Market Segment:
Full-size touring motorcycle for long-distance riding, offering comfort and luggage capacity.
Target Audience:
Harley-Davidson owners, independent repair shops, and motorcycle enthusiasts who perform their own maintenance and repairs.
Competitors:
Honda Gold Wing, Indian Roadmaster, BMW K1600 GTL, Yamaha Star Venture.
Touring Capabilities:
Large fairing for wind protection, integrated saddlebags and tour pack for cargo, comfortable seating position, powerful V-twin engine for cruising.
Manual Utility:
Provides essential information for maintaining and repairing one of Harley-Davidson's iconic touring models across a significant production era.
Model Years Covered:
1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991
Engine Variants Covered:
All FLTC Tour Glide models with the Shovelhead and Evolution V-Twin engines as applicable across these years.
Region Of Origin Focus:
North America (US Market focus, with general applicability to other regions)
Estimated Page Count:
~600-800 pages (typical for comprehensive service manuals of this era)
Manual Type:
Workshop Service and Repair Manual
Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of Shovelhead and Evolution V-Twin engines, including top-end (cylinders, pistons, heads, valves) and bottom-end (crankshaft, connecting rods, camshafts, bearings).
Fuel System:
Carburetor service (Keihin CV, Super E/G, etc.), fuel injection systems (if applicable to later models), fuel pumps, fuel lines, and tanks.
Ignition System:
Points and condenser, electronic ignition systems, ignition coils, spark plugs, timing procedures.
Transmission And Drivetrain:
4-speed and 5-speed transmission overhaul, clutch service and adjustment, primary drive, final drive (belt drive systems), drive belts, sprockets.
Electrical System:
Wiring diagrams for all years covered, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, horn, instrumentation, battery maintenance.
Suspension:
Front fork service (fork seals, oil changes, damping adjustments), rear shock absorber maintenance and replacement, swingarm service.
Brakes:
Front and rear brake caliper service, master cylinders, brake fluid flush and bleeding, pad replacement, rotor inspection.
Frame And Bodywork:
Chassis inspection, frame components, fairing removal and installation, body panel service, luggage systems (saddlebags, tour pack).
Wheels And Tires:
Wheel bearing maintenance, tire inspection and replacement, wheel balancing.
Cooling System:
Air-cooled engine thermal management, oil cooler service (if equipped).
Routine Maintenance:
Oil and filter changes, air cleaner service, spark plug replacement, chain/belt adjustment, lubrication points, brake adjustments.
Troubleshooting:
Systematic diagnostic procedures for common starting, running, electrical, and braking issues, with fault code identification (if applicable).
Component Overhaul:
Detailed step-by-step instructions for rebuilding major components like engines, transmissions, and carburetors.
Electrical Diagnostics:
Testing of electrical components, wiring continuity checks, voltage and resistance measurements.
Specifications And Torques:
Essential torque specifications for fasteners, clearances, and other critical measurements.
Depth Of Coverage:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Suitable for professional mechanics and advanced DIY enthusiasts.
Diagnostic Capabilities:
Detailed troubleshooting guides, diagnostic flowcharts, and symptom-based problem resolution.
Diagrams And Illustrations:
Includes detailed exploded views, wiring diagrams, and procedural illustrations to clarify complex steps.
Engine Type:
Air-cooled, 45-degree V-twin
Displacement Early:
1337cc (81.5 cubic inches) - Shovelhead
Displacement Later:
1337cc (81.5 cubic inches) / 1450cc (88 cubic inches) - Evolution (convertible or introduced later in the range)
Bore X Stroke Shovelhead:
3.4375 in x 4.25 in (87.31 mm x 107.95 mm)
Bore X Stroke Evolution 81.5:
3.4375 in x 4.25 in (87.31 mm x 107.95 mm)
Bore X Stroke Evolution 88:
3.5625 in x 4.375 in (90.48 mm x 111.13 mm)
Compression Ratio Shovelhead:
Approx. 7.5:1 to 8.0:1
Compression Ratio Evolution:
Approx. 8.5:1 to 9.0:1
Horsepower Approx:
65-75 HP (varies by engine and tuning)
Torque Approx:
75-85 lb-ft (varies by engine and tuning)
Carburetor Common:
Keihin CV 40mm, S&S Super E/G
Fuel Requirement:
Unleaded gasoline, 87-91 octane (minimum)
Initial Service:
Typically at 1,000 miles (1600 km)
Routine Oil Change:
Every 2,500-5,000 miles (4000-8000 km) or annually, depending on usage and oil type.
Primary Chain Tensioner Check:
Every 5,000 miles (8000 km) or as needed.
Belt Drive Tension Check:
Every 5,000 miles (8000 km) or as needed.
Engine Oil Type:
Harley-Davidson 20W50 (or equivalent API SG or higher)
Engine Oil Capacity:
Approx. 3 quarts (2.8 liters)
Transmission Oil Type:
Harley-Davidson Gear Oil (or equivalent SAE 75W90 synthetic) - check manual for specific grades.
Transmission Oil Capacity:
Approx. 1 quart (0.95 liters)
Primary Chain Case Oil Type:
Harley-Davidson Primary Chaincase Lubricant (or equivalent SAE 30 or 20W50 motorcycle oil)
Primary Chain Case Oil Capacity:
Approx. 1 quart (0.95 liters)
Brake Fluid Type:
DOT 4 (for most models of this era, always verify)
Shovelhead Engine Quirks:
Potential for oil leaks, valve seat wear, and ignition timing sensitivity.
Evolution Engine Quirks:
Cam chain tensioner wear (later models), potential for oil leaks, early evolution engines can be sensitive to overheating.
Electrical Gremlins:
Common across many vintage bikes, particularly related to aging wiring insulation, connectors, and charging system components.
Suspension Wear:
Fork seals and rear shock absorber deterioration over time leading to leaks and reduced damping.
Carburetor Tuning:
CV carburetors can require periodic adjustment and rebuild due to diaphragm wear or jet clogging.
Brand Legacy:
Harley-Davidson, founded in 1903, is an American motorcycle manufacturer with a rich history of producing iconic V-twin motorcycles, particularly known for its touring and cruiser models.
Tour Glide Introduction:
The Tour Glide model line evolved from earlier Harley-Davidson touring platforms, offering a full fairing and integrated luggage for long-distance comfort and practicality.
Engine Transition:
This period saw the transition from the venerable Shovelhead engine (used in earlier FL models) to the then-new Evolution V-twin engine, which offered improved reliability and performance.
Manufacturing Location:
United States (York, Pennsylvania assembly plant primarily)
Key Production Years Covered:
1984-1991
