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99466-98_cvr:RERUN_OWNRS MANUAL
8/6/08
10:03 AM
Page 1
Part No. 99466-98
Printed in U.S.A.
*99466-98*
Harley-Davidson Motor Company
Technical Communications
Milwaukee, WI 53201
IMPORTANT NOTICE!
Statements in this manual preceded by the following words are of special significance:
1WARNING
Means there is the possibility of injury to yourself or others.
1CAUTION
Means there is a possibility of damage to the vehicle.
NOTE
Other information of particular importance has been placed in italic type.
We recommend you take special notice of these items.
This motorcycle is not equipped with a spark arrester and is designed to be used only on the road.
Operation off-road in some areas may be illegal. Obey local laws and regulations. This manual should be
considered a permanent part of the motorcycle and should remain with the motorcycle when resold.
Printed in the U.S.A.
99466-98
99466-98
YOUR OWNER’S MANUAL
Welcome to the Harley-Davidson Motorcycling Family! Your new Harley-Davidson motorcycle is designed and manufactured to
be the finest in its field. Your Harley-Davidson motorcycle conforms to all applicable U.S. Federal Motor Vehicle Safety Standards
and U.S. Environmental Protection Agency regulations effective on the date of manufacture.
This manual has been prepared to acquaint you with the operation, care and maintenance of your motorcycle, and to provide you
with important safety information. Follow these instructions carefully for maximum motorcycle performance and for your personal
motorcycling safety and pleasure.
Your Owner’s Manual contains instructions for operation and minor maintenance. Major repairs are covered in the HarleyDavidson Service Manual. Such major repairs require the attention of a skilled technician and the use of special tools and
equipment. Your Harley-Davidson dealer has the facilities, experience and Genuine™ Harley-Davidson parts necessary to
properly render this valuable service. We recommend that any emission system maintenance be performed by an authorized
Harley-Davidson dealer.
WE CARE ABOUT YOU
When enjoying your Harley-Davidson motorcycle, be sure to ride safely, defensively and within the limits of the law. Ride with
your headlamp on, always wear a helmet, proper eyewear and protective clothing, and insist your passenger does too. Never ride
while under the influence of alcohol or drugs. Know your Harley® and read your Owner’s Manual cover to cover. Protect your
privilege to ride by joining the American Motorcyclist Association.
Harley-Davidson Motor Company
©COPYRIGHT 1997
HARLEY-DAVIDSON MOTOR COMPANY
ALL RIGHTS RESERVED
CMI-.75M-08/08
Printed in the U.S.A.
i.
99466-98
PERSONAL INFORMATION
VEHICLE INFORMATION
Name
Vehicle Identification No.
Address
Ignition Key No.
Telephone No.
This owner’s manual illustrates and describes features that are standard or available as extra cost options. Therefore, some of
the equipment shown in this publication may not be on your motorcycle.
ii.
99466-98
TABLE OF CONTENTS
Page No.
TOURING.................................................................. 1
VEHICLE IDENTIFICATION
NUMBER (V.I.N.)
FLHT/C/ULTRA/I,
FLHR/I, FLTR/I...................................................... 3
SPECIFICATIONS .......................................... 17
Dimensions ...................................................................... 17
Weight .............................................................................. 17
Capacities ........................................................................ 17
Ignition System................................................................. 17
Spark Plugs...................................................................... 17
Engine .............................................................................. 18
Transmission.................................................................... 18
Number of Sprocket Teeth ............................................... 18
Overall Gear Ratios.......................................................... 18
Tire Data .......................................................................... 18
Fuel .................................................................................. 20
Gasoline Blends ............................................................... 20
Catalytic Converter............................................................ 21
Bulb Chart - FLHT/C/ULTRA/I, FLHR/I, FLTR/I ............... 22
CUSTOM .................................................................. 25
Page No.
VEHICLE IDENTIFICATION
NUMBER (V.I.N.)
FLSTC/F/S, FXSTC/S, FXD/L/WG,
FXDS-CON ............................................................ 27
SPECIFICATIONS ........................................... 47
Dimensions ...................................................................... 47
Weight .............................................................................. 47
Capacities ........................................................................ 47
Ignition System................................................................. 48
Spark Plugs...................................................................... 48
Engine .............................................................................. 48
Transmission.................................................................... 48
Number of Sprocket Teeth ............................................... 48
Overall Gear Ratios.......................................................... 48
FLSTC/F/S, FXSTC/S Models .................................. 48
FXD Models .............................................................. 48
Tire Data .......................................................................... 48
Fuel .................................................................................. 50
Gasoline Blends ............................................................... 50
Catalytic Converter............................................................ 51
Bulb Chart - FLSTC/F/S, FXSTC/S.................................. 52
Bulb Chart - FXD/L/WG/CON........................................... 54
iii.
99466-98
Page No.
