Haynes Harley-Davidson Glides Owners Workshop Manual 1970 thru 1991 156392000X, 9781563920004

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rARLEY-DAVIDSON | GLIDES 1970 thru 1991

74 cubic inch 080 cubic inch Big-twins

Owners Workshop Manua

_ Digitized by the Internet Archive in 2023 with funding from Kahle/Austin Foundation

https://archive.org/details/harleydavidsonglO000choa

629,.28775 C45ih Chonte, Curt. Harley-Tinvidson Glides owners workshop manual 16.93

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MID-CONTINENT PUBLIC LIBRARY South Independence Branch

13700 E. 35th St.

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Independence, MO 64055

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by Curt Choate,

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Tom Schauwecker

and John H Haynes Member of the Guild of Motoring Writers

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Models covered: _ All Glide models — 1970 through 1991

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(5T1 — 703)

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Haynes Publishing Group Sparkford Nr Yeovil

Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park California 91320 USA ———————

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Acknowledgements Our thanks to the Champion Spark Plug Company for contributing the spark plug condition photos used in Chapter 1. Thanks also to Jon LaCourse for supplying several tools and the motorcycle used for photography of the Evolution engine repair procedures and the rear cover illustration. ©

Haynes North America, Inc.

1991

With permission from J.H. Haynes & Co. Ltd.

A book in the Haynes Motorcycle Repair Manual Series Printed in the USA All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 56392 000 X Library of Congress Catalog Card Number 89-82762 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library While every attempt is made to ensure that the information in this manualis correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

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ONTINENT

0 10766775 4

Contents Introductory pages About this manual Introduction to the Harley-Davidson Glides Identification numbers Buying parts Maintenance techniques, tools and working facilities Motorcycle chemicals and lubricants Safety first! Troubleshooting

6 6 i 10 10 16 17 18

Chapter 1 Tune-up and routine maintenance

26

Chapter 2 Engine, clutch and transmission

57

Chapter 3 Fuel and lubrication systems

122

Chapter 4 Ignition system

141

Chapter 5 Frame and suspension

145

Chapter 6 Wheels, brakes and tires

Chapter 7 Electrical system

Wiring diagrams English/American terminology

211

Conversion factors

212

Index

213

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About this manual Its purpose The purpose of this manual is to help you maintain and repair your motorcycle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop, it provides information and procedures for routine maintenance and it offers diagnostic and repair procedures to follow when trouble occurs. We hope you will use the manual to tackle the work yourself. For many simple jobs, doing it yourself may be quicker than arranging an appointment to get the machine into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment you feel after doing the job yourself.

Using the manual The manual is divided into several Chapters. Each Chapter is divided into numbered Sections which are headed in bold type between horizontal

lines. Each Section consists of consecutively numbered Paragraphs (often referred to as “Steps” in the text). The two types ofillustrations used (line drawings and photographs) are all referenced by anumber preceding each caption. The number denotes the Section and Paragraph the illustration is intended to clarify (i.e. illustration 3.4 means Section 3, Paragraph [or Step] 4). A “Refer to illustration ...” entry under the Section head (or in some cases, a sub-head) will alert you to the illustrations which apply to the procedure you're following. Procedures, once described in the text, are not normally repeated. Whenit’s necessary to refertoanother Chapter, the reference willbe given as Chapter and Section number (i.e. Chapter 1, Section 16). Cross-references given without use of the word “Chapter” apply to Sections and/or Paragraphs in the same Chapter. For example, “see Section 8” means in

the same Chapter. Reference to the left or right side of the motorcycle is based on the assumption you're sitting on the seat, facing forward. Even though extreme care has been taken during the preparation of this manual, neither the publisher nor the author can accept responsibility for any errors in, or omissions from, the information given.

NOTE ANote provides information necessary to properly complete a procedure or information which will make the procedure easier to understand.

CAUTION A Caution provides a special procedure or special steps which must be taken while completing the procedure where the Caution is found. Not heeding a Caution can result in damage to the assembly being worked on.

WARNING A Warning provides a special procedure or special steps which must be taken while completing the procedure where the Warning is found. Not heeding a Warning can result in personal injury.

