Target Audience:
Harley-Davidson FXST Softail owners, independent mechanics, and restoration specialists.
Value Proposition:
Provides in-depth technical knowledge and procedures to maintain, repair, and restore the specified Harley-Davidson models.
Manual Type Comparison:
This is a comprehensive workshop manual, distinct from a simpler owner's manual or a parts catalog. It offers the necessary detail for actual repair work.
Pictorial Content:
Likely includes detailed diagrams, exploded views, and illustrations of components and procedures.
Diagnostic Flowcharts:
Expected to contain troubleshooting flowcharts to systematically identify and resolve issues.
Technical Drawings:
Includes technical drawings for component identification and assembly.
Engine:
Evo V-Twin Engine (Shovelhead variants may be present in early models and covered in relation to transition)
Fuel System:
Carburetion (Keihin CV Carburetor), Fuel Lines, Fuel Tank, Fuel Pump (if applicable)
Ignition System:
Electronic Ignition, Spark Plugs, Coils, Ignition Module
Transmission:
5-Speed Constant Mesh Transmission (e.g., Baker 5-speed, stock Harley-Davidson transmission)
Clutch:
Wet Multi-plate Clutch, Clutch Actuation System
Drivetrain:
Belt Drive System (Primary and Final Drive), Belt Tensioning
Suspension:
Front Fork (Telescopic), Rear Swingarm, Shock Absorbers, Suspension Linkages
Brakes:
Front and Rear Disc Brake Systems, Calipers, Master Cylinders, Brake Lines, Brake Fluid
Electrical System:
Battery, Charging System (Alternator/Generator), Lighting (Headlight, Taillight, Turn Signals), Starter Motor, Wiring Harnesses, Fuses, Relays
Chassis Frame:
Frame Components, Headstock, Swingarm Pivot
Bodywork:
Fenders, Fuel Tank, Seat, Fairings (if applicable), Handlebars, Controls
Scheduled Maintenance:
Oil Changes, Filter Replacements, Chain/Belt Adjustments, Brake Fluid Flushes, Spark Plug Replacement, Lubrication Points
Engine Overhaul:
Top-End Rebuild (Cylinder Head, Piston), Bottom-End Rebuild (Crankshaft, Connecting Rods), Engine Disassembly and Reassembly Procedures
Transmission Repair:
Gearbox Disassembly, Reassembly, Bearing Replacement, Seal Replacement
Suspension Servicing:
Fork Seal Replacement, Shock Absorber Servicing, Bushing Replacement
Brake System Maintenance:
Brake Pad Replacement, Rotor Inspection/Replacement, Bleeding Procedures, Master Cylinder Rebuild
Electrical Troubleshooting:
Wiring Diagram Interpretation, Fault Finding, Component Testing (e.g., charging system, starter)
Carburetor Tuning:
Adjustment Procedures, Jetting, Rebuilds
Ignition Timing:
Setting and Adjustment of Ignition Timing
Wheel Bearing Service:
Inspection and Replacement of Wheel Bearings
Tire Mounting Balancing:
Procedures for Tire Installation and Balancing
Depth Of Coverage:
Comprehensive - Covers routine maintenance to complete engine and transmission overhauls.
Diagnostic Capabilities:
Detailed troubleshooting guides, symptom analysis, and step-by-step diagnostic procedures.
Rebuild Instructions:
Specific torque specifications, clearances, and assembly sequences for major components.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Engine Family:
Harley-Davidson Evolution (Evo) V-Twin
Engine Configuration:
90-degree V-Twin, Air-Cooled
Displacement Cc:
Typically 80 cubic inches (1340cc) for these years, though earlier models might have had Shovelhead variations.
Bore X Stroke Inches:
Approx. 3.500" x 4.250" (for 80 cubic inch Evo)
Compression Ratio:
Varies by model year and specific configuration, typically around 8.0:1 to 8.5:1.
Horsepower Hp:
Estimated 55-65 HP at the crank (highly dependent on specific model and tuning).
Torque Lb Ft:
Estimated 70-80 lb-ft at the crank (highly dependent on specific model and tuning).
Carburetor Type:
Keihin CV (Constant Velocity) 40mm carburetor is standard for most of these years.
Fuel Tank Capacity Gallons:
Typically 3.5 - 4.0 gallons depending on specific Softail model variant (e.g., Standard, Custom).
Fuel Type:
Unleaded gasoline, minimum 87 octane recommended.
Engine Oil Type:
Harley-Davidson SYN3 (or equivalent V-twin specific motorcycle oil, e.g., 20W-50, SAE 50). Refer to manual for exact specifications.
Engine Oil Capacity Quarts:
Approximately 4 quarts (3.8 liters) with filter change.
Transmission Type:
5-Speed Manual Transmission
Gear Ratios:
Specific gear ratios are detailed within the manual, varying slightly between models.
Transmission Options:
While factory standard, aftermarket 6-speed transmissions became popular later.
Primary Drive:
Enclosed primary drive system with a wet multi-plate clutch and belt drive to the transmission.
Final Drive:
Belt drive (3-inch wide belt typically).
Transmission Oil Type:
Refer to manual for specific Harley-Davidson transmission fluid or equivalent SAE 80W-90 gear oil.
Transmission Oil Capacity Quarts:
Approximately 1 quart (0.95 liters).
Oil Change Interval Miles:
Typically every 2,500 - 5,000 miles or annually, depending on usage and oil type. Manual will specify exact intervals.
Primary Chain Adjustment Miles:
Recommended at 1,000 miles and then at regular intervals (e.g., every 5,000 miles) or as needed. Manual will provide precise procedure and slack specification.
Spark Plug Replacement Miles:
Typically at 10,000 - 15,000 mile intervals, or as per manual recommendations.
Brake Fluid Flush Miles:
Recommended every 1-2 years or as specified in the manual.
Front Fork Oil Type:
Refer to manual for specific fork oil grade (e.g., 10W, 15W) and quantity.
Brake Fluid Type:
DOT 4 or DOT 5 (depending on original system and rebuilds; manual will clarify).
Common Wear Items:
Clutch plates, primary and final drive belts, wheel bearings, fork seals, and brake pads are common wear items.
Carburetor Issues:
CV carburetor can sometimes develop tuning issues or require rebuild due to aging rubber components.
Electrical Gremlins:
Older wiring harnesses can become brittle and connections can corrode, leading to intermittent electrical faults.
Cam Chain Tensioner:
Hydraulic cam chain tensioners on early Evo engines were known to wear and require replacement (later models had improved designs).
Harley Davidson Legacy:
Harley-Davidson has a long-standing reputation for building iconic V-twin motorcycles known for their distinctive styling, sound, and rider experience.
Softail Platform Introduction:
The Softail platform, introduced in 1984, featured a revolutionary design with hidden rear shock absorbers, mimicking the hardtail look while providing modern suspension comfort.
Fxst Development:
The FXST Softail was a core model within the Softail family, often serving as a base for custom variants.
Production Era:
1984-1990 represents a significant period in the evolution of the Evo-powered Softail, encompassing the introduction of the platform and early refinements.
Engine Transition:
This period marks the transition from the Shovelhead engine to the more reliable and powerful Evolution (Evo) engine, with the Evo becoming dominant in the FXST line.
