Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson enthusiasts, owners seeking to perform maintenance and repairs, customizers.
Competitors Era:
V-Twin cruisers from Indian, custom choppers from smaller manufacturers, Japanese cruisers (e.g., Honda Shadow, Yamaha Virago/V-Star).
Distinctive Feature:
Telescopic Springer front fork, delivering a classic aesthetic and unique ride feel.
Model Platform:
Softail frame, designed to mimic the look of a hardtail rear suspension with hidden shock absorbers.
Powertrain:
Engine assembly, disassembly, inspection, lubrication, cooling system, fuel system (carburetor), ignition system, exhaust system, starter system, charging system.
Drivetrain:
Clutch operation and adjustment, transmission (5-speed, Cruise Drive - specific designation for this period), primary drive, final drive belt, drive sprocket, rear pulley.
Chassis:
Frame construction, steering head bearing service, front fork (Springer fork) overhaul, rear suspension (shocks, swingarm, pivot), wheel bearings, wheel alignment.
Electrical:
Wiring diagrams (detailed schematics), battery service, charging system, ignition system components (coil, spark plugs), lighting system (headlight, taillight, turn signals), instrument cluster, starter motor, accessory wiring.
Brakes:
Front and rear brake system components (calipers, master cylinders, brake lines, rotors), hydraulic system bleeding, brake pad replacement, parking brake (if applicable).
Fuel System:
Carburetor (likely Keihin CV) identification, disassembly, cleaning, adjustment (idle, mixture), fuel tank, fuel lines, fuel filter.
Bodywork And Trim:
Fenders, fuel tank removal/installation, seat, handlebars, rider controls, footpegs, saddlebags (if equipped), chrome trim, paint care.
Routine Maintenance:
Oil change intervals and specifications, primary chaincase oil, transmission oil, brake fluid changes, air filter cleaning/replacement, spark plug inspection/replacement, drive belt tensioning.
Troubleshooting:
Diagnostic procedures for common starting issues, running problems, electrical faults, brake performance issues, and drivetrain noises.
Repair And Rebuild:
Complete engine overhaul (piston, rings, valves), transmission rebuild, carburetor rebuild, brake caliper overhaul, fork seal replacement, bearing replacement.
Inspection And Adjustment:
Valve clearance adjustment, clutch cable adjustment, throttle cable adjustment, belt tension adjustment, brake lever free play adjustment.
Diagnostic Capabilities:
Detailed diagnostic flowcharts, symptom-based troubleshooting guides, electrical testing procedures (resistance, voltage, continuity).
Component Specification:
Torque specifications for all fasteners, tolerances for wear parts, component measurements and limits.
Diagrams And Illustrations:
Exploded views of components, detailed wiring diagrams, service illustrations for key procedures.
Engine Type:
Air-cooled, 45-degree V-twin, Evolution engine
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.50 in x 4.47 in (88.9 mm x 113.5 mm)
Compression Ratio:
8.8:1 (typical for this engine)
Valve Train:
OHV, 2 valves per cylinder, pushrod actuated
Horsepower Rating:
Approximately 60-65 HP (estimated, as Harley-Davidson did not always publish official HP figures for this era)
Torque Rating:
Approximately 75-85 ft-lbs @ 3200 RPM (estimated)
Fuel Delivery:
Carbureted (Keihin CV 40mm) - Electronic Fuel Injection (EFI) was becoming more common, but FXSTSI typically featured carburetors in this period.
Fuel Type:
Unleaded gasoline, 91 octane (87 AKI) or higher recommended.
Initial Service:
1,000 miles (1600 km) or 1 month, whichever comes first.
Subsequent Services:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first.
Specific Checks:
Spark plug check every 10,000 miles (16,000 km), valve adjustment every 10,000 miles (16,000 km).
Engine Oil:
Harley-Davidson Genuine V-Twin 20W-50 (or equivalent API SG or higher specification oil).
Engine Oil Capacity:
Approximately 3.0 US quarts (2.8 Liters) with filter change.
Primary Chaincase Oil:
Harley-Davidson Genuine Primary Chaincase Lubricant, SAE 80W-90 (or equivalent API GL-4 specification).
Primary Chaincase Capacity:
Approximately 26 US fluid ounces (770 ml).
Transmission Oil:
Harley-Davidson Genuine Transmission Lubricant, SAE 85W-140 (or equivalent API GL-5 specification).
Transmission Oil Capacity:
Approximately 22 US fluid ounces (650 ml).
Brake Fluid:
DOT 4 Synthetic Brake Fluid.
Cam Chain Tensioner:
Early Evolution engines (pre-2007) had plastic cam chain tensioner shoes that could wear out prematurely, potentially leading to chain slap. Later models (2007+) used hydraulic tensioners. This manual should detail inspection and replacement.
Carburetor Performance:
Keihin CV carburetors can require periodic adjustment or cleaning for optimal performance, especially if the motorcycle is not stored properly or maintained regularly.
Oil Leaks:
Common across many Harley-Davidsons of this era, often from primary or transmission seals. The manual will provide procedures for diagnosis and sealing.
Springer Fork Service:
The Springer fork's specialized nature requires attention to lubrication and component wear, particularly the springs and pivot points. The manual is crucial for proper service.
Founding:
1903, Milwaukee, Wisconsin, USA
Signature Style:
Long-standing reputation for V-twin engines, classic styling, and rider individuality.
Softail Introduction:
The Softail platform was introduced in 1984, revolutionizing the look of Harley-Davidsons with hidden rear suspension.
Springer Fork History:
The Springer fork design dates back to early motorcycle engineering and was revived by Harley-Davidson for its iconic styling.
Production Years Fxstsi:
Introduced around 1997/1998, with the manual covering up to the 2005 model year.
Manufacturing Location:
York, Pennsylvania, USA and Milwaukee, Wisconsin, USA (varied by component and year).
