1997-1998 Harley Davidson Softail Service Manual – PDF DOWNLOAD
DESCRIPTION:
1997-1998 Harley Davidson Softail Service Manual – PDF DOWNLOAD
FOREWORD :
- This service and repair manual has been prepared with two purposes in mind. Fi rst, it will acquaint the reader with the construction of the Harley-Davidson motorcycle and assist in performing basic maintenance and repair.
- Secondly, it will introduce to the professional Harley-Davidson technician the latest field-tested and factory-approved major repair methods. We sincerely believe that this manual will make your association with Harley-Davidson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL :
Your Service Manual is arranged for quick, easy reference. This manual is divided into numbered sections. Sections are then divided into subjects. Use this manual as follows:
In order to find the desired subject, refer to the TABLE OF CONTENTS at the front of the manual, or check the INDEX at the back of the manual.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
1997-1998 Harley Davidson Softail Service Manual – PDF DOWNLOAD
SECTION 1 – MAINTENANCE
Service Intervals 1-1
Motorcycle Side Views 1-2
Storage 1-в
Fluid Requirements 1-9
Fastener Torque Values 1-10
Metric Conversion ТаЫе н 1
Troubleshooting 1-12
General 1-12
Engine 1-12
Lubrication System 1-13
Electrical System 1-13
Carburetor 1-13
Transmission 1-13
Brakes 1-14
Handling 1-14
Shop Practices 1-15
Repair Notes 1-15
Repair and Replacement Procedures 1-15
Cleaning 1-16
Tool Safety 1-17
Tools 1-19
Scheduled Service ТаЫе
and Lubricants 1-33
Scheduled Maintenance Procedures 1-38
Battery 1-38
Engine Oil/Engine Oil Filter 1-38
Primary Chain 1-38
Primary Chaincase Lubricant 1-39
Clutch Adjustment 1-40
Transmission Lubricant 1-41
Hydraulic Lifter Oil Screen 1-41
Wheel Bearings 1-41
Wheel Spokes (if applicaЬle) 1-42
Тires 1-42
Steering Head Bearings 1-42
Rocker Bearing Adjustment (FXSTS, FXSTSB, FLSTS) 1-42
Front Fork Oil (for models with hydraulic front forks) 1-42
Brake Fluid 1 -42
Brake Pad Linings and Discs 1-43
Brake Caliper Mounting Pin 1-43
Rear Brake Pedal Height (FXSTC, FXSTS, FXSTSB) 1-43
Drive Belt 1-43
Rear Fork Pivot Bolts 1-44
Rear Shock Absorbers 1 -44
Air Cleaner 1-44
Fuel Тапk Filter 1-44
Page No
Fuel System Lines апd Fittings 1-45
Enrichener Control 1-45
Throttle СаЫеs 1-46
Engine Mounts 1-46
Spark Plugs 1-46
Electrical Components 1-47
Engine ldle Speed 1-47
lgnition Timing and V O E S 1-48
Fasteners 1-48
Road Test 1-48
SECTION 2 – CHASSIS
Specifications 2-1
Dimensions 2-1
Weight 2-1
Capacities 2-1
Tire Data 2-1
Torque Values 2-2
Vehicle ldentification Number (V I N ) 2-3
Front Wheel (Models with Hydraulic
Forks) 2-4
Removal 2-4
DisassemЫy 2-4
Cleaning and lnspection 2-4
AssemЫy 2-6
lnstallation 2-7
Front Wheel – Springer Fork
(FXSTS, FXSTSB) 2-9
Removal 2-9
DisassemЫy 2-9
Cleaning апd lnspection 2-9
AssemЫy 2-9
lnstallation 2-1 о
Front Wheel – Springer Fork (FLSTS) 2-11
Removal 2-11
DisassemЫy 2-11
Cleaning and lnspection 2-11
AssemЫy 2 -11
lnstallation 2-12
Laced or Disc Rear Wheel 2-15
Aemoval 2-15
DisassemЫy 2-16
Cleaning and lnspection 2-16
AssemЫy 2-16
lnstallation 2-17
