1984-1999 Harley Davidson Softail Service Manual – PDF DOWNLOAD

Description

1984-1999 Harley Davidson Softail Service Manual – PDF DOWNLOAD

DESCRIPTION:

1984-1999 Harley Davidson Softail Service Manual – PDF DOWNLOAD

GENERAL INFORMATION:

This service and repair manual covers all Harley— Davidson 1340 cc Soñail models from 19844 999. 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 uses, think of acceptable substitutes for special tools there is aiways another way. This can be as simple as using a few pieces of threaded rod. washers and nuls to remove or install a bearing or fabricating a tool from scrap material.
• However, using a substituts 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 safety 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 OF CONTENTS:

1984-1999 Harley Davidson Softail Service Manual – PDF DOWNLOAD

QUICK REFERENCE DATA VII
CHAPTER ONE
GENERAL INFORMATION 1
Manual organization
Notes, cautions and warnings
Safety first
Service hints
Serial numbers
Parts replacement
Torque specifications
Fasteners
Lubricants
RTV gasket sealant
Thread lock
CHAPTER TWO
Gasket remover
Expandable supplies
Basic hand tools
Test equipment
Precision measuring tools
Cleaning solvent
Other special tools
Mechanic’s tips
Ball bearing replacement
Oil seals
TROUBLESHOOTING 33
Operating requirements
Troubleshooting instruments
Testing electrical components
Emergency troubleshooting
Engine performance
Starting system
Charging system
Ignition system
Fuel system
CHAPTER THREE
Engine noises
Engine lubrication
Clutch
Transmission
Electrical problems
Excessive vibration
Front suspension and steering
Brake problems
PERIODIC LUBRICATION, MAINTENANCE AND TUNE-UP 76
Routine safety checks
Maintenance intervals
Cleaning your Harley
Tires and wheels
Periodic lubrication
Periodic maintenance
Tune-up
Breakerless ignition service
Carburetor adjustments
Storage
CHAPTER FOUR
ENGINE 126
Service precautions
Special tools
Servicing engine in frame
Engine removal
Rocker arm cover/cylinder head
Valves and valve components
Cylinder
Pistons and piston rings
CHAPTER FIVE
Pushrods
Tappets and tappet guides
Oil pump
Oil filter mount (1992-on)
Gear case cover and timing gears
Crankcase and crankshaft
Engine break-in
CLUTCH, PRIMARY DRIVE AND STARTER DRIVE 184
Dry clutch (early 1984 FXST)
Wet clutch (late 1984-1989)
Wet clutch (1989-on)
Primary chain
CHAPTER SIX
Compensating sprocket
Primary chain case
Electric starter drive (1984-1988)
Starter jackshaft (1989-on)
4-SPEED TRANSMISSION 228
Transmission
Shifter cover
Shift forks
CHAPTER SEVEN
Kickstarter and starter clutch
Side cover (electric start)
Shifter adjustment
5-SPEED TRANSMISSION 254
Production gears (1994 models)
Shift cam assembly
Shift forks
Transmission
CHAPTER EIGHT
Transmission case
Transmission side cover (1987-on)
Transmission adjustments
FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS 281
Air cleaner
Ca rbu re tor ( 1984-1989)
Carburetor (1990-on)
Carburetor rejetting
Throttle and idle cable replacement
Choke/enrichener cable replacement
CHAPTER NINE
Fuel tanks
Fuel shutoff valve
Exhaust system
Emission control (1985-1991 California models)
Evaporative emission control system (1992-on
California models)
ELECTRICAL SYSTEM 329
Battery
Charging system
Ignition system
Ignition coil
Starter
Starter solenoid (1984-1988)
Starter solenoid (1989-1990)
Starter solenoid (1991-on)
Starter relay
Switches
Horn
Turn signal module (1991-on)
Circuit breakers
CHAPTER TEN
WHEELS, HUBS AND TIRES 368
Front wheel
Front hub
Rear wheel
Rear hub
Driven sprocket assembly
Drive chain
Drive belt
CHAPTER ELEVEN
FRONT SUSPENSION AND STEERING
Laced wheels
Cast or disc wheels
V\/heel balance
Tires
Tire repairs (tube-type tires)
Tire repairs (tubeless type)
(MODELS WITH TELESCOPIC FRONT FORKS) 403
Handlebar
Steering head and stem
Steering head bearing race
CHAPTER TWELVE
Steering adjustment
Front fork
SPRINGER FRONT FORK 417
Steering adjustment
CHAPTER THIRTEEN
REAR SUS PENS ION 443
Rear shock absorbers Rear swing arm
CHAPTER FOURTEEN
BRAKES 457
Front brake pads
Front brake caliper
Front master cylinder
Rear disc brake
Rear brake pad replacement
Rear brake caliper (1984-early 1987 models)
Rear brake caliper (late 1987-on)
Rear master cylinder and reservoir (1984-early 1987
FXST)
CHAPTER FIFTEEN
Rear master cylinder (early 1987 FLST)
Rear master cylinder (late 1987-on FXST)
Rear master cylinder (late 1987-on FLST)
Brake hose and line replacement
Brake disc (front and rear)
Bleeding the system
FRAME, BODY AND FRAME REPAINTING 504
Jiffy stand (side stand)
Foot pegs
Front fender (1993-on FXSTS)
Front fender (all other models)
Rear fender
Saddlebags (1993-on)
Frame
CHAPTER SIXTEEN
SUPPLEMENT
Ignition system
Routine safety checks
Periodic maintenance
Breakerless ignition service (1995-1999)
Engine removal (1996-1999)
Wet clutch (1998-1999)
Clutch shell Compensating sprocket and primary drive
chain (1998-1999)
Evaporative emission
Control systems (1996-1999)
Battery (1998-1999)
CHAPTER SEVENTEEN
Ignition system (1995-1999)
Lighting system (1995-1999)
Switches (1997-1999)
Turn signal module (1997-1999)
Front wheel (1996-1999)
Front hub (1996-1999 Springer models)
Rear hub (1997-1999)
Springer front forks (1997-1999)
Front brake caliper (1997-1999 FLSTS)
Front master cylinder (1997-1999)
Front fender (1995-1999 FLSTS)
INDEX 577
CHAPTER EIGHTEEN
WIRING DIAGR AMS 581

1984-1999 HARLEY DAVIDSON SOFTAIL SERVICE MANUAL – PDF DOWNLOAD:

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