Positioning:
Essential documentation for owners and independent repair shops working on the iconic Harley-Davidson 1340cc Softail platform during a significant era of its development.
Competitors:
Other third-party repair manuals, but this is an 'Official Full Workshop' manual, indicating a high level of accuracy and manufacturer-backed information.
Value Proposition:
Empowers DIY mechanics with the detailed knowledge required to maintain, troubleshoot, and repair their Softail models, saving significant costs compared to dealership service.
Content Type:
Covers a broad range of model years and includes specific updates for later models, offering comprehensive support.
Engine:
Cylinder heads, cylinders, pistons, crankshaft, connecting rods, camshafts, valve train, lubrication system, cooling (oil cooling) system, ignition system, fuel delivery system (carburetor/early EFI)
Transmission:
Gearbox (5-speed, Cruise Drive), clutch, primary drive, secondary drive (belt/chain)
Chassis:
Frame, suspension (front forks, rear shocks), steering, wheels, tires, brakes (front and rear)
Electrical:
Battery, charging system (stator, regulator/rectifier), starting system (starter motor), lighting, instrumentation, wiring diagrams, ignition switch, turn signals
Fuel System:
Carburetor (e.g., Keihin CV), fuel tank, fuel lines, fuel filter, and early Electronic Fuel Injection (EFI) systems for later models
Bodywork And Trim:
Fenders, fuel tank, seat, handlebars, controls, exhaust system, side covers, and related hardware
Maintenance:
Routine inspections, lubrication, filter changes, spark plug replacement, chain/belt adjustment, brake pad replacement, tire pressure checks
Troubleshooting:
Diagnostic charts for common performance issues, starting problems, electrical faults, and drivability concerns
Repair:
Detailed step-by-step instructions for component disassembly, repair, and reassembly (e.g., engine rebuilds, transmission overhauls, fork seal replacement, brake caliper service)
Adjustment:
Carburetor tuning, clutch adjustment, primary chain tension, belt tension, ignition timing (where applicable)
Specifications And Tolerances:
Torque values, clearances, measurements for all major components
Depth:
Comprehensive. Covers everything from basic servicing to full engine and transmission rebuilds, including detailed electrical system diagnostics.
Engine Code:
Evolution (often referred to as 'Evo' or 'Big Twin Evolution')
Bore Stroke:
Typically 3.500" x 4.250" (90 mm x 108 mm) for 1340cc models
Compression Ratio:
Varies by year and model, often around 8.5:1 to 9.0:1
Valvetrain:
Overhead Valves (OHV), 2 valves per cylinder, operated by pushrods and lifters
Horsepower Range:
Approximately 60-70 HP (at the crankshaft, figures vary by year and tuning)
Torque Range:
Approximately 75-85 ft-lbs (at the crankshaft, figures vary by year and tuning)
Carburetor Common:
Keihin CV (Constant Velocity) 40mm is prevalent for most of this period.
Efi Introduction:
EFI systems began to appear on some models in the mid-to-late 1990s, covered by the supplement.
Type:
Electronic Ignition (points were phased out early in this era for many models)
Type:
Dry Sump (oil tank separate from crankcase)
Oil Capacity Quarts:
Typically 3.5 - 4.0 quarts (check specific model year for exact)
Oil Filter Part Number Example:
Harley-Davidson P/N 63731-36 (often used across many models of this era, but variations exist).
Type:
5-speed Constant Mesh
Gear Ratios Example:
Varies by year, but typical 1st gear ratio might be around 9.33:1, with top gear close to 1:1 (check manual for exact ratios).
Type:
N/A (5-speed was standard for Softail models in this range)
Primary Drive:
Enclosed primary chain drive (wet clutch)
Secondary Drive:
Belt Drive (most common for Softail) or Chain Drive (less common for Softail, more on Dyna/Touring)
Type:
Primary chaincase lubricant (e.g., Harley-Davidson Primary Chaincase Lubricant, Spectro HD Primary Fluid, or equivalent SAE 20W-50 motorcycle oil for primary chaincase).
Wheelbase Inches:
Typically around 63.5 - 64.5 inches (varies by specific Softail model and year)
Seat Height Inches Unladen:
Generally low, around 25-27 inches
Dry Weight Lbs:
Approximately 550-600 lbs (varies by model and equipment)
Gross Vehicle Weight Rating Lbs:
Typically around 1000 lbs (check specific model for exact GVWR)
Capacity:
Around 4.0 - 5.0 gallons (varies by specific Softail model)
Crash Test Ratings:
N/A (Motorcycle safety is not rated by organizations like NHTSA or Euro NCAP in the same way as cars).
Brakes:
Hydraulic disc brakes (single disc front, often single disc rear, though some later models may have dual front discs). ABS was not standard or commonly available on most models in this era.
Lighting:
Headlight, taillight, brake light, turn signals.
Frame Construction:
Steel tube frame providing structural integrity.
Features:
Minimal by modern standards. Typically includes analog gauges (speedometer, tachometer, oil pressure, voltage meter), odometer, trip meter. Some models may have optional radio or CB interfaces, but not integrated infotainment systems.
Features:
None (No modern driver-assistance systems like ABS, traction control, or cruise control were standard on most models in this era, though some later models might have offered cruise control as an option).
Features:
N/A. No Bluetooth, smartphone integration, or networked systems.
Oil Change Miles:
Typically every 2,500 - 5,000 miles or annually, whichever comes first (check manual for exact intervals).
Primary Chain Tension Check Miles:
Every 1,000 - 2,500 miles.
Spark Plug Replacement Miles:
Typically every 10,000 - 15,000 miles.
Belt Tension Check Miles:
Every 1,000 - 2,500 miles, especially after initial break-in.
Engine Oil Type:
Harley-Davidson SYN3, Mobil 1 V-Twin 20W-50, Spectro 20W-50, or equivalent SAE 20W-50 motorcycle specific oil. Always check manual for specific grade and Harley-Davidson recommendations.
Transmission Fluid Type:
See Transmission section: Primary Chaincase Lubricant.
Brake Fluid Type:
DOT 4 (for hydraulic disc brakes, check manual for specific Harley-Davidson approved types).
Common Problems:
Cam chain tensioner wear (especially older hydraulic style), oil leaks (gaskets, seals), potential for stator failure, carburetor tuning quirks, electrical connector corrosion, rear shock absorber wear over time.
Carburetor Notes:
Keihin CV carburetor requires careful adjustment for optimal performance, especially with aftermarket exhausts or air cleaners.
Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer with a rich history of producing V-twin powered motorcycles known for their distinctive sound, styling, and customization potential.
Softail Lineage:
The Softail platform, introduced in 1984, was revolutionary for its hidden rear suspension, designed to mimic the rigid look of earlier hardtail choppers while providing a more comfortable ride. It quickly became a flagship model.
Evolution Engine:
The 1340cc Evolution engine, introduced in 1984, replaced the Shovelhead and Panhead engines, offering improved reliability, performance, and a more modern design, becoming the heart of Harley-Davidson for over a decade.
Manufacturing Location:
United States (primarily Milwaukee, Wisconsin and York, Pennsylvania)
Key Milestones 1984-1999:
Introduction of the Evolution engine and Softail chassis, increasing displacement to 1450cc (in later years, not covered by this specific manual), introduction of fuel injection on some models.
