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Harley Davidson Softail 1984-1999. Service manual - page 3

TROUBLESHOOTING

Every motorcycle engine requires an uninterrupted supply of fuel and air. proper ignition and adequate compression. If any of these are lacking, the engine will not run.

Diagnosing mechanical problems is relatively simple if you use orderly procedures and keep a few basic principles in mind.

The troubleshooting procedures in this chapter analyze typical symptoms and show logical methods of isolating causes. These are not the only methods. There may be several ways to solve a problem, but only a systematic approach can guarantee success.

Never assume anything. Do not overlook the obvious. If you are riding along and the bike suddenly quits, check the easiest, most accessible problem spots first. Is there gasoline in the tank? Has a spark plug wire fallen off?

If nothing obvious turns up in a quick check, look a little further. Learning to recognize and describe symptoms will make repairs easier for you or a mechanic at the shop. Describe problems accurately and fully. Saying “it won’t run” isn’t the same thing as saying “it quit at high speed and won’t start,” or “it sat in my garage for 3 months and then wouldn’t start.”

Gather as many symptoms as possible to aid in diagnosis. Note whether the engine lost power gradually or all at once. Remember that the more
complicated a machine is, the easier it is to troubleshoot because symptoms point to specific problems.

After the symptoms are defined, areas which could cause problems are tested and analyzed. Guessing at the cause of a problem may provide the solution, but it can easily lead to frustration, wasted time and a series of expensive, unnecessary parts replacements.

You do not need fancy equipment or complicated rest gear to determine whether repairs can be attempted at home. A few simple checks could save a large repair bill and lost time while the bike sits in a dealer’s service department. On the other hand, be realistic and do not attempt repairs beyond your abilities. Service departments tend to charge heavily for putting together a disassembled engine that may have been abused. Some won’t even take on such a job—so use common sense, don’t get in over your head.

Table 1 (electrical specifications) is at the end of the chapter.

OPERATING REQUIREMENTS

An engine needs 3 basics to run properly: correct fuel/air mixture, compression and a spark at the correct time (Figure 1). If one or more are missing,

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