Harley Davidson Touring Models 84-98 FLH, FLHT, FXR. Service manual — page 1

CHAPTER ONE

GENERAL INFORMATION

This detailed and comprehensive service manual covers the Harley-Davidson FLH, FLT and FXR series models from 1984-1998, the FXSB and FXEF models from 1985 and FXWG models from 1985-1986.

The text provides complete information on maintenance, tune-up, repair and overhaul. Hundreds of photographs and illustrations created during the complete disassembly of the motorcycle guide the reader through every job. All procedures are in step-by-step format and designed for the reader who may be working on the motorcycle for the first time.

MANUAL ORGANIZATION

A sen/ice and repair manual is a tool and, as in all service manuals, the chapters are thumb tabbed for easy reference. Main headings are listed in the table of contents and the index. Frequently used specifications and capacities from the tables at the end of each individual chapter are listed in the Quick Reference Data section at the front of the manual. Specifications and capacities are provided in U.S. standard and metric units of measure.
During some of the procedures, there will be references to headings in other chapters or sections of the manual. When a specific heading is called out in a step it will be italicized as it appears in the manual. If a subheading is indicated as being "in this section" it is located within the same main heading. For example, the subheading Handling Gasoline Safely is located within the main heading Safety.

This chapter provides general information on shop safety, tools and tool usage, service fundamentals and shop supplies. Tables 1-12, at the end of the chapter, list the following:

Table 1 lists model identification.

Table 2 lists general specifications (FLH, FLT and FXR series models).

Table 3 lists general specifications (FXSB, FXEF and FXWG).

Table 4 lists motorcycle weight (dry).

Table 5 lists motorcycle weight ratings.

Table 6 lists fuel tank capacity.

Table 7 lists decimal and metric equivalents.

Table 8 lists general torque specifications.

Table 9 lists conversion tables.

Table 10 lists technical abbreviations.

Table 11 lists American tap and drill sizes.

Table 12 lists special tools.

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

Chapter Three explains all routine maintenance necessary to keep the motorcycle running well. Chapter Three also includes recommended tune-up procedures, eliminating the need to constantly consult the chapters on the various assemblies.

Subsequent chapters describe specific systems such as engine, transmission, clutch, drive system, fuel system, suspension, brakes, cruise control, fairing and exhaust system. Each disassembly, repair and assembly procedure is discussed in step-by-step form.

WARNINGS, CAUTIONS AND NOTES

The terms WARNING, CAUTION and NOTE have specific meanings in this manual.

A WARNING emphasizes areas where injury or even death could result from negligence. Mechanical damage may also occur. WARNINGS are to be taken seriously.

A CAUTION emphasizes areas where equipment damage could result. Disregarding a CAUTION could cause permanent mechanical damage, though injury is unlikely.

A NOTE provides additional information to make a step or procedure easier or clearer. Disregarding a NOTE could cause inconvenience but would not cause equipment damage or injury.

SAFETY

Professional mechanics can work for years and never sustain a serious injury or mishap. Follow these guidelines and practice common sense to safely service the motorcycle.

1. Do not operate the motorcycle in an enclosed area. The exhaust gasses contain carbon monoxide, an odorless, colorless and tasteless poisonous gas. Carbon monoxide levels build quickly in small enclosed areas and can cause unconsciousness and death in a short time. Make sure to properly ventilate the work area or operate the motorcycle outside.

2. Never use gasoline or any extremely flammable liquid to clean parts. Refer to Cleaning Parts and Handling Gasoline Safely in this section.

3. Never smoke or use a torch in the vicinity of flammable liquids such as gasoline or cleaning solvent.

4. If welding or brazing on the motorcycle, move the fuel tank to a safe distance at least 50 ft. (15 m) away.

5. Use the correct type and size of tools to avoid damaging fasteners.

6. Keep tools clean and in good condition. Replace or repair worn or damaged equipment.

7. When loosening a tight fastener, be guided by what would happen if the tool slips.

8. When replacing fasteners, make sure the new fasteners are the same size and strength as the original ones.

9. Keep the work area clean and organized.

10. Wear eye protection anytime the safety of the eyes is in question. This includes procedures that involve drilling, grinding, hammering, compressed air and chemicals.