Wheel Lacing -16 in Rim 2-19
Wheel Lacing – 21 in Aim 2-21
Truing Laced Wheel 2-2з
iii
r-c:1yt:: 1’1U
Oil Filter Mount 3-39
Removal 3-39
lnstallation 3-40
Hydraulic Valve Lifters and Guides 3-41
General 3-41
RemovaVDisassemЫy 3-41
Cleaning and lnspection 3-42
AssemЫy/lnstallation 3-42
Gearcase Cover and Timing Gears 3 -43
Generaf 3-43
DisassemЫy 3-43
AssemЬly 3-44
Cleaning and lnspection 3-46
Oil Screen 3-46
Cam and Pinion Gears 3-46
Pinion Shaft and Bearing 3 -46
Cam Shaft and Needle Bearing 3-46
Cam and Pinion Gear Bushings 3-48
Crankcase 3-51
General 3-51
Adjustment-Flywheel End Play 3-51
DisassemЫy 3-52
Flywheels 3-54
Flywheel DisassemЫy 3-54
Cleaning and lnspection 3-55
Flywheel AssemЫy 3-55
Truing Flywheels 3-56
Flywheel AssemЫy Repair 3-58
Flywheel Washers 3-58
Lapping Connecting Rod Races 3-58
Replacing Rod Bearings 3-58
EstaЫishing Proper Bearing Clearance 3-59
Repfacing Rod Bearing Outer Races 3-60
Repfacing Pinion Shaft Bearings 3-61
Removing/lnstalling Pinion Shaft lnner Race 3-62
Flywheel and Crankcase AssemЫy 3-64
lnner/Outer Sprocket Shaft Bearings lnstallation 3-64
Crankcase Torque Sequence 3-66
Cylinder Studs 3-67
Crankcase Bearing Repair 3-67
Replacing Crankcase Bearing 3-67
Lapping Crankcase Bearing 3-67
Cleaning Crankcase 3-68
Oil Tank 3-69
Removal 3-69
lnstallation 3 -69
vi
l”‘age NO
SECTION 4 – FUEL SYSTEM
Specifications 4 -1
Carburetor Jet Sizes 4-1
Fuel Tank Capacity 4-1
Torque Values 4-1
Carburetor 4-2
General 4-2
TrouЫeshooting 4-3
Vacuum Piston AssemЫy TrouЫeshooting 4-5
Operation 4-5
Enrichener 4-5
Fuel Supply System 4-6
Starter System (Enrichener) 4-7
ldle and Low Speed Circuit 4-8
Mid Range Slide Position and Fuel Discharge 4-9
High Speed Circuit Slide Position and
Fuel Discharge 4-1 о
Accelerator Pump System 4-11
Adjustments 4-12
Float Level 4-12
Float Bowl lnlet (Needle) Valve Replacement 4-12
Operation Check-Vacuum Piston 4-12
Opening Malfunction 4-12
Closing Malfunction 4-12
Carburetor Removal 4-14
lnstallation 4-16
DisassemЫy 4-16
Vacuum Piston Chamber 4-16
Carburetor Body 4-16
Accelerator Pump 4-16
Cleaning and lnspection 4-16
Vacuum Piston Components 4-16
Carburetor Body Components 4-16
Float Replacement 4-17
Accelerator Pump 4-17
AssemЫy 4-17
Vacuum Piston Chamber 4-17
Carburetor Body 4-17
Accelerator Pump 4-18
Fuel Supply Valve 4-19
General 4-19
Theory of Operation 4-19
Removal 4-19
Cleaning and lnspection 4-20
lnstallation 4-20
TrouЫeshooting 4-20
Diaphragm Replacement 4-21
Vacuum Test 4·21
Fuel Tank 4-22
General 4-22
Removal 4-22
Cleaning and lnspection 4-22
lnstallation 4-23
Vapor Valve 4-23
Air Cleaner – General 4-24
Removal 4-24
Cleaning and lnspection 4-24
lnstallation 4-25
Ai r Cleaner Backplate AssemЫy -California Models 4-26
1-‘age No PageNo
Evaporative Emissions Control – SECTION б – DRIVE
California Models Only 4-27
General 4-27
CharcoaJ Canister 4-28
Removal 4-28
lnstallation 4-28
Hose Routing/Replacement 4-29
Canister to Air Cleaner Hose 4-29
Exhaust System (Shorty Dual Exhaust) 4-30
Removal 4-30
DisassemЫy 4 -30
AssemЫy 4-30
lnstallation 4-30
Exhaust System (FLSTS) 4-32
Removal 4-32
lnstallation 4-32
SECTION 5 – ELECTRIC STARTER
Specifications 5-1
