🏷️ Basic Information

Make:

Harley-Davidson

Models Covered:

FLSTC Heritage Softail Classic, FLSTF Fat Boy, FXLR Low Rider Custom, FXSTC Softail Custom, FXSTS Springer Softail, FXSTSB Bad Boy

Model Years Covered:

1991, 1992

Softail Platform:

This manual covers models belonging to the Harley-Davidson Softail family, known for its distinctive hidden rear suspension system mimicking a hardtail frame.

👋 Introduction

Segment:

Cruiser Motorcycles (Harley-Davidson's iconic Softail line).

Competitors:

During this era, key competitors in the cruiser segment included models from Japanese manufacturers like Honda (Shadow series), Yamaha (V-Star series), Kawasaki (Vulcan series), and Suzuki (Intruder series), as well as other American brands like Indian.

Manual Advantage:

Provides detailed, model-specific information for owners and technicians, facilitating proper maintenance and repair, especially valuable for older models.

Digital Benefit:

Offers convenience and accessibility, allowing users to access repair information instantly on various devices, even in remote locations.

📋 Manual Details

Primary Coverage:

Comprehensive repair, maintenance, and troubleshooting for the specified 1991-1992 Harley-Davidson Softail models.

Secondary Coverage:

Includes information useful for parts lookup and routine ownership tasks.

Type:

Repair Manual / Service Manual

Language:

English

Format:

Electronic Download (PDF)

📖 Manual Coverage

Powertrain:

Engine, transmission, drive chain and sprockets, lubrication and cooling systems.

Chassis:

Frame, steering system, shocks (suspension), wheels, brakes, and bodywork.

Electrical:

Complete electrical system including wiring diagrams, ignition, lighting, and accessories.

Fuel System:

Fuel tank, fuel lines, carburetor (likely Keihin CV or similar for the era), and fuel pump (if applicable).

Intake Exhaust:

Air intake system and exhaust system components and servicing.

Maintenance:

Routine maintenance tasks, fluid changes, filter replacements, lubrication, and tune-ups.

Repair:

Detailed step-by-step repair procedures for various components and systems.

Troubleshooting:

Advanced troubleshooting guidance for diagnosing and resolving common and complex issues.

Installation:

Procedures for engine removal and installation.

Depth:

Comprehensive, covering from basic adjustments to major overhauls and diagnostics.

📊 Manual Specifications

Format:

PDF

Searchability:

Likely searchable text within the PDF for efficient information retrieval.

Quality:

Assumed high-quality digital reproduction, allowing for clear printing of individual pages.

Type:

N/A (Digital Download)

Type:

N/A (Digital Download)

Method:

Instant download after payment confirmation.

Policy:

Lifetime Protection Policy for lost or damaged downloads.

⚙️ Engine Specifications

Type:

Air-cooled, Evolution (Evo) V-twin engine.

Displacement:

Primarily 1337cc (81.5 cubic inches) for most models, with potential variations. Some earlier or specific models might have had 1200cc variants, but the 1991-1992 Softail lineup largely featured the 80ci Evo.

Bore X Stroke:

Approx. 3.496 in. x 4.250 in. (88.8 mm x 108.0 mm) for the 80ci engine.

Compression Ratio:

Typically around 8.5:1 to 9.0:1.

Fuel System:

Carburetor (likely Keihin CV 36mm or similar for this period).

Horsepower:

Estimated around 55-60 hp (at crankshaft), though official figures were not always prominently published.

Torque:

Estimated around 65-70 lb-ft (at crankshaft).

System Type:

Dry-sump lubrication system with an oil tank typically located in the frame cradle.

System Type:

Air-cooled.

🔧 Transmission

Type:

5-speed manual transmission.

Drive Type:

Belt drive to the rear wheel (primary drive).

Clutch:

Wet multi-plate clutch, operated by a cable-actuated lever.

Transmission Oil:

Specific Harley-Davidson transmission fluid or equivalent SAE 75W-90 gear oil is typically recommended. Check manual for exact type and quantity.

📐 Dimensions

Wheelbase:

Varies by model, but typically in the range of 63-65 inches.

Dry Weight:

Typically in the range of 575-630 lbs (260-285 kg), depending on the specific model and equipment.

🛡️ Safety Features

Crash Test Results:

Motorcycles of this era were not subject to the same rigorous crash testing standards as automobiles. Safety is primarily dependent on rider skill and proper maintenance.

Braking System:

Front and rear disc brakes. Typically a dual-piston caliper front and a single-piston caliper rear.

Lighting:

Headlight, taillight, brake lights, and turn signals.

💡 Technology Features

Features:

Basic instrumentation: speedometer, odometer, tachometer (on some models), engine warning lights. No integrated infotainment systems.

Features:

None. Motorcycles of this era rely entirely on rider input and mechanical systems.

Features:

None. No electronic connectivity features.

🔧 Maintenance

Oil Change:

Typically recommended every 2,500-3,000 miles or annually, whichever comes first. Refer to manual for precise interval.

Primary Chain Tension:

Regular checks and adjustment are critical for belt-drive motorcycles, usually around 5,000-mile intervals. Check manual.

Spark Plugs:

Replacement typically recommended every 7,500-10,000 miles.

Engine Oil:

Viscosity typically SAE 20W-50 or SAE 25W-50 motorcycle-specific oil. Harley-Davidson's own V-Twin synthetic or conventional oil is often recommended. Check manual for exact type and capacity (usually around 3 quarts).

Brake Fluid:

DOT 4 or DOT 5 brake fluid (depending on system type and year, check manual carefully as mixing is problematic). Harley-Davidson typically specified DOT 5 for this era, but confirmation is vital.

Primary Chain Case Oil:

Specific primary chain case lubricant or SAE 20W-50 engine oil. Check manual for exact type and capacity.

Evo Engine:

While generally robust, common areas for attention include oil leaks from seals and gaskets, potential cam bearing wear (especially on higher mileage units), and carb tuning.

Rear Suspension:

Shock absorbers may require service or replacement due to age and mileage. Check for leaks or sagging.

Electrical:

Aging wiring harnesses, connections, and components (e.g., voltage regulators, ignition modules) can be sources of intermittent issues.

Carburetor:

Keihin CV carburetors can sometimes be prone to diaphragm tears or adjustment drift, requiring tuning or rebuilding.

📚 Vehicle History

Legacy:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer with a rich heritage in V-twin engines and the cruiser segment.

Softail Introduction:

The Softail platform, designed by Bill Davis and later refined by Harley-Davidson, was introduced in 1984, offering a smoother ride than traditional hardtail frames while maintaining the classic appearance.

Manufacturing Location:

United States (primarily York, Pennsylvania and Milwaukee, Wisconsin).

Engine Development:

The Evolution engine (Evo) was introduced in 1984 for the Softail models, replacing the Shovelhead engine, and became a cornerstone of Harley-Davidson's lineup for many years due to its reliability and performance.

🏆 Awards & Recognition

Model Acclaim:

The Harley-Davidson Evolution engine and the Softail platform were highly acclaimed for their distinctive styling, torque, and the iconic Harley-Davidson riding experience, solidifying their place in motorcycle history.

Reliability:

The Evolution engine is generally considered reliable when properly maintained. Many of these models remain in regular use, a testament to their enduring design.