Engine:
Evolution V-Twin (1340cc), disassembly, assembly, inspection, diagnostics, tuning.
Fuel System:
Carburetor (CV 40mm), fuel pump, fuel tank, fuel lines, troubleshooting.
Ignition System:
Electronic ignition, ignition module, coil, spark plugs, wiring, troubleshooting.
Transmission:
5-speed manual gearbox, clutch, primary drive, final drive belt, disassembly, inspection, repair, fluid changes.
Brakes:
Front and rear disc brakes, hydraulic system, caliper service, pad replacement, fluid specifications, troubleshooting.
Suspension:
Front Springer fork (springer front end), rear swingarm, shock absorbers, fork oil specification and change, adjustment, troubleshooting.
Electrical System:
Wiring diagrams, lighting, starter system, charging system (alternator, regulator), battery, fuses, circuit breakers, horn, troubleshooting.
Chassis And Frame:
Frame inspection, headstock bearings, steering system, troubleshooting.
Wheels And Tires:
Wheel bearing inspection and replacement, tire pressure specifications, wheel balancing, spoke tension.
Bodywork And Fittings:
Fender removal and installation, fuel tank mounting, seat assembly, handlebars, controls, basic cosmetic repairs.
Diagnostic Procedures:
Troubleshooting guides for common issues, symptom-based diagnostics, electrical system checks.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication, brake bleeding, tire checks, battery maintenance.
Repair:
Engine overhauls, transmission repairs, brake system repairs, suspension adjustments, electrical component replacement.
Disassembly And Assembly:
Detailed step-by-step instructions for component removal and reinstallation.
Troubleshooting:
Systematic approaches to identifying and resolving faults.
Specifications And Tolerances:
Torque values, clearances, fluid capacities, critical measurements.
Level Of Detail:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers from basic maintenance to complex engine and drivetrain overhauls.
Engine Type:
Air-cooled, four-stroke, 45-degree V-twin OHV (Evolution Engine)
Displacement:
1339 cc (81.8 cubic inches)
Bore X Stroke:
3.496 in x 4.252 in (88.8 mm x 108 mm)
Compression Ratio:
9.0:1 (typical for this era)
Valve Train:
OHV, 2 valves per cylinder, pushrod actuated
Horsepower:
~60-65 HP (estimated, varies by tuning)
Torque:
~70-75 ft-lbs (estimated, varies by tuning)
Carburetor:
Keihin CV 40mm (Constant Velocity)
Fuel Type:
Unleaded gasoline, 91-92 octane minimum recommended
Oil Capacity:
Approximately 3 quarts (2.8 Liters) with filter change.
Oil Type:
API SG or higher, SAE 20W50 motorcycle specific oil recommended.
Engine Oil Change:
Every 2,500-3,000 miles or annually.
Primary Chain Tensioner Check:
Check and adjust at every 5,000 miles, or if chain noise is present.
Spark Plug Replacement:
Approximately every 10,000 miles.
Transmission Oil Change:
Every 10,000 miles or annually.
Belt Tension Check:
Every 5,000 miles.
Front Fork Oil:
Harley-Davidson Suspension Fluid or equivalent SAE 15W fork oil (check manual for exact type and quantity per fork leg).
Brake Fluid:
DOT 4 or DOT 5 (check manual for specific system requirement, though DOT 4 is common for this era).
Primary Chain Tensioner:
The original spring-loaded tensioner can wear out, leading to chain slap. Upgrade to an hydraulic tensioner is a common modification.
Cam Chain Tensioners:
Later Evolution engines (post-2000) addressed this more proactively, but early models can also exhibit wear. The manual will detail inspection and replacement.
Carburetor Issues:
CV carburetors can require tuning adjustments for altitude or modifications; idle instability or poor acceleration can be indicators.
Electrical Connectors:
Corrosion or loose connections in wiring harnesses, especially on older bikes, can cause intermittent electrical faults.
Manufacturer:
Harley-Davidson Motor Company, Milwaukee, Wisconsin, USA.
Softail Platform:
The Softail line, introduced in 1984, features a hidden rear suspension to mimic the look of a rigid frame.
Springer Front End:
The Springer front end is a retro styling element, inspired by earlier Harley-Davidson models, featuring a distinctive leading-link suspension system.
Production Period:
The FXSTS Springer Softail was produced from 1988 to 2007.
