Target Audience:
Harley-Davidson owners, independent repair shops, technicians
Value Proposition:
Provides OEM-level diagnostic and repair information for maintaining and restoring the 1999 Softail models.
Competitor Manuals:
Haynes, Clymer (often less detailed than factory manuals)
Completeness:
Official, factory-issued content ensuring accuracy and detail.
Detail Level:
Hundreds of pages offering in-depth coverage.
Engine Mechanics:
Detailed engine overhaul, assembly, disassembly, tuning, performance adjustments
Fuel System:
Carburetor (CV carburetor) service and adjustment, fuel tank, fuel lines, fuel pump (if applicable)
Ignition System:
Ignition timing, module service, spark plugs, wiring
Transmission Drivetrain:
5-speed transmission service, clutch operation and adjustment, primary drive, final drive belt maintenance
Electrical System:
Wiring diagrams, charging system (stator, regulator/rectifier), lighting, starter, battery maintenance
Suspension Steering:
Front fork service and overhaul, rear shock absorber replacement, steering head bearing adjustment
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake fluid bleeding, pad replacement
Wheel Tire Hub:
Wheel bearing inspection and replacement, tire changing procedures, spoke tensioning (spoked wheels)
Frame Chassis:
Frame inspection, component mounting, jiffy stand service
Bodywork Fenders:
Fender removal/installation, fuel tank mounting, seat removal/installation, fairing (if applicable)
Diagnostics Troubleshooting:
Step-by-step troubleshooting guides for common and complex issues
Routine Maintenance:
Oil changes, filter replacements, spark plug inspection/replacement, air cleaner service, chain/belt adjustment, lubrication points
Engine Rebuild:
Complete engine disassembly, inspection, measurement, component replacement, and reassembly
Transmission Service:
Clutch adjustment, primary chain tensioning, transmission oil change, seal replacement
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams, testing components
Brake System Repair:
Brake pad replacement, caliper rebuild, master cylinder service, bleeding procedure
Suspension Overhaul:
Fork seal replacement, oil level adjustments, shock absorber installation
Carburetor Tuning:
Idle speed adjustment, mixture screw settings, jetting recommendations
Component Installation:
Detailed instructions for replacing major components and accessories
Diagnostic Capabilities:
Advanced diagnostics with specific fault codes and troubleshooting trees
Rebuild Procedures:
Comprehensive procedures for complete engine and transmission rebuilds
Specifications Tolerances:
Precise torque specifications, clearances, and dimensional tolerances for all components
Wiring Diagrams:
Detailed, color-coded electrical schematics for accurate diagnosis and repair
Special Tools:
Identification and usage instructions for specialized Harley-Davidson tools required for specific tasks
Engine Family:
Evolution (Evo)
Engine Type:
Air-cooled, pushrod V-twin
Displacement Cc:
1340cc (82 cubic inches)
Bore X Stroke:
3.496 in x 4.25 in (88.8 mm x 108 mm)
Compression Ratio:
8.8:1 (typical for Evolution Big Twin)
Horsepower Est:
Approx. 65-70 HP (at crankshaft, varies by model and tuning)
Torque Ft Lbs Est:
Approx. 78-85 ft-lbs (at crankshaft, varies by model and tuning)
Carburetor Type:
Keihin CV (Constant Velocity) 40mm
Fuel Requirement:
87-91 Octane Unleaded Gasoline
Oil Change Interval:
Every 2,500-5,000 miles or annually (consult manual for exact recommendations based on usage).
Primary Chain Tension Check:
Inspect every 2,500 miles
Spark Plug Replacement Interval:
Every 10,000-20,000 miles (depending on plug type)
Belt Tension Check:
Check every 5,000 miles
Engine Oil Type:
Harley-Davidson 20W50 SYN3 or equivalent motorcycle-specific oil
Engine Oil Capacity Quarts:
Approx. 4 quarts (including filter)
Primary Chain Case Oil Type:
Harley-Davidson primary chain case lubricant or suitable heavy-duty motorcycle transmission oil
Primary Chain Case Oil Capacity Quarts:
Approx. 1 quart (26-28 oz)
Transmission Oil Type:
Harley-Davidson Formula+ Transmission Lubricant or suitable heavy-duty motorcycle transmission oil
Transmission Oil Capacity Quarts:
Approx. 20-24 oz
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Cam Chain Tensioner Wear:
Known wear issue on later Evo engines, potentially leading to noise or internal damage. Manual covers inspection and replacement procedures.
Crankcase Breather System:
Can require cleaning/maintenance to prevent oil blow-by. Manual details system operation and cleaning.
Rear Wheel Alignment:
Importance of proper rear wheel alignment and belt tension for tire wear and handling. Manual covers alignment checks.
Brand Origin:
Milwaukee, Wisconsin, USA - Founded 1903
Brand Identity:
Iconic American motorcycle manufacturer known for V-twin engines and cruiser styling.
Softail Introduction:
The Softail platform was introduced in 1983, featuring a hidden rear suspension designed to mimic the look of a hardtail frame.
1999 Updates:
The 1999 models generally represent a refined version of the Evo Softail platform, with minor updates for emissions and componentry over prior years.
Engine Production Years:
Evolution engine produced from 1984 to 1999 (air-cooled versions).
Softail Production Years:
1983-Present (continuous evolution of the platform)
