Motorcycle Segment:
Full-size touring motorcycle, flagship model for its era.
Target Audience:
Long-distance riders, touring enthusiasts, Harley-Davidson aficionados.
Key Competitors:
Honda Gold Wing, Indian Chief, BMW K1 series, Yamaha Venture Royale.
Touring Amenities:
Large fairing with windscreen, ample storage (saddlebags, tour-pak), comfortable seating for rider and passenger, robust touring chassis.
Powertrain:
Harley-Davidson's signature Evolution V-Twin engine, known for its torque and distinctive character.
Brand Iconography:
Embodiment of the classic Harley-Davidson touring experience, robust build quality, iconic styling.
Model Years Covered:
1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998
Estimated Page Count:
Hundreds (typical for comprehensive factory service manuals)
Manual Type:
Factory Service Repair Workshop Manual
Engine Service And Rebuild:
Complete disassembly, inspection, repair, and reassembly of the Evolution V-Twin engine (including Shovelhead variants where applicable for early models).
Transmission Service:
4-speed and 5-speed transmission overhaul, maintenance, and troubleshooting.
Fuel System And Carburetion:
Carburetor (e.g., Keihin CV) service, adjustment, and troubleshooting; fuel injection systems for later models.
Electrical System Diagnostics:
Wiring diagrams, component testing, troubleshooting for ignition, lighting, starting, charging, and accessory systems.
Brake System Maintenance:
Front and rear brake caliper service, master cylinder repair, hydraulic system bleeding, and component replacement.
Suspension And Steering:
Front fork (e.g., Showa) overhaul, rear shock absorber service, steering head bearing adjustment, and wheel bearing replacement.
Chassis And Frame Repair:
Frame inspection, alignment, and repair procedures; bodywork (fairings, saddlebags) removal, installation, and repair.
Cooling System Maintenance:
Oil cooling system service and inspection.
Exhaust System Service:
Exhaust system removal, installation, and inspection.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain adjustment (if applicable), brake fluid flushes, and general inspections.
Troubleshooting Guides:
Systematic diagnostic procedures for identifying and resolving common mechanical and electrical issues.
Component Overhaul And Rebuild:
Detailed steps for rebuilding engines, transmissions, carburetors, and brake systems.
Electrical Component Testing:
Procedures for testing ignition coils, voltage regulators, alternators, starters, and switches.
Special Tool Requirements:
Identification and usage instructions for specialized tools required for specific repair procedures.
Torque Specifications:
Precise torque values for critical fasteners across all systems.
Depth Of Coverage:
Comprehensive factory-level detail, suitable for professional technicians and advanced DIY mechanics.
Diagnostic Capability:
Advanced diagnostic information, including electrical schematics, fault codes (where applicable), and troubleshooting flowcharts.
Rebuild Procedures:
Complete engine and transmission rebuild procedures, including clearances, tolerances, and assembly sequences.
Engine Type:
Air-cooled, 45-degree V-twin, pushrod overhead valves
Engine Displacement:
80 cubic inches (approx. 1337 cc)
Bore X Stroke:
3.50 in x 4.25 in (88.9 mm x 108.0 mm)
Compression Ratio:
8.3:1 (typical for Evolution)
Valve Train:
Pushrod actuated overhead valves
Horsepower:
Approx. 65-70 HP (est. flywheel)
Torque:
Approx. 75-80 lb-ft @ 3000-4000 RPM (est.)
Fuel Delivery:
Carburetor (Keihin CV 40mm) for most years, potential for early fuel injection in later models (check specific year).
Fuel Type:
Unleaded gasoline, 89 octane or higher recommended.
Oil Type:
Harley-Davidson H-D 360 Motor Oil SAE 20W-50 or equivalent API SF, SG, SH, SJ, or higher rated oil.
Oil Capacity:
Approximately 3.5 quarts (3.3 liters) with filter change.
Ignition System:
Electronic ignition with single fire or dual fire (depending on year and configuration).
Pistons:
Cast aluminum alloy
Crankshaft:
One-piece forged
Length:
Approx. 93.2 inches (2367 mm)
Width:
Approx. 37.0 inches (940 mm)
Height:
Approx. 54.0 inches (1372 mm)
Wheelbase:
Approx. 63.5 inches (1613 mm)
Dry Weight:
Approx. 700-750 lbs (318-340 kg), varies by year and options.
