FXS originated from the FX Super Glide line, introduced in 1971, featuring a blend of Sportster and Electra Glide components. The FXS (Low Rider) model specifically debuted in 1977, characterized by its lower seat height, pullback handlebars, and extended front end, offering a more relaxed riding position.
Production Era:
The Shovelhead engine was produced from 1966 to 1984. The FXS Low Rider model was a significant variant within this era.
