2019 Harley-Davidson Softail Service Manual with Wiring References
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Complete service manual reference for 2019 Harley-Davidson Softail models equipped with Milwaukee-Eight 107 and 114 engines. Includes scheduled maintenance tables, factory torque specifications, drive belt adjustment, suspension preload setups, wheel building and truing, sealed bearing replacement, and complete front and rear ABS hydraulic brake rebuilding procedures.
Description
2019 Harley-Davidson Softail Service Manual with Wiring References
The 2019 Harley-Davidson Softail Service Manual with Wiring References provides factory-level maintenance, inspection, and chassis repair procedures for workshop technicians and dedicated motorcycle owners. Covering every production model in the 2019 Softail family, this manual delivers exact manufacturer specifications, detailed fastener torque charts, special tool references, and step-by-step instructions required to maintain, service, and rebuild major motorcycle assemblies.
File Details
| Attribute | Details |
|---|---|
| Manual Type | Service Manual with Wiring References |
| Brand | Harley-Davidson |
| Model Family | Softail (FLDE, FLFB, FLFBS, FLHC, FLHCS, FLSB, FLSL, FXBB, FXBR, FXBRS, FXDRS, FXFB, FXFBS, FXLR) |
| Model Year | 2019 |
| Engine Coverage | Milwaukee-Eight 107 (1753 cc) and Milwaukee-Eight 114 (1868 cc) |
| Language | English |
| Page Count | 2154 Pages |
| File Format |
Chapters Covered
- Foreword:
- General
- Manual Layout
- How to Use This Service Manual
- Preparation For Service
- Use Genuine Replacement Parts
- Shop Practices
- Cleaning
- Disposal and Recycling
- Tools and Materials
- Product Registered Marks
- Trademark Information
- Safety:
- General Safety Precautions
- Customer Safety
- Personal Protection
- Tool Safety
- Hazardous Materials
- Fuel Handling
- Battery Acid Safety
- Brake Fluid Hazards
- Engine Oil Handling
- Electrical System Care
- Maintenance:
- Fastener Torque Values in this Chapter
- Servicing a Motorcycle
- Secure the Motorcycle for Service
- Maintenance Schedule (1,000 to 50,000-mile regular service intervals)
- Fuel and Oil
- Gasoline Blends and Octane Ratings
- Engine Lubrication
- Winter Lubrication
- Replace Engine Oil and Filter
- Replace Primary Chaincase Lubricant
- Replace Transmission Lubricant
- Inspect Tires and Wheels
- Adjust Wheel Spokes
- Lubricate Cables and Chassis
- Inspect Brakes
- Replace Front Brake Pads
- Replace Rear Brake Pads
- Check and Replace Brake Fluid
- Check and Adjust Clutch
- Rebuild Front Fork and Replace Oil
- Adjust and Lubricate Steering Head Bearings
- Inspect Fuel Lines and Fittings
- Inspect and Lubricate Jiffy Stand
- Inspect and Adjust Drive Belt and Sprockets
- Adjust Suspension Preload
- Inspect Exhaust System
- Inspect Air Filter (Round, Oval, and Square Configurations)
- Inspect Battery and Voltage Testing
- Clean and Inspect Spark Plugs
- Storage Procedures
- Troubleshooting Guide (Engine, Starting System, Lubrication System, Electrical System, Transmission, Handling, and Brakes)
IMAGES PREVIEW
- Chassis:
- Fastener Torque Values in this Chapter
- Chassis Specifications (Capacities, Dimensions, and Running Weights)
- Vehicle Identification Number (VIN) Breakdown and Model Codes
- Front Wheel (Removal, Installation, Hub Cap, and Disc Hardware)
- Rear Wheel (Axle Alignment and Assembly)
- Wheel Lacing: Angle Flange Hub
- Checking and Truing Wheels (Radial and Lateral Runout Limits)
- Sealed Wheel Bearings (Removal, Inspection, and Installation)
- Tires (Tube-Type and Tubeless Valve Stems, Balance, and Runout Checks)