Gross Vehicle Weight Rating Gvwr:
Approx. 1160 lbs (526 kg)
Saddlebag Capacity:
Integrated hard saddlebags, substantial volume for touring.
Tour Pak Capacity:
Optional (standard on some Anniversary models), adds significant rear storage.
Front Tire Size:
MT90H16 or similar
Rear Tire Size:
130/90-16 or similar
Wheel Type:
Cast aluminum or spoke wheels, typically 16-inch diameter.
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inch) - typical for many Harley-Davidson models of this era.
Crash Test Data:
N/A (Motorcycle crash testing standards differ significantly from automobiles and are not typically rated by common agencies).
Braking System:
Dual disc front brakes, single disc rear brake with hydraulic actuation. ABS was not typically available on these models.
Suspension Stability:
Stable touring chassis designed for highway stability.
Lighting System:
Halogen headlight, auxiliary passing lamps (standard on FLHTC), front and rear turn signals, brake light.
Fairing Wind Protection:
Provides significant wind and weather protection for the rider.
Audio System:
Integrated AM/FM stereo radio with cassette player (standard on FLHTC), often with CB radio and intercom capability.
Display Technology:
Analog gauges for speedometer, tachometer, fuel, oil pressure, and voltage; often a separate clock.
Cruise Control:
Often equipped with mechanical cruise control, requiring manual activation and setting.
Passenger Communication:
Built-in intercom system for rider-to-passenger communication.
Headlight Type:
Halogen, 7-inch sealed beam unit.
Auxiliary Lighting:
Standard front fender driving/passing lamps on FLHTC models.
First Service:
Typically at 1,000 miles (1600 km) - includes engine oil change, filter change, inspection of primary drive, transmission, and all fasteners.
Subsequent Oil Changes:
Every 2,500 - 5,000 miles (4000 - 8000 km) or 6 months, whichever comes first, depending on usage and oil type.
Transmission Oil Change Interval:
Every 5,000 - 10,000 miles (8000 - 16000 km) or annually.
Primary Chaincase Oil Change Interval:
Every 2,500 - 5,000 miles (4000 - 8000 km) or annually.
Spark Plug Replacement:
Inspect at 5,000 miles, replace as needed or at recommended intervals (e.g., 10,000-20,000 miles).
Brake Fluid Flush:
Every 12-24 months, depending on climate and usage.
Engine Oil Specification:
SAE 20W-50 (e.g., Harley-Davidson H-D 360) - API SF, SG, SH, SJ or higher.
Transmission Oil Specification:
Heavy-duty gear oil (e.g., Harley-Davidson Transmission Oil SAE 85W-140) or equivalent.
Primary Chaincase Lubricant:
Motor oil (e.g., SAE 50 or 20W-50) or Harley-Davidson Primary Chaincase Lubricant.
Brake Fluid Type:
DOT 4 brake fluid (ensure compatibility with seal materials).
Primary Drive Leaks:
Potential for oil leaks from the primary drive case seals.
Carburetor Tuning:
Keihin CV carbs may require periodic adjustment for optimal performance and emissions.
Electrical Connections:
Corrosion or loose connections in the electrical system can lead to intermittent issues.
Suspension Wear:
Fork seals and rear shocks may require service or replacement over time due to mileage and use.
Cam Chain Tensioner Wear:
Early Evolution engines used spring-loaded cam chain tensioners which could wear out, requiring replacement with later hydraulic units.
Brand Legacy:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines, classic styling, and association with freedom and American culture.
Electra Glide Lineage:
The Electra Glide nameplate dates back to the 1960s, evolving through Shovelhead and Evolution engine platforms to become Harley-Davidson's premier touring machine.
Evolution Engine Introduction:
The Evolution engine, introduced in 1984 for the Softail and Sportster lines, quickly replaced the Shovelhead in Big Twin models, including the Electra Glide, offering improved reliability and performance.
Flhtc Development:
The FLHTC Electra Glide Classic was positioned as the more premium, fully-equipped touring model, often featuring standard amenities like a fairing, hard saddlebags, and a tour-pak.
Manufacturing Location:
United States (Milwaukee, Wisconsin and York, Pennsylvania)
Anniversary Editions:
Harley-Davidson frequently produced special anniversary editions to commemorate milestones, often featuring unique paint schemes, badging, and premium appointments.