SPORTSTER ........................................................ 57
VEHICLE IDENTIFICATION NUMBER
(V.I.N.) ....................................................................... 59
SPECIFICATIONS ........................................... 69
Dimensions ...................................................................... 69
Weight .............................................................................. 69
Capacities ........................................................................ 69
Ignition System................................................................. 69
Spark Plugs...................................................................... 69
Engine .............................................................................. 70
Transmission.................................................................... 70
Number of Sprocket Teeth ............................................... 70
Overall Gear Ratios.......................................................... 70
Tire Data .......................................................................... 70
Fuel .................................................................................. 71
Gasoline Blends ............................................................... 72
Catalytic Converter............................................................ 72
Bulb Chart - XLH....................................................... 73
SAFETY FIRST .................................................. 75
Safe Operating Rules....................................................... 75
Rules of the Road ............................................................ 79
Accessories and Cargo .................................................... 80
Page No.
CONTROLS AND INDICATORS .........83
Ignition/Light Key Switch ..................................................
Electric Starter Switch ......................................................
Engine Stop Switch ..........................................................
Throttle Control Grip.........................................................
Enrichener - Carbureted Models Only..............................
Constant Velocity (C.V.) Carburetor Enrichener
-Carbureted Models Only ..........................................
Clutch Hand Lever............................................................
Gear Shifter ......................................................................
Brakes ..............................................................................
Horn Switch ......................................................................
Headlamp Dimmer Switch................................................
Passing/Fog Lamp Switch - FLT, FLHR/C-I, FLSTS and
FLSTC Models .................................................................
Cruise Control - Ultra Models ...........................................
Theory of Operation ..................................................
Controls.....................................................................
Operation ..................................................................
Turn On the System ..................................................
Activate the System ..................................................
Set.............................................................................
Resume.....................................................................
Accelerate, Decelerate..............................................
De-activate/Turn Off the System...............................
De-activate the System .............................................
iv.
99466-98
83
86
86
86
88
88
88
89
90
90
90
90
91
91
91
92
92
93
93
93
93
93
93
Page No.
Turn Off the System................................................... 94
Turn Signal Switches - General........................................ 94
Turn Signal Switch Operation........................................... 94
Hazard Warning 4-way Flasher (Turn Signal Switches)... 95
Accessory Switch ..............................................................95
Sound System Controls.................................................... 95
Indicator Lights ................................................................. 96
XL Sport Indicator Lights ...................................................96
Ultra Models Indicator Lights............................................ 97
Sequential Port Fuel Injected Models Indicator Lights ..... 98
Tachometer ...................................................................... 98
Speedometer/Odometer................................................... 98
Trip odometer (Mechanical) ..............................................99
Electronic Speedometer ................................................. 100
Mirrors (Convex)............................................................. 100
Oil Pressure Gauge........................................................ 101
Voltmeter .........................................................................101
Clock (In Radio).............................................................. 101
Fuel Gauge......................................................................101
Jiffy Stand....................................................................... 101
Fork Lock........................................................................ 102
Fuel Supply Valve - Carbureted Models Only ................ 104
Fuel Filler Cap ................................................................ 105
Suspension Adjustments................................................ 106
Procedure A - Air Suspension Adjustments ....................106
FLT Models ............................................................. 106
Procedure B - Rear Shock Absorber Spring Adjustment 108
Page No.
Softail Models ......................................................... 108
Procedure C - Rear Shock Absorber Spring Adjustment 109
FXDL/WG/CON, XLH Models................................. 109
Procedure D - Suspension Adjustments - XL Sport ....... 110
Spring Preload......................................................... 111
Front Suspension Adjustments................................ 113
Rear Suspension Adjustments ................................ 114
Suspension Troubleshooting ................................... 116
Luggage......................................................................... 117
FLT Models.................................................................... 117
Tour-Pak Removal.................................................. 117
FLT Models Saddlebag Operation................................. 118
Open....................................................................... 118
Close ...................................................................... 119
Removal ................................................................. 119
Installation .............................................................. 119
Adjustments............................................................ 119
FLHRC-I Saddlebag Operation...................................... 119
Open....................................................................... 119
Close ...................................................................... 119
FLHR/C-I Windshield ...................................................... 121
Removal ................................................................. 121
Installation .............................................................. 121
FXDS-Con Saddlebags .................................................. 122
Removal ................................................................. 122
Installation .............................................................. 122
FXDS-Con Windshield ................................................... 124
v.
99466-98
Page No.
