1997-1998 Harley Davidson Softail Service Manual – PDF DOWNLOAD

1997-1998 Harley Davidson Softail Service Manual – PDF DOWNLOAD

DESCRIPTION:

1997-1998 Harley Davidson Softail Service Manual – PDF DOWNLOAD

• Proper preparation is very important for efficient service work. Acleanwork area at the start of each job will allow you to perform the repair as easily and quickly as possible. and reduce the incidenceof misplaced tools and parts. A motorcycle that is excessively dirty should be cleaned before work starts. Cleaning will occasionally uncover trouble sources.
• Tools. instrumentsand parts needed for the job should be gathered belore work is started. Interrupting a job to locate tools or parts is a needless delay. Special tools required for a job are listedat the end of Section 1.

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 1-8
Fluid Requirements 1-9
Fastener Torque Values 1-10
Metric Conversion Table 1-11
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 Table
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 applicable) 1-42
nres 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 Tank Filter 1-44
Page No
Fuel System Lines and Fittings 1-45
Enrichener Control 1-45
Throttle Cables 1-46
Engine Mounts 1-46
Spark Plugs 1-46
Electrical Components 1-47
Engine Idle Speed 1-47
Ignition Timing and V O E S 1·48
Fasteners 1-48
Road Test 1-48
SECTION 2 – CHASSIS
Speclfications 2-1
Dimensions 2-1
Weight 2-1
Capacities 2-1
Tire Data 2-1
Torque Values 2-2
Vehicle Identification Number (V I N ) 2-3
Front Wheel (Models with Hydraulic
Forks) 2-4
Removal 2-4
Disassembly 2-4
Cleaning and Inspection 2-4
Assembly 2·6
Installation 2-7
Front Wheel – Springer Fork
(FXSTS, FXSTSB) 2-9
Removal 2-9
Disassembly 2-9
Cleaning and Inspection 2-9
Assembly 2-9
Installation 2-10
Front Wheel – Springer Fork (FLSTS) 2-11
Removal 2-11
Disassembly 2-11
Cleaning and Inspection 2-11
Assembly 2-11
Installation 2·12
Laced or Disc Rear Wheel 2-15
Removal 2-15
Disassembly 2-16
Cleaning and Inspection 2-16
Assembly 2-16
Installation 2-17
Wheel Lacing – 16 in Rim 2-19
Wheel Lacing – 21 in Rim 2·21
Truing Laced Wheel 2-23
iii
Oil Filter Mount 3-39
“‘i:tg~NU
Removal
Installation
Hydraulic Valve Ufters and Guides
General
Removal/Disassembly
Cleaning and Inspection
Assemblyllnstallation
Gearcase Cover and Timing Gears
General
Disassembly
Assembly
Cleaning and Inspection
Oil Screen
Cam and Pinion Gears
Pinion Shaft and Bearing
Cam Shaft and Needle Bearing
Cam and Pinion Gear Bushings
Crankcase
General
Adjustment – Rywheel End Play
Disassembly
Flywheels
Flywheel Disassembly
Cleaning and Inspection
Flywheel Assembly
Truing Flywheels
Flywheel Assembly Repair
Flywheel Washers
Lapping Connecting Rod Races
Replacing Rod Bearings
Establishing Proper Bearing Clearance
Replacing Rod Bearing Outer Races
Replacing Pinion Shaft Bearings
Removing/Installing Pinion Shaft Inner Raoe
Flywheel and Crankcase Assembly
Inner/Outer Sprocket Shaft Bearings Installation
Crankcase Torque Sequence
Cylinder Studs
Crankcase Bearing Repair
Replacing Crankcase Bearing
Lapping Crankcase Bearing
Cleaning Crankcase
Oil Tank 3-69
Removal 3-69
Installation 3-69
vi
SECTION 4 – FUEL SYSTEM
Specifications
Carburetor Jet Sizes _
Fuel Tank Capacity
Torque Values
Carburetor
General
Troubleshooting
Vacuum Piston Assembly Troubleshooting
Operation ‘”
Enrichener
Fuel Supply System
Starter System (Enrichener)
Idle and Low Speed Circuit
Mid Range Slide Position and Fuel Discharge
High Speed Circuit Slide Position and
Fuel Discharge _
Accelerator Pump System
Adjustments
Float LeveL
Float Bowl Inlet (Needle) Valve Replacement
Operation Check – Vacuum Piston
Opening Malfunction
Closing Malfunction
Carburetor Removal
Installation
Disassembly
Vacuum Piston Chamber _
Carburetor Body
Accelerator Pump
Cleaning and Inspection
Vacuum Piston Components
Carburetor Body Components
