Target Audience:
Harley-Davidson Softail owners (FLST, FXST models) seeking to perform their own maintenance, repairs, and diagnostics.
Value Proposition:
Provides factory-level repair information, saving considerable costs compared to dealership service. Essential for proper upkeep and longevity of these iconic motorcycles.
Completeness:
Complete factory documentation ensures all repair and maintenance procedures are covered accurately.
Accessibility:
Instant PDF download provides immediate access to critical repair information.
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly procedures for Harley-Davidson Twin Cam 88 engine variants.
Fuel System:
Carburetor (CV carb) overhaul, fuel pump, fuel tank, fuel lines, and fuel filter servicing.
Ignition System:
Ignition module, coil, spark plugs, spark plug wires, and timing adjustments.
Transmission Clutch:
Five-speed gearbox service, clutch assembly inspection and adjustment, primary drive chain maintenance.
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instrumentation, and accessory circuits.
Chassis Frame:
Frame inspection, steering head bearing service, fork disassembly and assembly, swingarm, and rear shock absorber replacement.
Brakes:
Front and rear brake caliper service, master cylinder overhaul, brake line replacement, brake pad replacement, and brake fluid bleeding.
Wheels Tires:
Wheel bearing inspection and replacement, tire mounting and balancing, spoke adjustment (if applicable).
Exhaust System:
Exhaust pipe and muffler inspection, mounting, and replacement.
Bodywork Fenders:
Fender removal and installation, fuel tank mounting, seat removal and installation, and other body panel servicing.
Scheduled Maintenance:
Detailed schedules for routine maintenance tasks, including oil changes, filter replacements, and lubrication points.
Troubleshooting:
Diagnostic charts and procedures for identifying and resolving common mechanical and electrical problems.
Engine Rebuild:
Step-by-step instructions for complete engine disassembly, component inspection, measurement, and reassembly, including torque specifications.
Transmission Repair:
Procedures for transmission disassembly, gear inspection, bearing replacement, and reassembly.
Electrical Diagnostics:
Guidance on using multimeters and test equipment to diagnose electrical faults, with detailed wiring diagrams.
Brake System Maintenance:
Detailed instructions for brake bleeding, caliper rebuild, and master cylinder replacement.
Suspension Adjustment:
Procedures for fork oil changes, fork seal replacement, and rear shock absorber adjustments or replacement.
Depth Level:
Comprehensive Factory Level - suitable for dealership technicians and experienced DIY mechanics.
Diagnostic Capability:
Advanced diagnostic procedures and troubleshooting flowcharts for identifying complex issues.
Component Rebuild:
Detailed rebuild procedures for major components like the engine, transmission, and brake system.
Engine Family:
Harley-Davidson Twin Cam 88
Engine Type:
Air-cooled, 45-degree V-twin, overhead valve
Displacement:
1449 cc (88 cubic inches)
Bore X Stroke:
3.75 in x 4.00 in (95.25 mm x 101.6 mm)
Horsepower:
Approx. 65-70 HP (est. at crank, varies by tuning)
Torque:
Approx. 80-85 ft-lbs @ 3500 RPM (est. at crank, varies by tuning)
Fuel Delivery:
Keihin 40mm CV (Constant Velocity) carburetor
Fuel Type:
Unleaded gasoline, minimum 87 octane
Engine Oil Change:
Every 2,500 miles or annually, whichever comes first.
Transmission Primary Chaincase Lube:
Every 5,000 miles or annually.
Final Drive Belt Tension:
Check every 2,500 miles.
Spark Plug Replacement:
Every 10,000 miles.
Engine Oil Type:
Harley-Davidson SYN3 Synthetic Motorcycle Oil (or equivalent SAE 20W50)
Engine Oil Capacity:
3.5 US quarts (3.3 Liters) with filter change.
Brake Fluid Type:
DOT 4 (for models equipped with ABS, if applicable; otherwise check manual for specific requirements for non-ABS models, typically DOT 4 is standard).
Common Wear Items:
Cam chain tensioners (early Twin Cam 88 models may require upgrade), exhaust system gaskets, wheel bearings, and clutch wear.
Electrical Quirks:
Intermittent electrical connections, especially in older wiring harnesses; stator and regulator/rectifier failures are not uncommon with age.
Brand Origin:
Founded in Milwaukee, Wisconsin, USA in 1903, Harley-Davidson is an iconic American motorcycle manufacturer known for its cruiser and touring motorcycles.
Softail Lineage:
The Softail platform, introduced in 1983, is characterized by its concealed rear suspension, mimicking the appearance of a rigid 'hardtail' frame while providing modern suspension comfort.
Twin Cam Introduction:
The Twin Cam 88 engine, introduced in 1999, was a significant upgrade from the Evolution engine, offering increased displacement and improved performance.
Manufacturing Location:
York, Pennsylvania and Milwaukee, Wisconsin, USA
