Product Name:
Harley Davidson FX-FL Softail Evolution Motorcycle Complete Workshop Service Repair Manual
Engine Family:
Evolution (Big Twin)
Chassis Designation:
FXST (Softail Standard), FLST (Softail Heritage), FXSTC (Softail Custom), FXSTB (Softail Blackline), FLSTF (Fat Boy), FLSTN (Heritage Softail Nostalgia), FLSTS (Heritage Springer), FXRS (Sport Glide - sometimes considered a Softail variant)
Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson Softail Evolution owners seeking to perform maintenance, repairs, and diagnostics themselves to save costs and maintain their motorcycles.
Competitors:
Factory service manuals, other aftermarket repair manuals (e.g., Clymer, Haynes - though often less detailed for Harley-Davidsons).
Value Proposition:
Enables DIY repairs, significant cost savings, comprehensive coverage, easy-to-follow instructions with illustrations.
Accessibility:
Instant digital delivery via email, printable pages, and multi-device compatibility.
Years Covered:
1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Models Covered:
All FX-FL Softail Evolution models, including Standard, Custom, Heritage, Fat Boy, Nostalgia, Springer, and Sport Glide variants.
Estimated Pages:
Varies by specific edition, typically 700-900+ pages.
Type:
Complete Workshop Service Repair Manual
Format:
Downloadable Digital Format (PDF)
Powertrain:
Engine (Evolution V-Twin), Transmission (5-speed constant mesh), Drivetrain (Primary drive, belt drive, final drive).
Chassis:
Frame, suspension (forks, rear shock absorbers), steering, wheels, tires, brakes (front and rear).
Electrical:
Ignition system, starting system, charging system, lighting, instruments, wiring diagrams.
Fuel System:
Carburetor systems (Keihin CV, Mikuni HSR), fuel tank, fuel lines, fuel pump (if applicable).
Exhaust System:
Exhaust pipes, mufflers, heat shields.
Bodywork And Trim:
Fenders, fuel tank, seat, handlebars, controls, fairings (if applicable).
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication, brake inspections, tire pressure checks.
Engine Rebuild:
Top-end rebuild (cylinders, pistons, heads), bottom-end rebuild (crankshaft, connecting rods, bearings), valve adjustment, timing procedures.
Transmission And Drivetrain:
Clutch service, transmission gear replacement, primary drive maintenance, belt replacement.
Brake System Service:
Brake pad replacement, caliper service, brake fluid flush and bleeding, master cylinder service.
Electrical System Troubleshooting:
Diagnosis of ignition, charging, lighting, and starter issues using wiring diagrams.
Carburetor Tuning And Overhaul:
Jetting adjustments, idle speed settings, diaphragm replacement, cleaning and reassembly.
Suspension Service:
Fork seal replacement, fork oil changes, rear shock absorber inspection and replacement.
Diagnostic Procedures:
Troubleshooting common issues, diagnostic flowcharts, reading fault codes (if applicable for later models in the range).
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, electrical diagnostics, and chassis component overhauls.
Engine Type:
Air-cooled, 45-degree V-twin, Evolution (Big Twin) engine.
Displacement:
Typically 80 cubic inches (1340cc) for most models in this range. Later models within the range may also feature 88 cubic inches (1442cc) variants introduced in the late 1990s.
Horsepower:
Approximately 60-70 HP (estimated, varies by model year and tuning).
Torque:
Approximately 75-85 ft-lbs (estimated, varies by model year and tuning).
Carburetor Common:
Keihin CV (Constant Velocity) carburetor, primarily 40mm. Some models or aftermarket upgrades may utilize Mikuni HSR or S&S carburetors.
Fuel Delivery:
Gravity feed from fuel tank to carburetor, or electric fuel pump for models with a sealed fuel tank.
Ignition Type:
Electronic Ignition System (e.g., Harley-Davidson Electronic Ignition, Dyna-S).
Oil System:
Dry-sump lubrication system with oil tank typically mounted separately.
Wheelbase:
Typically around 60-63 inches (1524-1600mm), depending on model and specific configuration.
Seat Height:
Typically around 27-28 inches (686-711mm), depending on model and suspension setup.
Dry Weight:
Generally in the range of 550-650 lbs (250-295 kg), depending on model and accessories.
Gross Vehicle Weight Rating:
Typically around 900-1000 lbs (408-454 kg).
Safety Standards:
Designed to meet applicable motorcycle safety standards of the era. No formal crash test ratings like cars.
Braking System:
Dual disc front brakes, single disc rear brake. Hydraulic actuation.
Suspension Features:
Telescopic front forks, adjustable rear shock absorbers for ride height and damping.
Lighting:
Halogen headlamp, taillight, brake light, turn signals.
Oil Change Interval:
Typically every 2,500-5,000 miles or annually, whichever comes first. Refer to specific year/model within the manual for precise recommendations.
Primary Chain Tension:
Check and adjust as needed, typically every 5,000-10,000 miles, or per manual's guidance.
Spark Plugs:
Inspect and replace as needed, typically every 10,000-15,000 miles.
Belt Drive Inspection:
Inspect belt for wear and tension at regular intervals, adjust as needed.
Engine Oil:
Viscosity typically 20W50 or 20W-50 motorcycle-specific oil. Refer to manual for Harley-Davidson or equivalent specifications (e.g., Syn3). API CI-4 or higher recommended for engines pre-2007.
Primary Chain Case Oil:
Typically Harley-Davidson primary lubricant or a compatible motorcycle primary fluid. Avoid common ATF or motor oil.
Transmission Oil:
Typically Harley-Davidson transmission lubricant or a suitable heavy-duty gear oil (e.g., 80W-90 GL-5). Consult manual for specific recommendations.
Brake Fluid:
DOT 4 brake fluid for most models in this range.
Evolution Engine:
Potential for oil leaks from seals and gaskets, especially with age. Cam chain tensioner wear (on earlier models with hydraulic tensioners).
Carburetor:
Keihin CV carburetor can be sensitive to altitude and temperature changes; requires proper tuning. Diaphragm wear can cause poor performance.
Electrical:
Wiring harness chafing, regulator/rectifier failures, starter solenoid issues can occur.
Suspension:
Fork seal leaks are common with mileage. Rear shock absorber seals can also fail.
Marque:
Harley-Davidson, a storied American motorcycle manufacturer with a legacy dating back to 1903.
Softail Introduction:
The Softail chassis, introduced in 1984, revolutionized Harley-Davidson's styling by hiding the rear suspension components to mimic the look of a rigid hardtail frame while providing modern suspension comfort.
Evolution Engine Introduction:
The Evolution engine, first introduced in Sportsters in 1986 and Big Twins in 1984, was a significant redesign offering improved reliability and performance over the previous Shovelhead and Ironhead engines.
Manufacturing Location:
United States (primarily Milwaukee, Wisconsin and York, Pennsylvania).
Production Span:
The Evolution engine for Big Twins was produced throughout the period covered by this manual (1984-1999) and beyond, with the Softail platform continuing to evolve.
