Positioning:
The Harley-Davidson Softail series in this era represented a blend of classic styling with modern (for its time) technology, aiming for riders who appreciated traditional cruiser aesthetics but also required reliable performance for touring and everyday riding. It was positioned as a premium cruiser.
Competitors:
Competed with other large-displacement V-twin cruisers from manufacturers like Indian, and to some extent, Japanese brands offering larger displacement models in their cruiser lineups (e.g., some Yamaha V-Star models, Kawasaki Vulcan 1500).
Design Philosophy:
The Softail's signature feature is its hidden rear shock absorbers, mimicking the appearance of a hardtail frame while providing modern suspension comfort. This period also saw the widespread adoption of the Harley-Davidson Evolution engine.
Applicable Years:
1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Estimated Page Count:
~800-1200 pages (typical for comprehensive factory service manuals of this era, exact count varies)
Type:
Factory Service Manual / Workshop Manual / Repair Manual
Engine:
Evolution (Big Twin) Engine - 80 cu. in. (1340cc), including top-end, bottom-end, lubrication, cooling (air-cooled), fuel and ignition systems, carburetors (Keihin CV, etc.), and exhaust.
Transmission:
5-Speed Cruise Drive Transmission (Trapezoidal Case design), including clutch, gearbox, primary drive, and final drive.
Electrical System:
Full electrical diagnostics, wiring diagrams, battery, charging system (alternator, regulator), ignition system (electronic, ignition module), lighting (headlamp, tail lamp, turn signals), instrumentation, starting system, and accessory circuits.
Chassis And Suspension:
Frame, front fork (telescopic, often with air assist), rear suspension (shock absorbers, swingarm), steering head bearings, wheels, tires, and brakes (front and rear disc).
Bodywork And Trim:
Fuel tank, fenders, seat assembly, side covers, handlebars, controls, and related mounting hardware.
Maintenance Procedures:
Scheduled maintenance tasks, oil changes, filter replacements, chain adjustment (if applicable to specific models within Softail), brake pad replacement, spark plug service, air filter cleaning/replacement, and lubrication points.
Repair Procedures:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major vehicle systems.
Troubleshooting:
Diagnostic charts and procedures for identifying and resolving common mechanical and electrical problems, including symptoms, causes, and corrective actions.
Depth:
Comprehensive. Covers everything from basic fluid checks and adjustments to complete engine rebuilds, transmission overhauls, and electrical system diagnostics and component replacement. Includes torque specifications, clearances, and detailed schematics.
Engine Type:
Harley-Davidson Evolution V-Twin (also known as 'Evo' Big Twin)
Displacement:
80 cubic inches (1339 cc)
Bore X Stroke:
3.50 in. x 4.25 in. (88.9 mm x 108 mm) - typical for 80 cu in Evo
Compression Ratio:
Typically 8.5:1 or 9.0:1 depending on year and specific model variant
Horsepower Estimate:
Approx. 65-70 HP (at crankshaft, dependent on specific tuning and model year)
Torque Estimate:
Approx. 75-85 ft-lbs (at crankshaft, dependent on specific tuning and model year)
Carburetor:
Typically Keihin CV (Constant Velocity) 40mm carburetor. Some earlier models or aftermarket conversions might use different carburetors.
Fuel Type:
Unleaded gasoline, minimum 87 octane (AKI). Higher octane may be recommended for some performance tuning or specific conditions.
Transmission Type:
5-Speed Manual Constant Mesh
Transmission Case Design:
Trapezoidal case design (distinct from earlier FLH transmissions).
Optional Transmission:
None factory offered within the Softail range in this period, but aftermarket 6-speed conversions exist.
Clutch Type:
Wet, multi-plate, diaphragm spring clutch.
Primary Drive:
Enclosed primary chain drive system, typically 1.5-inch wide chain.
Final Drive:
Belt drive system (usually 1-inch wide belt).
Wheelbase:
Approx. 63.5 inches (1613 mm), varies slightly by model year and variant (e.g., FXST vs. FLST)
Length:
Approx. 90 inches (2286 mm), varies
Width:
Approx. 35 inches (889 mm) at handlebars, varies
Dry Weight:
Approx. 580-630 lbs (263-286 kg), varies significantly by model (e.g., FLSTC vs. FXST)
Gross Vehicle Weight Rating Gvwr:
Typically around 900-950 lbs (408-431 kg)
Front Tire Size:
Typically 100/90-19 or 3.50-19
Rear Tire Size:
Typically 130/90-16 or 150/80-16
Wheel Bolt Pattern:
Not applicable; Harley-Davidson wheels use a hub-mounted bearing system with axle mounting.