Introduction to the Harley-Davidson Glides William S. Harley and Arthur Davidson jointly designed and built their first motorcycle during 1903, constructed along the lines of a powered bicycle. The single cylinder, air-cooled engine had a bore and stroke of 2-1/8 x 2-7/8 inches and is alleged to have been one of several built for experimental purposes. The weaknesses of the powered bicycle approach soon became apparent and a larger capacity engine followed, with much heavier flywheels. With the new, more powerful engine, the bicycle was able to climb hills more easily but, in turn, weaknesses in the frame design became apparent. And so the design progressed until something usable and marketable was available. Land was purchased in Milwaukee for the erection of a simple, two story factory and the Harley-Davidson joined the ranks of the world’s motorcycles. By the end of 1906, fifty machines had

been assembled at Chestnut Street and the order book was full, portending well for the year to follow. The year 1909 proved to be a milestone in the history of the company, for it was during that year the company launched its first V-twin. It was this model, and others that followed, that helped create the legend of the large capacity V-twin, a field in which Harley-Davidson ruled supreme for many years. In private hands it gave astandard of comfort, performance and reliability second to none, while on the racetrack it became a snarling, powerful beast, with the ability to perform incredible feats of speed and endurance that made the headlines. Contrary to expectations, the American motorcycle boom didn’t last long and by the 1930s, it had all but petered out. It was largely the more sporting side that kept things going, although motorcycles were also used

by police for law enforcement purposes. The American “speed cop’ was very much a part of life and a big, powerful V-twin gave him a certain amount of flexibility that wouldn't have been possible in a patrol car. The modern Harley-Davidson Electra Glide was never introduced as a model, as such, but is a development of such machines as the model 74K, which was introduced in 1941, and more recently the Duo-Glide of the late 50’s. This can be seen when it’s noted that many parts installed on the latest models are not only similar, but in many cases identical, to components installed on the wartime machines. The policies of the company, reflecting the motorcycling needs of the home market, have produced a machine ideally suited to the task of traveling vast distances in comfort, and which has evolved a personality and charisma which has made Harley-Davidson a household name. The Super Glide model was introduced in 1971 to caterto the rider requiring a sportier and lighter machine, yet not lacking in the glamor of its more heavily dressed stablemate. The development of the Evolution engine, which was introduced in 1984 models, ensures the big twin mystique will continue, since the new engine is as reliable, oil-tight and serviceable as the engines in competitive motorcycles, without discarding the unique characteristics of previous Harley engines. Because it’s more powerful across the board, lighter, cooler running and cleaner, in terms of exhaust emissions, than its predecessor, it launched a new era for the big V-twin engine and continues the trend toward refinement that should produce many more generations of satisfied Harley customers. ‘

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identification numbers

Harley-Davidson motorcycles have a Vehicle Identification Number VIN) stamped into the frame on the right side of the steering head, as well as on the right side of the engine crankcase (see illustrations). All 1978 and later models also have an adhesive-backed label, attached to the right ront frame downtube, with the VIN on it (see illustration). The VIN is nade up of a model code, a serial code, a serial number, the model year and the manufacturer’s identification. The VIN number should be recorded and kept in a safe place so it can ye furnished to law enforcement officials in the event of theft. The VIN should also be available when purchasing or ordering parts for the mashine. It’s a good idea to write it on a card and keep it tucked away with our driver’s license, then it'll be handy when you need it.

Frame VIN number location

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Engine VIN number location nn

Frame tube label on 1978 and later models ee EEE

Identification numbers

Next Five

Digits (Sequential Number)

(Manufacturer)

FEton FER

10000

Harley-Davidson

Um, FX FXE FXS FLH-1200 FX-1200 FXE-1200 FXEF-1200 FXEF-80 FXS-1200 FLH-80 FXE-80 FXS-80 FXWG-80 FLH-80 Classic FLHS-80 FL-80 FLH-1200

and up

First Two

Digits (Model)

(5 digits)

Second

Last

Digit

Last Digit

(Model) (Season)

H

8 (1978 %) 9 (1979)

Police

FLH-1200 Shrine FLH-80 Police FLH-80 Shrine Fiat

Examples:

O (1980)

1979 FLH-1200, 1980 FLH-1200,

2A12141H9 2A12141JO

VIN key for pre-1980 models

Identification numbers

9

FLH-80 FLHP-80 Police FLH-80 Shrine FLHP-80 Police FLHS-80 FLH-80 Shrine FXE-80 FXWG-80 FXSB-80

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