- Wheel Alignment Procedures
- Front Brake Master Cylinder (Overhaul, Piston Replacement, and Bench Assembly)
- Front Brake Caliper (4-Piston Caliper Overhaul and Seal Replacement)
- Rear Brake Master Cylinder (Disassembly, Return Spring Setup, and Rebuild Kit Installation)
- Rear Brake Caliper (Floating Caliper Overhaul, Piston Removal, and Slider Pin Servicing)
- Brake Lines (Non-ABS and ABS Rigid/Flexible Line Routing)
- ABS Module (Removal, Frame Bracket Installation, and Digital Technician II Diagnostics)
- Bleed Brakes (Vacuum Bleeding and ABS Hydraulic Unit Bleeding)
- Engine System Architecture (Contents Listing):
- Fastener Torque Values
- Specifications and Service Wear Limits
- Oil Flow and Pressure Operations
- Diagnostic Symptom Trees
- Cylinder Heads
- Valves and Seats
- Cylinders
- Pistons
- Cam Compartment
- Needle Bearings
- Oil Pump
- Engine Replacement
- Crankcase Repair
- Flywheel
- and Oil Pan
- Drive and Transmission Architecture (Contents Listing):
- Specifications and Wear Limits
- Power Flow
- Drive Belt
- Shifter Linkage
- Clutch Release Cover
- Primary Chaincase Cover
- Hub and Clutch Pack Rebuild
- Primary Housing
- Transmission Sprocket
- Main Drive Gear
- Needle Bearings
- and Transmission Case
- Fuel and Exhaust Architecture (Contents Listing):
- Specifications
- Air Cleaner Backplate Assembly
- Instrument Console
- Fuel Pressure Test
- Fuel Line Purging
- Fuel Tank
- Internal Fuel Pump
- Injectors
- Induction Module
- Heated Oxygen Sensors (HO2S)
- Mufflers
- and California Evaporative Emission Systems
- Electrical and Wiring Systems (Contents Listing):
- Fastener Torque Values
- Fuses and Power Disconnect
- Starter
- Alternator
- Voltage Regulator
- Handlebar Control Modules (LHCM/RHCM)
- Instrument Module
- Headlamp Configurations
- Turn Signals
- Tail Lamps
- BCM
- ECM
- Security Siren
- System Sensors (CKP, ET, KS, ACR, VSS, WSS, JSS)
- Main Wire Harness
- Wiring Diagrams
- and Wire Harness Connector End Views
- Reference:
- Acronyms and Abbreviations Glossary
- Metric Conversion Tables
- United States, Metric, and British Imperial Fluid Conversions
- Backmatter:
- Service Reference Data and Indexing
This technical publication serves as an essential shop reference for the complete 2019 Softail family. While the comprehensive master table of contents outlines all major powertrain, electrical, and powertrain subsystems, this specific service release provides thorough, step-by-step procedural coverage, detailed assembly drawings, diagnostic workflows, and torque specifications focused on regular scheduled servicing, chassis mechanics, steering and suspension adjustment, wheel building, and hydraulic brake/ABS overhauls.
Scheduled Maintenance, Fluids & Adjustments
Routine service intervals dictate the longevity of your motorcycle. This manual contains the complete scheduled maintenance interval matrix spanning 1,000 miles (1,600 km) to 50,000 miles (80,000 km). Technicians will find exact fluid capacities and approved lubricant grades, including Genuine Harley-Davidson H-D 360 20W50 motor oil, Screamin’ Eagle SYN3 synthetic, Formula+ primary chaincase and transmission fluid, and DOT 4 hydraulic brake fluid. Clear step-by-step instructions guide technicians through engine oil changes, oil filter replacement using filter wrenches HD-94863-10 or HD-94686-00, primary chaincase wet (36 oz / 1.06 L) and dry (40 oz / 1.18 L) fluid refills, and transmission oil service. Mechanical clutch adjustments are detailed at the primary hub adjuster screw and two-piece clutch cable mechanism with internal spring free-play checks.
