Target Audience:
DIY mechanics, independent repair shops, and Harley-Davidson enthusiasts seeking to maintain and repair their Softail models.
Diy Empowerment:
Designed to empower owners with the knowledge and confidence to tackle a wide range of service tasks, reducing reliance on expensive dealership labor.
Value Proposition:
Offers a cost-effective alternative to dealership service labor, empowering owners to perform their own maintenance and repairs with expert guidance.
Manual Usability:
Features a clickable menu, keyword search functionality, bookmarks for easy navigation, and zoom capabilities for detailed illustration viewing.
Visual Aids:
Includes detailed diagrams, illustrations, photographs, and exploded views to clarify repair procedures and component identification.
Step By Step Instructions:
Provides clear, sequential, step-by-step instructions for all maintenance and repair tasks.
Systems:
General Information, Periodic Maintenance, Fuel System, Cooling System, Engine Top End, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Crankcase, Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System
Engine Systems:
Engine Top End (Cylinder heads, valves, camshafts), Engine Lubrication System (Oil pump, oil filter, oil passages), Crankshaft/Crankcase (Crankshaft assembly, connecting rods, bearings, crankcase components).
Drivetrain Systems:
Transmission (Internal components, shifting mechanism, primary chain, clutch), Wheels/Tires (Wheel bearings, spokes, tire mounting and balancing), Final Drive (Belt drive system, pulleys).
Chassis Systems:
Brakes (Hydraulic system, calipers, rotors, master cylinders, brake lines), Suspension (Front forks, rear shock absorbers, linkages), Steering (Headstock, steering bearings, handlebars), Frame (Frame inspection, component mounting).
Electrical Systems:
Ignition system, lighting system (headlight, taillight, signals), charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), battery, wiring diagrams, switches, and gauges.
Fuel And Air Systems:
Fuel tanks, fuel lines, fuel filters, carburetors, air filters, and associated linkages and controls.
Cooling And Exhaust Systems:
Engine cooling fins, oil cooler (if equipped), exhaust pipes, mufflers, and mounting hardware.
Body And Frame:
Fenders, fuel tank, seat mounting, handlebars, controls, and frame inspection.
Lubrication And Cooling:
Detailed coverage of the oil pump, oil lines, oil filter housing, and any oil coolers, as well as engine cylinder cooling fins.
Procedures:
Repair, Diagnostics, Troubleshooting, Maintenance, Component Overhaul, System Inspection, Adjustments, Replacement
Diagnostic Procedures:
Troubleshooting charts for common electrical and mechanical issues, fault finding for engine performance problems, and diagnostic steps for specific component failures.
Tune Up Procedures:
Comprehensive guidance on ignition timing, carburetor adjustment, and valve adjustments for optimal engine performance.
Tire And Wheel Service:
Procedures for tire replacement, wheel balancing, wheel bearing maintenance, and spoke tensioning.
Component Replacement:
Step-by-step guides for replacing common wear items and parts like brake pads, clutch plates, cables, and filters.
Depth:
Comprehensive (covering all repair topics from basic maintenance to detailed component rebuilds and diagnostics)
Component Rebuilds:
Detailed instructions for overhaul and rebuilding of major components such as the engine, transmission, and brake systems.
Wiring Diagrams:
Includes detailed, often color-coded, wiring diagrams essential for diagnosing and repairing electrical faults.
Torque Specifications:
Extensive torque specifications for all fasteners throughout the motorcycle, critical for safe and proper assembly.
Illustrations And Diagrams:
Richly illustrated with technical drawings, schematics, and photographic sequences for clarity.
File Format Details:
PDF (Portable Document Format)
Compatibility:
Compatible with all versions of Windows and Mac operating systems.
Reader Requirement:
Requires Adobe PDF Reader or a compatible PDF viewer.
Printability:
Fully printable, allowing for single page, chapter, or full manual printing for workshop use.
Digital Features:
Clickable table of contents and index, keyword searchable text for quick information retrieval.
