Segment:
Full-size touring motorcycle.
Target Audience:
Long-distance riders, touring enthusiasts, Harley-Davidson owners seeking detailed maintenance and repair information.
Competitors:
Honda Gold Wing, Indian Chief, Kawasaki Vulcan, Yamaha Royal Star.
Model Identity:
Iconic American touring motorcycle, known for comfort, V-twin rumble, and long-distance capability.
Benefit To Owner:
Empowers owners to perform routine maintenance, diagnose issues, and carry out repairs, saving time and money.
Engine:
Complete engine overhaul, tuning, carburetor service (Keihin CV), ignition system, cooling, lubrication.
Transmission:
Gearbox disassembly, assembly, inspection, clutch service, drive belt inspection and adjustment.
Electrical:
Wiring diagrams, lighting systems, charging system (stator, regulator/rectifier), starting system, battery, ignition switch, instrument panel.
Brakes:
Front and rear brake system service, caliper overhaul, brake line replacement, master cylinder service, bleeding procedures.
Suspension:
Front fork service (telescopic), fork oil change, rear shock absorber inspection and replacement.
Chassis And Body:
Frame inspection, fairing removal/installation, fuel tank service, seat service, fender service, handlebars, controls.
Wheels And Tires:
Wheel bearing inspection and replacement, tire inspection and replacement, spoke tensioning (if applicable).
Diagnostics And Troubleshooting:
Fault finding procedures for common issues, diagnostic charts, electrical troubleshooting flowcharts.
Maintenance:
Routine maintenance checks, oil changes, filter replacements, spark plug service, chain/belt adjustment, lubrication points.
Repair:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.
Rebuilds:
Detailed procedures for engine and transmission rebuilds, including component specifications and tolerances.
Tuning:
Carburetor adjustment, ignition timing verification and adjustment (if applicable).
Depth:
Comprehensive, covering all aspects from basic maintenance to full engine/transmission overhauls and advanced diagnostics.
Searchability:
Searchable text within the PDF document.
Printability:
Printable pages for on-the-bench use.
Quality:
High-resolution scanned pages ensuring clarity of text and diagrams.
Binding:
Not Applicable (Digital PDF)
Paper:
Not Applicable (Digital PDF)
Engine Type:
Air-cooled, Evolution (V-twin)
Displacement:
1337.9 cc (81.8 cubic inches)
Bore X Stroke:
3.499 in x 4.250 in (88.9 mm x 108.0 mm)
Valve Train:
Overhead valves (OHV), 2 valves per cylinder
Horsepower Approximate:
65-70 HP @ 5000 RPM (Estimated)
Torque Approximate:
78-83 ft-lbs @ 3200 RPM (Estimated)
Fuel Delivery:
Keihin CV (Constant Velocity) Carburetor (e.g., CV40)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Ignition System:
Electronic Ignition (CDI)
Oil Type:
Harley-Davidson H-D 360 SAE 20W50 Motorcycle Oil (or equivalent)
Oil Capacity:
Approx. 3 quarts (2.8 liters) with filter change
Transmission Type:
5-speed constant mesh
Clutch Type:
Wet, multi-plate
Primary Drive:
Multi-plate clutch, chain drive to transmission
Gear Ratios:
Specific gear ratios will be detailed within the manual for each gear.
Transmission Oil Type:
Harley-Davidson Primary Chaincase Lubricant (or equivalent)
Transmission Oil Capacity:
Approx. 1 quart (0.95 liters)
Length:
Approx. 93.5 inches (2375 mm)
Width Handlebars:
Approx. 35 inches (889 mm)
Height:
Approx. 56.5 inches (1435 mm)
Wheelbase:
Approx. 63.5 inches (1613 mm)
Dry Weight:
Approx. 700 lbs (318 kg)
Gross Vehicle Weight Rating Gvwr:
Not typically published for motorcycles, but inferred by frame/suspension limits.
Fuel Capacity:
5.0 US gallons (18.9 L)
Crash Safety Ratings:
Motorcycles are not subject to standardized crash test ratings like automobiles.
Braking System:
Dual disc front brakes, single disc rear brake (typical for this era).
Lighting:
Halogen headlight, taillight, brake lights, turn signals.
Frame Construction:
Steel cradle frame.
Fairing:
Batwing fairing for rider protection from elements.
Audio System:
Often equipped with an AM/FM stereo radio and cassette player, sometimes with CB radio and intercom features depending on trim level.
Speakers:
Fairing-mounted speakers.
ABS:
Anti-lock Braking System (ABS) was an optional feature for some models in these years, check specific bike for availability. Manual will detail if present.
Connectivity Features:
Basic radio controls, potentially rider-to-rider communication features with optional CB/intercom.
Oil Change Interval:
Every 2,500 - 5,000 miles (or as specified in manual, depending on usage).
Spark Plug Replacement Interval:
Every 10,000 - 15,000 miles (typically).
Belt Tension Check:
Every 5,000 miles or annually.
Fork Oil Change Interval:
Recommended every 2 years or 20,000 miles, or if performance degrades.
Engine Oil Grade:
SAE 20W50 Harley-Davidson H-D 360 (or API CG-4 rated)
Primary Chaincase Oil Grade:
Harley-Davidson Primary Chaincase Lubricant (or equivalent)
Brake Fluid Type:
DOT 4 Brake Fluid (for ABS models, if equipped; typically non-ABS for this era, check manual for specifics)
Coolant Type:
Not Applicable (Air-cooled engine)
Carburetor Issues:
CV carburetor can require tuning/rebuild over time, potential for leaks at gasket seals.
Electrical Gremlins:
Aging wiring harnesses can develop issues; pay attention to regulator/rectifier and stator health.
Rocker Box Gaskets:
Can leak oil over time, requiring gasket replacement.
Drive Belt:
Inspect for wear and proper tension; replacement is a significant job.
Cam Chain Tensioners:
Hydraulic tensioners can wear out; early Evolution engines (pre-1999) had less robust designs. Manual will cover inspection.
Brand Founding:
Founded in 1903 in Milwaukee, Wisconsin.
Brand Reputation:
Iconic American motorcycle manufacturer known for its V-twin engines and cruiser/touring motorcycles.
Electra Glide Introduction:
The Electra Glide lineage dates back to the 1960s, evolving into the benchmark for American touring motorcycles.
Evolution Engine:
The 1990s saw the continued refinement of the Evolution engine, offering increased reliability and performance over earlier Shovelhead and Panhead designs.
Production Period:
1995-1998 model years for this specific manual's coverage.
Manufacturing Location:
York, Pennsylvania and Milwaukee, Wisconsin, USA.
