Target Audience:
Harley-Davidson owners, independent repair shops, motorcycle enthusiasts
Value Proposition:
Provides complete and authoritative guidance for maintaining and repairing Harley-Davidson Softail models from 1991-1992.
Original Manuals:
Compares favorably to OEM service manuals in terms of scope and detail.
Comprehensiveness:
Covers all repairs A-Z, mechanical and electrical.
Visuals:
Numerous detailed pictures and diagrams enhance understanding.
Practicality:
Printable format allows for focused use on specific tasks.
Engine Mechanical:
Engine assembly, disassembly, tuning, cooling, lubrication, internal components (pistons, cylinders, crankshaft, camshafts, valves), timing
Engine Management:
Ignition system, carburetion (including specific carburetor models like Keihin CV), fuel delivery
Transmission Drivetrain:
Clutch, primary drive, transmission gears, final drive (belt drive system), lubrication
Electrical System:
Wiring diagrams, lighting (headlight, taillight, signals), starting system, charging system (alternator, regulator), ignition system, battery, fuses, switches
Suspension Steering:
Front forks (including Showa or Marzocchi variants), rear shock absorbers, swingarm, steering head bearings, wheel bearings
Brakes:
Front and rear brake systems (calipers, master cylinders, brake lines, rotors), brake fluid specifications, bleeding procedures
Wheels Tires:
Wheel types, tire sizes, inflation pressures, spoke tension (if applicable to specific models)
Bodywork Frame:
Frame integrity, body panels, fenders, fuel tank, seat, handlebars, controls
Instruments Controls:
Speedometer, tachometer, indicator lights, hand controls, foot controls
Routine Maintenance:
Oil changes, filter replacements, chain adjustment (if applicable), spark plug checks, brake checks
Troubleshooting:
Diagnosis of common problems, diagnostic flowcharts, electrical troubleshooting guides
Component Rebuilds:
Complete disassembly and reassembly of engine, transmission, forks, brake systems
Adjustments:
Carburetor tuning, ignition timing, clutch adjustment, cable adjustments
Electrical Diagnostics:
Fault finding in ignition, charging, lighting, and starting circuits
Depth:
Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts
Detail Level:
Detailed step-by-step instructions with torque specifications, clearances, and assembly sequences
Visual Aid Quality:
Tons of detailed pictures and diagrams
Engine Family:
Evolution (Evo) V-Twin
Engine Displacement Options:
Typically 80 cubic inches (1340cc) for this era, with potential variations depending on specific Softail model (e.g., Heritage Softail, Fat Boy, Sport Glide).
Engine Configuration:
45-degree V-twin, air-cooled
Bore X Stroke:
Approximately 3.500 in. x 4.250 in. (88.9 mm x 108.0 mm) for 80ci models.
Compression Ratio:
Typically around 8.5:1 to 9.0:1, depending on specific model and tuning.
Horsepower Estimate:
Around 65-70 HP (actual figures vary significantly with tuning and model specifics).
Torque Estimate:
Around 70-80 ft-lbs (actual figures vary significantly with tuning and model specifics).
Fuel Delivery:
Carburetor (most commonly Keihin CV 40mm or similar).
Ignition System:
Electronic Ignition (points system phased out by this era).
Oil Change Interval:
Typically every 2,500 - 5,000 miles or annually, whichever comes first (consult specific manual for exact intervals).
Primary Chain Tension:
Periodic checks and adjustment recommended, often every 5,000 miles.
Spark Plug Replacement:
Typically every 10,000 - 15,000 miles.
Engine Oil:
Recommended: Harley-Davidson 20W50 or equivalent (check manual for specific viscosity and API service classification).
Primary Chain Case Oil:
Harley-Davidson Primary Chain Lubricant or equivalent.
Transmission Oil:
Harley-Davidson Transmission Lubricant or equivalent (often a heavier viscosity than engine oil).
Brake Fluid:
DOT 4 recommended (check manual for specific fluid type).
Carburetor Issues:
Potential for wear in the slide diaphragm of CV carburetors, leading to poor idle or acceleration.
Crankcase Seals:
Age-related degradation of crankcase seals can lead to oil leaks.
Rear Brake Pads:
Rear brake pads can wear at a faster rate due to the weight and torque of the motorcycle.
Electrical Connections:
Corrosion or loose connections in electrical connectors can cause intermittent faults.