11. Wear the correct clothing for the job. Tie up or cover long hair so it does not get caught in moving equipment.

12. Do not carry sharp tools in clothing pockets.

13. Always have an approved tire extinguisher available. Make sure it is rated for gasoline (Class B) and electrical (Class C) fires.

14. Do not use compressed air to clean clothes, die motorcycle or the work area. Debris may be blown into the eyes or skin. Never direct compressed air at anyone. Do not allow children to use or play with any compressed air equipment.

15. When using compressed air to dry rotating parts, hold the pan so it does not rotate. Do not allow the force of the air to spin the part. The air jet is capable of rotating parts at extreme speed. The part may disintegrate or become damaged and cause serious injury.

16. Do not inhale the dust created by brake pad and clutch wear. These particles may contain asbestos. In addition, some types of insulating materials and gaskets may contain asbestos. Inhaling asbestos particles is hazardous to health.

17. Never work on the motorcycle while someone is working under it.

18. When placing the motorcycle on a stand, make sure it is secure before walking away.

Handling Gasoline Safely

Gasoline is a volatile flammable liquid and is one of the most dangerous items in the shop. Because gasoline is used so often, many people forget it is hazardous. Only use gasoline as fuel for gasoline internal combustion engines. When working on the machine, keep in mind gasoline is always present in the fuel tank, fuel line and throttle body. To avoid a disastrous accident when working around the fuel system, carefully observe the following precautions:

1. Never use gasoline to clean parts. Refer to Cleaning Parts in this section.

2. When working on the fuel system, work outside or in a well-ventilated area.

3. Do not add fuel to the fuel tank or service the fuel system while the motorcycle is near open flames, sparks or where someone is smoking. Gasoline vapor is heavier than air; it collects in low areas and is more easily ignited than liquid gasoline.

4. Allow the engine to cool completely before working on any fuel system component.

5. Do not store gasoline in glass containers. If the glass breaks, a serious explosion or fire may occur.

6. Immediately wipe up spilled gasoline with rags. Store the rags in a metal container with a lid until they can be properly disposed of, or place them outside in a safe place for the fuel to evaporate.

7. Do not pour water onto a gasoline fire. Water spreads the fire and makes it more difficult to put out. Use a class В, BC or ABC fire extinguisher to extinguish the fire.

8. Always turn off the engine before refueling. Do not spill fuel onto the engine or exhaust system. Do not overfill the fuel tank. Leave an air space at the top of the tank to allow room for the fuel to expand due to temperature fluctuations.

Cleaning Parts

Cleaning parts is one of the more tedious and difficult service jobs performed in the home garage. Many types of chemical cleaners and solvents are available for shop use. Most are poisonous and extremely flammable. To prevent chemical exposure, vapor buildup, fire and serious injury, read each product warning label and note the following:

1. Read and observe the entire product label before using any chemical. Always know what type of chemical is being used and whether it is poisonous and/or flammable.

2. Do not use more than one type of cleaning solvent at a time. If mixing chemicals is required, measure the proper amounts according to the manufacturer.

3. Work in a well-ventilated area.

4. Wear chemical-resistant gloves.

5. Wear safety glasses.

6. Wear a vapor respirator if the instructions call for it.

7. Wash hands and anus thoroughly after cleaning parts.

8. Keep chemical products away from children and pets.

9. Thoroughly clean all oil, grease and cleaner residue from any part that must be heated.

10. Use a nylon brush when cleaning parts. Metal brushes can cause a spark.

11. When using a parts washer, only use the solvent recommended by the manufacturer. Make sure the parts washer is equipped with a metal lid that will lower in case of fire.

Warning Labels

Most manufacturers attach information and warning labels to the motorcycle. These labels contain instructions that are important to personal safety when operating, servicing, transporting and storing the motorcycle. Refer to the owner’s manual for the description and location of labels. Order replacement labels from the manufacturer if they are missing or damaged.

SERIAL NUMBERS

Serial numbers are stamped on various locations on the frame, engine, transmission and carburetor. Record these numbers in the Quick Reference Data section in the front of the manual. Have these numbers available when ordering parts.

The frame serial number (Figure 1) is stamped on the right side of the frame down tube.

The VIN number label is located just below the frame number on the right side frame down tube.

The engine serial number is stamped on a pad on the left side of the crankcase (Figure 2) at the base of the rear cylinder block.