Crash Test Ratings:
Motorcycles are not typically subjected to standardized crash testing like automobiles. Safety is primarily addressed through design and rider control.
Braking System:
Dual disc front brakes, single disc rear brake. Typically with 4-piston calipers (though specific caliper types may vary slightly).
Lighting:
Halogen headlamp, integrated taillight/stoplight, front and rear turn signals. Some models (e.g., FLSTC) featured headlight nacelles and passing lamps.
Audio System:
Optional on some models, typically basic AM/FM radio with single CD player or cassette on later models within the range. Often integrated into fairings or dashboard areas.
Instrumentation:
Analog speedometer and tachometer, odometer, trip meter, fuel gauge, and indicator lights. Often housed in a dashboard console or on the handlebar.
ABS:
Anti-lock Braking System (ABS) was generally not standard or widely available on Softail models in this specific 1984-1999 timeframe, though it began appearing on some Harley-Davidson models later in the period or as an option.
Bluetooth Or Usb:
Not available on factory models within this 1984-1999 production run. Modern aftermarket solutions exist.
Oil Change Interval:
Typically every 2,500-5,000 miles or annually, whichever comes first. Check manual for specific year and oil type.
Primary Chain Tensioner:
Inspect regularly; early models (pre-2000) had known issues with hydraulic tensioner wear. Replacement with improved aftermarket or updated OEM tensioners is common.
Spark Plug Replacement:
Typically every 10,000-15,000 miles.
Belt Drive Inspection:
Check belt tension and condition regularly (e.g., every 5,000 miles). Adjust tension as per manual specifications. Replace belt when wear indicators appear or damage is present (typical lifespan 30k-50k miles).
Engine Oil Type:
Harley-Davidson recommended SAE 20W50 motorcycle oil (e.g., Harley-Davidson Syn3 or similar viscosity for air-cooled V-twins). Check manual for specific year and temperature range recommendations.
Primary Chain Case Fluid:
Harley-Davidson primary lubricant or SAE 20W50 motorcycle oil.
Transmission Fluid:
Harley-Davidson transmission lubricant or SAE 80W-90 gear oil (API GL-5 rated recommended).
Fork Oil Type:
Specific weight fork oil recommended by Harley-Davidson (e.g., 15W or 20W), check manual for capacity and weight per model.
Brake Fluid Type:
DOT 4 brake fluid (for most models in this range, confirm with manual).
Primary Chain Tensioner Wear:
Hydraulic chain tensioner in the primary drive can wear out, leading to noise and potential damage. Upgraded or manual tensioners are common fixes.
Carburetor Tuning:
Keihin CV carburetor can sometimes require fine-tuning for optimal performance, especially after modifications or at different altitudes. Idle speed adjustment and jetting are common tasks.
Oil Leaks:
Common on older V-twins, often from primary or transmission seals, rocker boxes, or pushrod tubes. Regular inspection and gasket replacement are necessary.
Electrical Connections:
Corrosion or loose connections in the wiring harness can lead to intermittent electrical issues. Thorough inspection of grounds and connectors is vital.
Brand Legacy:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines, distinctive styling, and strong rider community. The brand represents a lifestyle and a heritage of American manufacturing.
Softail Introduction:
The Softail platform was introduced in 1984, designed by Bill Davis and later refined by Harley-Davidson. Its key innovation was the concealed rear suspension, providing the look of a rigid frame with improved ride comfort.
Engine Transition:
The 1984-1999 period is synonymous with the widespread adoption and evolution of the Harley-Davidson Evolution (Evo) engine, replacing the Shovelhead and Panhead designs. The 80 cubic inch (1340cc) displacement became the standard for Big Twins during much of this time.
Variations Within Range:
The Softail line included various models such as the FXST (Standard), FLST (Heritage), FXSTS (Springer Softail - featuring a girder front fork), and FLSTS (Heritage Springer). Variations in styling, features (like fairings, saddlebags, and chrome), and sometimes engine tuning were common.
Manufacturing Location:
Primarily manufactured in Milwaukee, Wisconsin, USA.
Production Span:
The Softail platform has continuously evolved and been produced since its introduction in 1984 through to the present day, with significant technological updates over the decades.
