Target Audience:
Harley-Davidson Softail owners and independent repair shops seeking professional service information.
Value Proposition:
Provides authoritative, factory-level repair and maintenance data for optimal vehicle care and longevity.
Alternative Sources:
Limited to official dealer service departments or less comprehensive aftermarket guides.
Accuracy And Completeness:
Derived from original Harley-Davidson factory documentation, ensuring the highest level of detail and accuracy.
Accessibility:
Instant download format allows immediate access to critical repair information.
Engine Service:
Engine assembly, disassembly, inspection, tuning, troubleshooting of Evolution V-Twin engines.
Fuel System:
Carburetor (Keihin CV) service, fuel pump, fuel lines, fuel tank maintenance.
Ignition System:
Ignition module, spark plugs, coils, timing adjustments, troubleshooting.
Transmission Drivetrain:
Clutch service, primary drive, transmission assembly/disassembly, final drive belt inspection and replacement.
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, starter, switches, fuses.
Suspension:
Front fork (e.g., Showa, with specific model fork type) disassembly, service, seal replacement, rear shock absorber inspection and replacement.
Brakes:
Front and rear brake caliper service, master cylinder, brake lines, bleeding procedures, rotor inspection.
Wheels Tires:
Wheel bearing replacement, tire pressure, mounting and balancing.
Frame Chassis:
Frame inspection, steering head bearing service, jiffy stand, footboards/pegs.
Bodywork Fenders:
Fender removal and installation, fuel tank removal, seat service, handlebar installation.
Diagnostic Troubleshooting:
Section dedicated to identifying and resolving common issues with detailed diagnostic trees.
Preventative Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication points, brake checks.
Tune Up Procedures:
Carburetor adjustment, ignition timing checks, spark plug replacement, air filter cleaning/replacement.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement.
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams and test procedures.
Brake System Service:
Complete brake pad replacement, caliper rebuild, fluid flush and bleeding.
Fork Service:
Front fork oil changes, seal replacement, spring replacement.
Belt Drive Maintenance:
Belt tension adjustment, inspection for wear, replacement procedures.
Wheel Bearing Replacement:
Step-by-step guide for removing and installing wheel bearings.
Steering Head Service:
Adjustment and replacement of steering head bearings.
Depth Level:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds.
Diagnostic Capability:
Detailed troubleshooting guides and diagnostic procedures for identifying and resolving issues.
Specifications Detail:
Includes torque specifications, clearances, fluid capacities, and electrical resistance values.
Engine Family:
Harley-Davidson Evolution (Evo) V-Twin
Engine Displacement Typical:
1340cc (82 cubic inches)
Engine Configuration:
Air-cooled, 45-degree V-twin
Bore X Stroke Typical:
3.500 in. x 4.250 in. (88.9 mm x 108.0 mm)
Compression Ratio Typical:
8.8:1 to 9.0:1 (depending on specific model and tuning)
Horsepower Approximate:
Typically in the 55-65 HP range, with torque being the primary performance metric.
Torque Approximate:
Around 70-80 ft-lbs at lower RPMs.
Fuel Delivery:
Carburetor (Keihin CV 40mm typically)
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended.
Valvetrain:
Overhead valves (OHV), pushrod actuated.
Oil System:
Dry sump with oil tank separate from the crankcase.
Initial Service:
Typically at 1,000 miles (1600 km).
Subsequent Service:
Generally every 5,000 miles (8000 km) or annually, whichever comes first for routine checks and fluid changes.
Engine Oil Change:
Recommended every 2,500-5,000 miles, or per manual, using appropriate Harley-Davidson oil.
Transmission Oil Change:
Recommended at 10,000-15,000 mile intervals, or as per manual.
Engine Oil Type:
Harley-Davidson 20W-50 Motorcycle Oil or equivalent.
Primary Chaincase Fluid:
HD Formula+ or equivalent.
Brake Fluid:
DOT 4 for most models of this era, refer to manual for precise type and capacity.
Fork Oil Type:
Harley-Davidson Type E (Heavy) or Type B (Medium) fork oil, or equivalent, depending on desired damping characteristics and model.
Cam Chain Tensioners:
Evolution engines of this era have known issues with the spring-loaded cam chain tensioners. Upgrade to hydraulic tensioners is a common modification.
Carburetor Tuning:
Keihin CV carburetor may require periodic adjustment for optimal performance and idle.
Oil Leaks:
Can occur from various seals and gaskets with age; proper torque and seal replacement are key.
Rear Suspension Bushings:
Bushings in the rear shock mounts can wear over time, affecting ride quality.