Suspension tuning is fully documented with dedicated rider/passenger/cargo preload tables for each individual chassis platform: FLDE, FLFB/FLFBS, FLHC/FLHCS, FLSB, FLSL, FXBB/FXLR, FXBR/FXBRS, FXFB/FXFBS, and FXDRS. Procedures show how to set cam-style, external hydraulic, and under-seat hydraulic shock adjusters using spanner kit 14900102. Steering head bearing adjustment includes critical pull-force testing using a 0–25 lb pull scale to verify proper steering head neck bearing preload.
Chassis, Wheels, Sealed Bearings & Alignment
The 2019 Harley-Davidson Softail Service Manual delivers deep chassis coverage, including cast and laced wheel assemblies. It includes complete wheel lacing procedures for angle flange hubs, rim offset verification, spoke tightening sequences, and truing tolerances on wheel truing stand HD-99500-80. Both lateral and radial rim runout service limits are specified at 0.76 mm (0.030 in). Sealed wheel bearing servicing outlines checking end play against the 0.051 mm (0.002 in) service limit and replacing bearings using bearing remover/installer HD-44060D, detailing critical orientations for standard and ABS encoder bearings. Rear wheel alignment procedures describe building a custom alignment rod tool or using alignment plugs HD-48856-B to ensure precise swingarm pivot-to-axle alignment and correct secondary drive belt tracking.
Hydraulic Brakes & ABS Module Service
Braking system safety is paramount. The manual provides complete rebuild and overhaul steps for front and rear master cylinders and calipers. Detailed illustrations guide the technician through front fixed four-piston caliper disassembly, cleaning with denatured alcohol, seal installation using G40M brake grease, and piston insertion. Rear caliper service covers floating slider pins, sleeve screws, and piston removal using piston removal tool HD-48648. Brake line routing and torque specifications are outlined for both non-ABS and ABS-equipped models. Procedures specify the removal, bracket mounting, and bleeding of the Anti-Lock Braking System (ABS) hydraulic control module, highlighting the mandatory use of Digital Technician II (HD-48650) and vacuum bleeder BB200A to evacuate all trapped air from the ABS valve body.
Torque Values & Mechanical Specifications
To prevent hardware failure and maintain factory structural integrity, comprehensive fastener torque tables are included throughout the text. Critical chassis torque specifications include:
| Component | Torque Specification |
|---|---|
| Front Wheel Axle | 94.9–101.6 N·m (70–75 ft-lbs) |
| Rear Axle Nut (All except FXDRS) | 128.8–142.4 N·m (95–105 ft-lbs) |
| Rear Axle Nut (FXDRS) | 149.1–162.7 N·m (110–120 ft-lbs) |
| Front Brake Caliper Mounting Bolts | 38–51.5 N·m (28–38 ft-lbs) |
| Brake Caliper Pad Hanger Pins | 14.7–19.6 N·m (11–14 ft-lbs) |
| Rear Sprocket Screws (Initial / Final) | 81.3 N·m (60 ft-lbs) / 104.4–112.5 N·m (77–83 ft-lbs) |
| Front Brake Disc Screws | 22–33 N·m (16–24 ft-lbs) |
| Rear Fork Pivot Shaft Nut | 209–230 N·m (154–170 ft-lbs) |
| Engine Oil Drain Plug | 19–28.5 N·m (14–21 ft-lbs) |
| Primary Chaincase Drain Plug | 19–28.5 N·m (14–21 ft-lbs) |
| Transmission Drain Plug | 19–28.5 N·m (14–21 ft-lbs) |
| Spark Plugs | 10–15 N·m (89–133 in-lbs) |
| Spoke Nipples | 6.2 N·m (55 in-lbs) |
Professional Workshop Reference & Instant PDF Access
The 2019 Harley-Davidson Softail Service Manual with Wiring References gives you the professional diagnostic procedures, exact wear limits, fastener torques, and assembly sequences necessary to perform work correctly the first time. Working with verified factory specifications ensures you avoid stripped threads, damaged brake seals, misaligned belts, or improper bearing preloads. Delivered as an instant PDF download immediately upon checkout, there are no shipping delays or worn paper pages to worry about. Open the file on your smartphone, tablet, workshop computer, or print out crisp, clean copies of individual repair steps right at your workbench.
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