Harley Davidson Softail 1984-1999. Service manual — page 1

Chapter One General Information

Chapter Two Troubleshooting

Chapter Three

Periodic Lubrication, Maintenance & Tune-up

Chapter Four Engine

Chapter Five

Clutch, Primary Drive & Starter Drive

Chapter Six

4-Speed Transmission

Chapter Seven

5-Speed Transmission

Chapter Eight

Fuel, Exhaust & Emission Control Systems

Chapter Nine Electrical System

Chapter Ten Wheels, Hubs & Tires

Chapter Eleven

Front Suspension & Steering (Models with Telescopic Front Forks)

Chapter Twelve Springer Front Fork

Chapter Thirteen Rear Suspension

Chapter Fourteen Brakes

Chapter Fifteen

Frame, Body & Frame Repainting

Chapter Sixteen Supplement

Chapter Seventeen Index

Chapter Eighteen Wiring Diagrams
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CHAPTER ONE

GENERAL INFORMATION

This service and repair manual covers all Harley-Davidson 1340 cc Softail models from 1984-1999.

Procedures unique to 1995-1999 models are covered in the supplement at the end of the manual.

Troubleshooting, tune-up, maintenance and repair are not difficult, if you know what tools and equipment to use and what to do. Step-by-step instructions guide you through jobs ranging from simple maintenance to complete engine and suspension overhaul.

This manual can be used by anyone from a first time do-it-yourselfer to a professional mechanic. Detailed drawings and clear photographs give you all the information you need to do the work right.

Some of the procedures in this manual require the use of special tools. The resourceful mechanic can. in many cases, think of acceptable substitutes for special tools there is always another way. This can be as simple as using a few pieces of threaded rod. washers and nuts to remove or install a bearing or fabricating a tool from scrap material. However, using a substitute for a special tool is not recommended as it can be dangerous and may damage the part.

If you find that a tool can be designed and safely made, but will require some type of machine work, you may want to search out a local community college or high school that has a machine shop curriculum. Shop teachers sometimes welcome outside work that can be used as practical shop applications for advanced students.
Table 1 lists model coverage.

General specifications arc listed in Table 2 while gross vehicle weight ratings are listed in Table 3. Fuel lank capacity is listed in Table 4.

U.S. to metric conversion is given in Table 5.

Critical torque specifications are found in table form at the end of each chapter (as required). The general torque specifications listed in Table 6 can be used when a torque specification is not listed for a specific component or assembly.

Inch Lap drill sizes can be found in Table 7.

A wind chill chart is found in Table 8 that can be used to better prepare yourself when riding your Harley in cold weather.

MANUAL ORGANIZATION

This chapter provides general information useful to Harley vehicle owners and mechanics. In addition, information in this chapter discusses the tools and techniques for preventive maintenance, troubleshooting and repair.

Chapter Two provides methods and suggestions for quick and accurate diagnosis and repair of problems. Troubleshooting procedures discuss typical symptoms and logical methods to pinpoint the trouble.

Chapter Three explains all periodic lubrication and routine maintenance necessary to keep your