Target Audience:
Harley-Davidson owners, independent repair shops, motorcycle technicians
Value Proposition:
Provides dealership-level repair information, enabling cost-effective maintenance and repair
Competitors:
Other aftermarket repair manuals (e.g., Clymer, Haynes), official Harley-Davidson service bulletins
Authenticity:
Matches the quality and detail of official dealer workshop manuals
Comprehensiveness:
Covers the entire model range within the specified years, including all major systems
Instructional Method:
Step-by-step instructions with supporting visual aids for ease of understanding and execution
Engine Mechanical:
Engine disassembly, inspection, assembly, tuning for all specified engine types (e.g., Evolution Big Twin)
Fuel System:
Carburetor (e.g., Keihin CV) and fuel injection (EFI) systems, fuel pump, fuel lines, fuel tank maintenance and repair
Ignition System:
Ignition module, spark plugs, ignition coils, timing adjustment, troubleshooting
Transmission:
5-speed constant mesh transmission: disassembly, inspection, assembly, troubleshooting, clutch operation
Drivetrain:
Primary drive, belt drive, final drive, output shaft, drive sprocket maintenance and repair
Brakes:
Front and rear brake systems: hydraulic components, calipers, rotors, brake fluid specifications, bleeding procedures, service
Suspension:
Front fork (e.g., Showa) disassembly, seal replacement, oil specifications, rear shock absorbers, air suspension systems (if applicable)
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, horn, instrumentation
Chassis Frame:
Frame inspection, steering head bearing service, swingarm maintenance, wheel bearings
Bodywork:
Fairing removal and installation, fuel tank, seat, fenders, saddlebags, mounting hardware
Diagnostics Troubleshooting:
Problem identification, symptom analysis, diagnostic charts, common failure modes
Preventive Maintenance:
Regular service intervals, lubrication points, fluid changes, filter replacements, belt tensioning
Major Repairs:
Complete engine rebuilds, transmission overhaul, fork rebuilds, brake caliper servicing
Component Replacement:
Detailed steps for replacing common wear items like brake pads, clutch plates, spark plugs, tires, and batteries
Adjustments:
Carburetor tuning, ignition timing, clutch and brake lever adjustments, cable adjustments
Troubleshooting Guides:
Systematic approaches to diagnose and fix mechanical and electrical issues
Electrical Diagnostics:
Fuse checking, voltage testing, continuity testing, interpreting wiring diagrams
Depth Level:
Professional Level (Covers all aspects from basic maintenance to complete engine and transmission rebuilds)
Diagnostic Capabilities:
Advanced diagnostic procedures and troubleshooting trees for complex issues
Rebuild Instructions:
Detailed, step-by-step instructions for disassembling, inspecting, repairing, and reassembling all major components
Diagrams Illustrations:
Abundant, clear, step-by-step diagrams and exploded views for visual guidance
Engine Type:
Harley-Davidson Evolution (Evo) Big Twin
Engine Displacement:
Commonly 80 cubic inches (1340cc), with potential for earlier 74 cubic inch (1200cc) models within the range depending on specific FLHT variant
Engine Configuration:
Air-cooled, 45-degree V-twin
Bore X Stroke:
Approximately 3.500 in. x 4.250 in. for 80ci
Horsepower Estimate:
Varies by year and specific tune, typically 65-75 HP (crankshaft)
Torque Estimate:
Varies by year and specific tune, typically 75-85 ft-lbs (crankshaft)
Fuel Delivery:
Keihin CV 40mm Carburetor (standard on most models) or Electronic Fuel Injection (EFI) on later models within the range
Fuel Type:
Unleaded gasoline, minimum octane rating of 87 (check specific year requirements)
Ignition Type:
Electronic Ignition (Points ignition on very early models, but typically replaced by electronic)
Oil Type:
Harley-Davidson Genuine V-Twin Motor Oil or equivalent API SG or higher, SAE 20W50 recommended for most conditions
Oil Capacity:
Approximately 3 US quarts (2.8 liters) with filter change
Cooling Method:
Air-cooled
Initial Service:
Typically around 1,000 miles (1600 km) for first service (oil change, primary check, adjustments)
Regular Oil Change:
Every 2,500 - 5,000 miles (4,000 - 8,000 km) or annually, depending on usage and oil type (refer to manual for exact recommendations)
Belt Tension Check:
Recommended at every service interval
Brake Fluid Change:
Recommended every 1-2 years or as per manual specifications due to moisture absorption
Engine Oil Grade:
SAE 20W50 recommended for most operating temperatures
Transmission Oil Grade:
SAE 80W-90 GL-5 gear oil
Primary Chaincase Oil Grade:
Harley-Davidson Genuine Transmission and Primary Chaincase Lubricant or equivalent
Brake Fluid Type:
DOT 4 recommended (check specific year for exact type)
Evo Engine Considerations:
Cam chain tensioner wear (especially on earlier models), oil leaks, valve seat wear (on some earlier Evo heads)
Transmission Wear:
Potential wear on shift forks and dog teeth, bearing wear
Electrical Gremlins:
Wiring harness issues, regulator/rectifier failures, starter solenoid problems can occur with age
Suspension Wear:
Fork seal leaks, worn rear shock bushings
Brand Foundation:
Harley-Davidson is an iconic American motorcycle manufacturer founded in 1903
Brand Philosophy:
Known for its distinctive V-twin engines, cruiser styling, and strong rider community
Touring Lineage:
The FLHT Touring series represents a long lineage of comfortable, long-distance motorcycles designed for two-up riding and luggage capacity
Evolution Engine Introduction:
The Evolution engine was introduced in 1984, replacing the Shovelhead and Panhead engines, and became the backbone of Harley-Davidson for many years
Flht Development:
The FLHT (Electra Glide Standard) was a key model in the Touring lineup, offering a balance of features and performance for riders focused on the journey
Production Era:
1984-1998 covers a significant period of the Evolution engine's life and the refinement of Harley-Davidson's touring platform
Manufacturing Location:
Primarily manufactured in Milwaukee, Wisconsin, USA
