Market Segment:
Cruiser Motorcycles (Luxury/Performance)
Target Audience:
Harley-Davidson Softail owners, independent repair shops, enthusiasts seeking detailed technical information.
Competitors:
Other cruiser manufacturers (Indian, custom builders), other Harley-Davidson models.
Motorcycle Platform:
Softail platform characterized by its rigid look and hidden rear suspension.
Engine Type:
Air-cooled V-twin Evolution engine.
Manual Value Proposition:
Empowers owners and technicians with the knowledge to perform maintenance, diagnostics, and repairs, saving time and money compared to dealership service.
Engine System:
Complete overhaul, top-end and bottom-end repairs, ignition system, fuel system (carburetor and early EFI), lubrication, cooling (air-cooled), timing, emissions.
Transmission System:
5-speed gearbox disassembly, inspection, repair, clutch system, primary drive, final drive.
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), starting system, lighting, instrumentation, ignition system components, fault diagnosis.
Chassis System:
Frame, swingarm, front fork (telescopic, possibly with air assist), rear shock absorbers, steering system, wheel bearings, suspension tuning.
Braking System:
Front and rear brake caliper service, master cylinders, brake lines, bleeding procedures, rotor inspection.
Fuel System:
Carburetor models (e.g., Keihin CV) overhaul and tuning, fuel injection system (EFI) basic diagnostics and component identification, fuel tank, fuel lines, fuel pump.
Bodywork And Trim:
Fender removal and installation, fuel tank mounting, seat removal, fairings (if applicable to specific Softail models), chrome and cosmetic component service.
Maintenance Procedures:
Oil changes, filter replacement, spark plug service, belt tension adjustment (primary and final drive), brake fluid flush, air filter cleaning/replacement, battery maintenance, tire pressure checks.
Troubleshooting Procedures:
Step-by-step diagnostic flowcharts for common running issues, electrical faults, starting problems, and performance degradation.
Repair Procedures:
Engine rebuilds, transmission overhauls, suspension component replacement, electrical component diagnostics and replacement, brake system repairs.
Diagnostic Procedures:
Use of diagnostic tools (e.g., for EFI models), interpreting fault codes, circuit testing, component testing.
Depth:
Comprehensive from basic user maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and repair.
Engine Type:
Air-cooled, 45-degree V-twin, Evolution Big Twin
Displacement:
88 cubic inches (1442 cc)
Bore X Stroke:
3.50 in x 4.47 in (88.9 mm x 113.5 mm)
Compression Ratio:
8.8:1 (typical)
Horsepower:
Approx. 65-70 HP (varies slightly by model/tuning)
Torque:
Approx. 80-85 ft-lbs @ 3000-3500 RPM (varies slightly)
Fuel Delivery Carburetor:
Keihin CV (Constant Velocity) 40mm
Fuel Delivery Efi:
Electronic Fuel Injection (EFI) - available on select models/years
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended
Oil Type:
Harley-Davidson SYN3 (Synthetic) SAE 20W-50 or equivalent motorcycle-specific oil
Oil Capacity:
Approx. 4 quarts (3.8 liters) with filter change
Type:
5-speed constant mesh, helical gear
Primary Drive:
Enclosed, wet, multi-plate clutch, chain drive
Clutch Type:
Hydraulic actuation
Transmission Oil Type:
Harley-Davidson Formula + or equivalent transmission lubricant
Transmission Oil Capacity:
Approx. 26 US fl oz (770 ml)
Wheelbase:
Approx. 64.5 inches (1638 mm) (varies slightly by model, e.g., Fat Boy vs. Heritage)
Overall Length:
Approx. 92.0 inches (2337 mm)
Seat Height:
Approx. 26.5 inches (673 mm) (unladen)
Dry Weight:
Approx. 600-650 lbs (272-295 kg) (varies by model)
Gross Vehicle Weight Rating Gvwr:
Approx. 950-1000 lbs (431-453 kg)
Fuel Capacity:
Approx. 4.0-5.0 gallons (15.1-18.9 L) (varies by model)
NHTSA Rating:
N/A (Motorcycle safety ratings are not typically standardized by NHTSA in the same way as passenger cars).
Braking System:
Dual disc front, single disc rear with hydraulic actuation and dual-piston calipers.
Lighting:
Headlight, taillight, brake light, turn signals, indicator lamps.
Frame Construction:
Steel tube frame providing structural integrity.
Audio System:
Optional accessory audio systems (radio, speakers) available, not standard on all models.
Instrumentation:
Analog speedometer, tachometer (optional/model dependent), fuel gauge, voltage meter, indicator lights for turn signals, oil pressure, high beam, neutral.
ABS:
Anti-lock Braking System (ABS) was an optional feature on some models during this period.
Diagnostic Ports:
Diagnostic connectors for EFI models (e.g., for connection to Harley-Davidson's Digital Technician).
Initial Service:
Check and adjust at 1,000 miles (1600 km)
Regular Maintenance:
Every 5,000 miles (8,000 km) or annually, whichever comes first (includes oil change, inspection).
Major Service:
Includes spark plugs, transmission oil, primary chaincase oil, brake fluid flush at specified intervals (e.g., 10,000-15,000 miles).
Engine Oil:
Harley-Davidson SYN3 SAE 20W-50 or equivalent motorcycle-specific 20W-50
Transmission Oil:
Harley-Davidson Formula + or equivalent motorcycle transmission lubricant
Primary Chaincase Oil:
Harley-Davidson Formula + or equivalent motorcycle transmission lubricant (same as transmission)
Cam Chain Tensioner:
Early models (pre-2007) used plastic cam chain tensioners that could wear and fail, potentially causing engine damage. This manual would detail inspection and replacement with updated hydraulic tensioners.
Carburetor Tuning:
Keihin CV carburetors may require periodic adjustment for optimal performance, especially after modifications or altitude changes.
Rear Shock Seals:
Rear shock absorber seals can degrade over time, leading to fluid leakage and reduced damping performance.
Starter Solenoid:
Starter solenoids can sometimes fail, preventing the engine from cranking.
Maintenance Schedules Coverage
Detailed Schedules:
Provides clear, mileage-based and time-based maintenance schedules for all major components.
Manufacturer Origin:
United States
Brand Reputation:
Iconic American motorcycle manufacturer renowned for its cruiser styling, V-twin engines, and distinctive sound.
Softail Concept:
Introduced in 1983, the Softail line features a concealed rear shock absorber system, giving the appearance of a hardtail (rigid frame) motorcycle while providing a more comfortable ride.
2000-2005 Era:
This period represents a significant evolution of the Softail platform, with refinement of the Evolution engine, introduction of EFI on some models, and updates to braking and chassis components.
Manufacturing Plant:
York, Pennsylvania and Kansas City, Missouri (USA)