Suggested Binding:
3-ring binder recommended by users for easy page replacement when soiled.
Ideal Paper Type For Printing:
Durable, matte finish paper suitable for workshop environments.
Engine Family:
Evolution (Evo) V-Twin
Engine Design:
Air-cooled, 45-degree V-twin cylinder configuration.
Engine Cooling:
Air-cooled, with oil being circulated for lubrication and additional cooling. Oil cooler present on some higher-spec models.
Typical Displacement:
80 cubic inches (1339cc) for most models within this range, with some earlier models potentially having 74 cubic inches (1200cc) or later evolution to 88 cubic inches (1450cc) in the later years not fully covered here.
Torque Output:
Typically in the range of 70-85 ft-lbs (95-115 Nm) depending on specific engine size and tuning, with the manual providing detailed specifications.
Typical Fueling:
Carbureted (e.g., Keihin CV Carburetor) for most of the covered years, with early models and some specific trims potentially featuring early fuel injection systems towards the end of the covered period (1995-1999).
Carburetor Details:
Details on adjustment, cleaning, and overhaul of common carburetors like the Keihin CV and Mikuni HSR.
Routine Maintenance Intervals:
Typical oil change intervals around 2,500-5,000 miles (4,000-8,000 km) or annually, with other checks and services at 5,000, 10,000, and 20,000-mile intervals, all detailed within the manual.
Brake Fluid Service:
Recommended periodic replacement of brake fluid (DOT 4) typically every two years, as detailed in the manual.
Engine Oil Type:
Harley-Davidson recommends specific viscosity grades (e.g., 20W50) and proprietary oil formulations for their Evolution engines, with specific capacities detailed for each model variant.
Transmission Fluid:
Harley-Davidson requires specific transmission lubricant, typically a heavy-duty gear oil with appropriate API ratings. Manual specifies exact type and capacity.
Primary Drive Fluid:
Primary chaincase lubricant, often a specific Harley-Davidson primary fluid or equivalent, with capacities detailed in the manual.
Common Wear Items:
Primary chain tensioner wear, cam bearing wear (early Evo engines), carburetor tuning, battery maintenance, brake pad replacement, and suspension bushing wear are common maintenance points.
Electrical Common Faults:
Voltage regulator/rectifier failure, starter solenoid issues, and intermittent switch failures are sometimes noted.
Engine Performance Issues:
Carburetor jetting for altitude or modifications, idle speed control, and ignition module function are common areas for tuning.
Brand Significance:
Harley-Davidson's Softail line represents a significant evolution in their cruiser design, blending classic styling with modern engineering and a distinctive rear suspension system that mimics a hardtail appearance.
Softail Legacy:
The Softail line established Harley-Davidson's dominance in the cruiser market for decades, with this era representing a pivotal period of development and popularization.
Softail Development:
Introduced in 1984, the Softail platform revolutionized Harley-Davidson's cruiser offerings with its hidden rear shock absorbers, providing a smoother ride while maintaining the iconic rigid frame look. The covered period (1984-1999) encompasses significant updates to the Evolution engine, chassis refinements, and the introduction of popular variants like the Fat Boy and Springer.
Engine Updates:
The Evolution engine, introduced in 1984, was a major technological advancement for Harley-Davidson, offering improved reliability and performance over previous Shovelhead engines. The manual covers its evolution through the 1980s and 1990s.
Styling Evolution:
The Softail line became a canvas for iconic Harley-Davidson styling, from the classic FXST to the distinctive Fat Boy and the retro Springer models, all covered by this manual's scope.
Specific Model Introductions:
The range covers the initial FXST introduction, the customization of the FXSTC, the classic styling of the Heritage FLST and FLSTC, the unique Springer front end of the FXSTS, and the iconic Fat Boy FLSTF.
Manufacturing Location:
United States (primarily York, Pennsylvania and Milwaukee, Wisconsin).
