Vehicle Segment:
Full-size Touring Motorcycle
Target Audience:
Long-distance touring riders, Harley-Davidson enthusiasts, independent mechanics
Key Competitors Era:
Honda Gold Wing, Kawasaki Voyager, Yamaha Royal Star (though Tour Glide predates some of these in direct form factor)
Touring Amenities:
Large fairing with wind protection, integrated saddlebags, comfortable seating for two, often equipped with radio and cruise control.
Engine Type:
Harley-Davidson Evolution Big-Twin (popular and reliable for the era)
Manual Value Proposition:
Essential resource for maintaining and repairing the iconic FLTC Tour Glide, enabling cost savings and maximizing lifespan.
Model Years Covered:
1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991
Engine Variants Covered:
Evo Big-Twin 1340cc (80ci)
Estimated Page Count:
Approximately 500-700 pages (typical for comprehensive service manuals of this era)
Manual Type:
Service Repair Workshop Manual
Powertrain:
Engine, Transmission, Final Drive
Chassis Suspension:
Frame, Front Fork, Rear Suspension, Wheels, Tires
Brakes:
Front and Rear Brake Systems (Hydraulic, Discs)
Electrical System:
Ignition, Charging System (Alternator, Regulator), Starting System, Lighting, Gauges, Wiring Diagrams
Fuel System:
Carburetion (Keihin CV), Fuel Tank, Fuel Lines, Fuel Pump (if applicable)
Exhaust System:
Exhaust Headers, Mufflers, Heat Shields
Bodywork Fittings:
Fairing, Saddlebags, Seat, Handlebars, Controls, Body Panels
Routine Maintenance:
Oil Changes, Filter Replacements, Spark Plug Service, Chain/Belt Adjustment (if applicable), Lubrication Points
Engine Repair:
Top-End Rebuild (Cylinder Head, Piston), Bottom-End Rebuild (Crankshaft, Connecting Rods), Valve Adjustment, Camshaft Replacement
Transmission Overhaul:
Gearbox Disassembly and Reassembly, Clutch Service, Primary Drive Maintenance
Electrical Diagnostics:
Troubleshooting Wiring Faults, Component Testing (Ignition Coil, Stator, Regulator), Battery Testing
Suspension Service:
Fork Seal Replacement, Shock Absorber Service, Bushing Replacement
Brake System Maintenance:
Brake Pad Replacement, Fluid Bleeding, Caliper Overhaul
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon issues
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds)
Diagnostic Capability:
Includes detailed diagnostic procedures, specifications for component testing (e.g., resistance, voltage, amperage)
Rebuild Procedures:
Detailed step-by-step instructions for overhauling major components
Engine Family:
Harley-Davidson Evolution (Evo) Big-Twin
Displacement:
1340 cc (80 cubic inches)
Configuration:
V-twin, 45-degree cylinder angle
Cooling System:
Air-cooled
Bore X Stroke:
3.500 in x 4.250 in (88.9 mm x 108.0 mm)
Compression Ratio:
Approx. 8.0:1 to 8.6:1 (varies slightly by year/model)
Valve Train:
Overhead Valve (OHV), 2 valves per cylinder, pushrod actuated
Horsepower Estimated:
Approx. 60-68 HP @ 5000 RPM (approximate, varies by tuning and year)
Torque Estimated:
Approx. 75-85 lb-ft @ 3200 RPM (approximate, varies by tuning and year)
Carburetor:
Keihin CV (Constant Velocity) 40mm
Fuel Type:
Unleaded gasoline, minimum 87 octane (91 AKI)
Oil Capacity With Filter:
Approx. 4 U.S. quarts (3.8 liters)
Oil Type Specification:
Harley-Davidson Genuine Motor Oil SAE 20W50 or equivalent API SG, SF, or SE rated oil.
Wheelbase:
Approx. 63.5 inches (1613 mm)
Length:
Approx. 94.0 inches (2388 mm)
Height:
Approx. 53.0 inches (1346 mm) to top of fairing
Dry Weight Estimated:
Approx. 680-700 lbs (308-318 kg)
Fuel Capacity:
Approx. 5.0 U.S. gallons (18.9 liters)
Saddlebag Capacity Estimated:
Significant, designed for touring luggage
Safety Certification:
Manufactured to meet DOT and relevant safety standards for motorcycles of the era.
Braking System:
Dual front disc brakes, single rear disc brake (hydraulic actuation)
Lighting:
Halogen headlight, taillight, brake light, turn signals
Fairing Windscreen:
Provides rider protection from wind and debris
Audio System:
Many Tour Glides were equipped with AM/FM radio, often with CB radio and intercom capabilities. Cassette tape players were also common.
Cruise Control:
Optional on many models, providing comfort for long-distance riding.
Original Era Connectivity:
Primarily analog controls and basic electrical systems. No digital connectivity in the modern sense.
Oil Change Interval:
Typically every 2,500 - 5,000 miles or 6 months, whichever comes first (refer to manual for exact spec).
Primary Chain Tensioner Inspection:
Regular inspection and replacement as needed, critical for transmission longevity.
Spark Plug Replacement:
Generally every 5,000 - 10,000 miles.
Drive Belt Inspection And Tensioning:
Regular checks for wear and correct tension are vital.
Engine Oil Grade:
SAE 20W50
Transmission Oil Grade:
SAE 80W-90 Gear Oil
Brake Fluid Type:
DOT 4 (refer to manual for specific recommendations)
Primary Drive Tensioner Wear:
Early hydraulic tensioners could wear prematurely, leading to noise and potential chain damage if not addressed.
Carburetor Tuning:
Keihin CV carburetors can require occasional adjustments for optimal performance and emissions.
Electrical Connector Corrosion:
Due to age and exposure, electrical connectors can corrode, leading to intermittent issues.
Wheel Bearing Maintenance:
Regular inspection and lubrication of wheel bearings is necessary for safety and longevity.
Brand Foundation:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer known for its V-twin engines and cruiser motorcycles.
Touring Lineage:
The FLTC Tour Glide is a descendant of Harley-Davidson's long history of large displacement, comfortable touring motorcycles. It evolved from earlier FL models, incorporating aerodynamic fairings and luggage systems.
Key Technological Shift:
The introduction of the Evolution engine in 1984 marked a significant advancement in reliability and performance over the Shovelhead engine.
Production Years:
1984-1991 (This specific manual covers this range)
Manufacturing Location:
United States (York, Pennsylvania and Milwaukee, Wisconsin facilities)
