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.