Roat Replacement
Accelerator Pump
Assembly
Vacuum Piston Chamber
Carburetor Body
Accelerator Pump
Fuel Supply Valve
General
Theory of Operation
Removal
Cleaning and Inspection
Installation
Troubleshooting
Diaphragm Replacement
Vacuum Test _
Fuel Tank
General ‘”
Removal
Cleaning and Inspection
Installation
Vapor Valve
Air Cleaner – General 4-24
Removal 4-24
Cleaning and Inspection 4-24
Installation 4-25
Air Cleaner Backplate Assembly -California Models 4-26
page NO Page No
Evaporative Emissions Control – SECTION 6 – DRIVE
California Models Only 4-27
General 4-27
Charcoal Canister 4-28
Removal 4-28
Installation 4-28
Hose Routing/Replacement 4-29
Canister to Air Cleaner Hose 4-29
Exhaust System (Shorty Dual Exhaust) 4-30
Removal 4-30
Disassembly 4-30
Assembly 4-30
Installation 4-30
Exhaust System (FLSTS) 4-32
Removal 4-32
Installation 4-32
SECTION 5 – ELECTRIC STARTER
Specifications 5-1
Starter Motor 5-1
Service Wear Umits 5-1
Torque Values 5-1
Starter System 5-2
General 5-2
Operation 5-2
DiagnosticslTroubleshooting 5-4
General 5-4
Voltage Drops 5-4
Starting Activation Circuits 5-5
Starting System Diagnosis 5-6
Troubleshooting 5-8
Starter 5-10
On Motorcycle Testing 5-10
Removal 5-10
Installation 5-11
Testing Assembled Starter 5-11
Disassembly and Testing 5-14
Assembly 5-18
Starter Solenoid 5-19
General 5-19
Disassembly 5-19
Assembly 5-19
Starter Jackshaft 5-20
Removal/Disassembly 5-20
Assemblyllnstallation 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
Installation 6-2
Primary Chaincase Housing 6-2
Removal 6-2
Inspection 6-3
Installation 6-3
Drive Components 6-5
Primary Chain 6-5
Removal 6-5
Installation 6-5
Sprocket Alignment 6·6
Compensating Sprocket 6·7
Chain Tensioner Shoe 6·7
Clutch (1997 Models) 6-8
Disassembly on Motorcycle 6-8
Complete Clutch Disassembly 6·8
Cleaning and Inspection 6-10
Assembly 6-11
Clutch (1998 Models) 6-12
General 6-12
RemovaVlnstallation 6-12
Partial Disassembly-Clutch Pack Only 6·12
Assembly-Clutch Pack Only 6-12
Cleaning and Inspection 6-12
Complete Disassembly-Clutch Pack and Bearing 6-14
Assembly-Clutch Pack and Bearing 6-15
Transmission Sprocket 6-16
Removal 6-16
Cleaning and Inspection 6-16
Installation 6-16
Drive Belt and Sprocket 6-18
General 6-18
Removal 6-18
Installation , 6-18
vii
Handlebar Switch Assemblies
General
Removal
Installation
Switch Repair/Replacement
APPENDIX A – ELECTRICAL
CONNECTORS
Amp Multilock Electrical Connectors
Removing Socket/Pin Terminals
Installing Socket/Pin Terminals
Crimping Instructions
Deutsch Electrical Connectors
Removing/Disassembling
Removing/Installing Sockets
Removing/Installing Pins
Assembling/Installing
Crimping Instructions
Sealed Butt Connectors
Installing Sealed Butt Connectors
Packard Electrical Connectors
Push- To-Seat Terminals
Removing
Installing
Crimping Instructions
Amp Electrical Connectors
‘t-Place Connector
Socket Terminal Removal
Socket Terminal Installation
Pin Terminal Removal
Pin Terminal Installation
Crimping Tables _
General ‘”
Crimping Information
Crimping Table Legend
1997 Components
1997 Main Harness
1997 Starter to 30 A Circuit Breaker
1997 Passing Lamp Harness
1997 Rear Lighting Harness
1998 Components
1998 Main Harness
1998 Starter to 30 A Circuit Breaker
1998 Passing Lamp Harness
1998 Rear Lighting Harness
CONNECTOR LOCATIONS
1997 and 1998 Softail Electrical Connector Locations
WIRING DIAGRAMS
1997 Softail Wiring Diagrams
Main Wiring Diagram
Instruments
Headlamp, Front/Rear Turn Signals and Tailamp
1998 Softail Wiring Diagrams
Main Wiring Diagram
Instruments
Headlamp, Front/Rear Turn Signals and Tailamp
INDEX

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1997-1998 Harley Davidson Softail Service Manual – PDF DOWNLOAD

1997-1998 Harley Davidson Softail Service Manual – PDF DOWNLOAD

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

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