Market Segment:
Cruiser motorcycle, iconic American V-twin cruiser.
Competitors:
Other Harley-Davidson Softail models, Indian Chief, select Japanese cruisers (e.g., Yamaha V-Star, Honda Shadow).
Design Philosophy:
Retro styling, low seat height, comfortable riding position, robust V-twin engine.
Target Audience:
Riders seeking classic American cruiser aesthetics, comfort for long rides, and the distinctive Harley-Davidson experience.
Covered Years:
1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Manual Type:
Workshop Service Manual
Engine Systems:
Engine teardown, assembly, inspection, troubleshooting, performance tuning, ignition system, fuel delivery system (carburetion), oiling system.
Transmission Drivetrain Systems:
Primary drive, clutch operation and service, transmission assembly and disassembly, final drive (belt drive maintenance and adjustment), wheel bearings.
Chassis Suspension Systems:
Frame inspection and repair, front fork service (including oil changes and seal replacement), rear shock absorber service and replacement, swingarm and pivot bearing service.
Electrical Systems:
Wiring diagrams, battery service, charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), lighting system, ignition system troubleshooting, accessory wiring.
Braking Systems:
Front and rear brake caliper service, master cylinder service, brake line replacement, brake pad replacement, brake fluid bleeding and specifications.
Bodywork Fittings:
Fuel tank removal and installation, fender service, seat removal and installation, handlebar service, fairing and component removal/installation (if applicable).
Maintenance Procedures:
Scheduled maintenance intervals, oil changes, filter replacements, spark plug replacement, drive belt inspection and adjustment, brake system maintenance, battery maintenance.
Repair Procedures:
Engine overhaul, transmission rebuild, clutch service, fork rebuild, brake caliper rebuild, electrical component testing and replacement.
Troubleshooting Guides:
Diagnostic procedures for common engine, electrical, and mechanical issues, fault finding charts, symptom-based troubleshooting.
Depth Of Coverage:
Comprehensive; covers from basic maintenance to complete engine and transmission rebuilds, including detailed disassembly and assembly instructions with torque specifications.
Engine Type:
Evolution V-Twin
Displacement:
1339.7 cc (81.8 cubic inches)
Bore X Stroke:
3.4375 in x 4.25 in (87.31 mm x 107.95 mm)
Compression Ratio:
8.3:1 (typical for this era)
Valve Train:
Overhead Valves (OHV), 2 valves per cylinder
Cooling System:
Air-Cooled
Horsepower Approximate:
~55-60 HP (at crankshaft, estimated for the era)
Torque Approximate:
~70-75 lb-ft (at crankshaft, estimated for the era)
Fuel Delivery:
Keihin CV (Constant Velocity) Carburetor, typically 40mm
Fuel Type:
Unleaded Gasoline, 87-91 Octane
Crash Test Ratings:
N/A (Motorcycle safety ratings are not standardized like passenger vehicles)
Braking System:
Dual disc front brakes, single disc rear brake.
Lighting:
Halogen headlight, taillight, brake light, turn signals.
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first.
Engine Oil Type:
Harley-Davidson 20W50 motorcycle oil or equivalent API SG or higher rated oil.
Primary Chain Case Fluid:
Harley-Davidson Primary Chain Lubricant or equivalent Harley-Davidson compatible fluid.
Transmission Fluid Type:
Harley-Davidson Transmission Lubricant (e.g., Formula+ or equivalent)
Brake Fluid Type:
DOT 4 (or DOT 5 if specified for specific systems, check manual for exact type).
Fork Oil Type:
Specific fork oil viscosity as per manual (e.g., Harley-Davidson Suspension Fork Oil or equivalent).
Common Wear Items:
Clutch plates, brake pads, wheel bearings, fork seals, drive belt.
Potential Failures:
Carburetor adjustments, ignition module issues, starter solenoid failure, oil leaks from seals/gaskets.
Electrical Concerns:
Aging wiring harnesses, corrosion in connectors, stator/regulator issues.
Brand Legacy:
Harley-Davidson, established 1903, synonymous with American motorcycle culture and iconic V-twin engines.
Softail Platform Introduction:
The Softail platform, featuring a hidden rear suspension system that mimics a rigid frame appearance, was introduced in 1983.
Fat Boy Introduction:
The FLSTF Fat Boy model was introduced in 1990, quickly becoming a flagship model known for its distinctive styling cues.
Manufacturing Location:
United States (York, Pennsylvania and Milwaukee, Wisconsin)
Production Period:
1990-1999 model years covered by this manual.