Starter Motor 5-1
Service Wear Limits 5-1
Torque Values 5-1
Starter System 5 2
General 5-2
Operation 5-2
DiagnosticsrrrouЫeshooting 5-4
General 5-4
Voltage Drops 5-4
Starting Activation Circuits 5-5
Starting System Diagnosis 5-6
TrouЫeshooting 5-8
Starter 5-10
On Motorcycle Testing 5-1 О
Removal 5-1 О
lnstallation 5-11
Testing AssemЫed Starter 5-11
DisassemЫy and Testing 5-14
AssemЫy 5-18
Starter Solenoid 5 19
General 5-19
DisassemЫy 5-19
AssemЫy 5-1 9
Starter Jackshaft 5-20
RemovaVOisassemЫy 5-20
Assembly/lnstallation 5-21
Specifications 6-1
Clutch (1997/1998 Models) 6-1
Sprockets 6-1
Overall Gear Ratios 6-1
Torque Values 6-1
Primary Chaincase 6-2
General 6-2
Primary Chaincase Cover 6-2
Removal 6-2
lnstallation 6-2
Primary Chaincase Housing 6-2
Removal 6-2
lnspection 6-3
lnstallation 6-3
Drive Components 6-5
Primary Chain 6-5
Removal 6-5
lnstallation 6-5
Sprocket Alignment 6-6
Compensating Sprocket 6-7
Chain Tensioner Shoe 6-7
Clutch (1997 Models) 6-8
DisassemЫy оп Motorcycle 6-8
Complete Clutch DisassemЫy 6 -8
Cleaning алd lnspection 6-10
AssemЫy 6-11
Clutch (1998 Models) 6-12
General 6-12
Removal/lnstallation 6-12
Partial DisassemЫy-Clutch Pack Only 6-12
AssemЫy-Clutch Pack Only 6-12
Cleaning and lnspection 6-12
Complete DisassemЫy-Clutch Pack and Bear1ng 6-14
AssemЫy-Clutch Pack and Bearing 6-15
Transmission Sprocket 6-16
Removal 6-16
Cleaning and lnspection 6-16
lnstallation 6-16
Drive Belt and Sprocket 6-18
General 6-18
Removal 6-18
lnstallation 6-18
vii
Handlebar Switch AssemЫies 8-69
General 8-69
Removal 8-69
lnstallation 8 -69
Switch Repair/Replacement 8-72
APPENDIX А – ELECTRICAL
CONNECTORS
Amp Multilock Electrical Connectors д-з
Removing Socket/Pin Terminals А-3
lnstalling Socket/Pin Terminals А-3
Crimping lnstructions А-6
Deutsch Electrical Connectors д-7
Removing/DisassemЫing А-7
Removing/lnstalling Sockets А-7
Removing/lnstalling Pins А-9
AssemЫing/lnstalllng А-9
Crimping lnstructions А-1 О
Sealed Butt Connectors д-12
lnstalling Sealed Butt Connectors А-12
Packard Electrical Connectors д-1з
Push-To-Seat Terminals
Removing
lnstalling
Crimping lnstructions
Amp Electrical Connectors
1-Place Connector
Socket Terminal Removal
Socket Terminal lnstallation
Pin Terminal Removal
Pin Terminal lnstallation
Crimping ТаЫеs д-17
General А-19
Crimping lnformation А-19
Crimping ТаЫе Legend А-19
1997 Components А-19
1997 Main Harness А-20
1997 Starter to 30 А Circuit Breaker А-20
1997 Passing Lamp Hamess А-20
1997 Rear Lighting Harness А-20
1998 Components А-21
1998 Main Harness А-21
1998 Starter to 30 А Circuit Breaker А-21
1998 Passing Lamp Harness А-22
1998 Rear Lighting Harness А-22
CONNECTOR LOCATIONS д-23
1997 and 1998 Softail Electrical Connector Locations А-25
WIRING DIAGRAMS д-27
1997 Softail Wiring Diagrams А-27
Main Wiring Diagram
lnstruments
Headlamp, Front/Rear Turn Signals and Tailamp
1998 Softail Wiring Diagrams
Main Wiring Diagram
lnstruments
Headlamp, Front/Rear Turn Signals and Tailamp
INDEX
VIDEO PREVIEW OF THE MANUAL:
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- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
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