Removal.................................................................. 124
Installation............................................................... 124
FLSTS and FLHR Passenger Seat................................. 126
Removal.................................................................. 126
Installation............................................................... 126
OPERATION ....................................................... 127
Operating Recommendations ........................................ 127
Break-in - The First 500 Miles ........................................ 128
Pre-riding Checklist ........................................................ 128
Starting the Engine ........................................................ 129
General .......................................................................... 129
Carbureted Models.......................................................... 129
Cool Engine.................................................................... 130
Outside Temperature Cooler Than 50° .......................... 130
Cool Engine.................................................................... 130
Outside Temperature Warmer Than 50° ........................ 130
Warm or Hot Engine....................................................... 130
Sequential Port Fuel Injected Models ............................ 131
Stopping the Engine....................................................... 131
Shifting Gears ................................................................ 132
MAINTENANCE AND
LUBRICATION................................................. 135
Safe Operating Maintenance ......................................... 135
Break-in Maintenance .................................................... 135
Check at First 500 Miles................................................. 136
Page No.
Lubrication Summary ..................................................... 138
Regular Service Intervals ............................................... 139
Engine Lubrication.......................................................... 142
Checking Oil Level ......................................................... 142
Engine Oil Filter.............................................................. 145
Winter Lubrication .......................................................... 145
Hydraulic Lifter Oil Filter Screen (1340cc
Engines Only).......................................................... 146
Transmission Lubrication ............................................... 147
1340cc Models ........................................................ 147
Primary Chaincase Lubrication - General ...................... 148
Checking Chaincase Lubricant....................................... 148
1340cc Models ........................................................ 148
XLH Models............................................................. 150
Primary Chain................................................................. 151
Rear Drive Belt ............................................................... 151
Chassis Lubrication .........................................................152
Greasing..........................................................................152
Oil Applications............................................................... 152
Front Fork Oil ................................................................. 153
Fuel Strainer................................................................... 153
Carburetor ...................................................................... 153
Air Cleaner ..................................................................... 153
Hydraulic Lifters.............................................................. 154
Clutch ............................................................................. 155
Brakes ............................................................................ 155
Tires ............................................................................... 158
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99466-98
Page No.
Shock Absorbers ............................................................ 158
Vehicle Alignment........................................................... 158
Isolation Mounted Engine Models .................................. 158
All Models....................................................................... 159
Wheel Bearings .............................................................. 159
Front Fork Bearings........................................................ 159
Rear Fork Pivot Shaft ..................................................... 159
Spark Plugs .................................................................... 160
Ignition Timing ................................................................ 160
Headlamp ....................................................................... 161
Alternator Charging Rate and Voltage Regulator........... 162
Battery ............................................................................ 162
Battery Sulfation ............................................................. 164
Jump-Starting Procedure ............................................... 165
Seat ................................................................................ 167
Removal .................................................................. 167
Installation ............................................................... 168
Dyna Glide Battery and Cover Removal ........................ 168
Battery and Cover Installation ........................................ 169
Circuit Breakers.............................................................. 169
Fuses.............................................................................. 169
FLT Model Fuse Replacement ........................................169
XL Models Fuse Replacement ........................................173
General Maintenance ..................................................... 174
Cleaning Your Motorcycle .............................................. 174
Accessories Maintenance .............................................. 175
Leather .................................................................... 175
Page No.
Cloth ....................................................................... 176
Vinyl........................................................................ 176
Windshields ............................................................ 176
Whitewall Tires ....................................................... 176
Hinges, Latches - Fuel Door, Tour-Pak®,
Saddlebags - FLT Models ...................................... 177
Storage .......................................................................... 178
Placing Motorcycle in Storage ....................................... 178
Removal from Storage................................................... 180
RIDER TROUBLESHOOTING ........... 181
General ........................................................................... 181
Engine............................................................................. 181
Starter Does Not Operate Or Does Not
Turn Engine Over ................................................... 181
Engine Turns Over But Does Not Start .................. 181
Starts Hard ............................................................. 181
Starts But Runs Irregularly or Misses ..................... 182
A Spark Plug Fouls Repeatedly.............................. 182
Pre-ignition or Detonation (Knocks or Pings) ......... 182
Overheats ............................................................... 182
Excessive Vibration ................................................ 182
Lubrication System ........................................................ 182
Oil Does Not Return to Oil Tank ............................. 182
Engine Leaks Oil from Cases, Push Rods, Hoses . 183
Electrical System ........................................................... 183
Alternator Does Not Charge ................................... 183
vii.
99466-98
Page No.
Alternator Charge Rate is Below Normal ................
Carburetor ......................................................................
Carburetor Floods ...................................................
Transmission..................................................................
Transmission Shifts Hard........................................
Transmission Jumps Out of Gear ...........................
Clutch Slips .............................................................
Clutch Drags or Does Not Release.........................
Clutch Chatters .......................................................
Brakes ............................................................................
Brakes Do Not Hold Normally .................................
183
183
183
183
183
183
183
183
183
184
184
WARRANTY AND
RESPONSIBILITIES .................................... 185
Owner’s Identification Card ............................................ 185
Warranty and Maintenance ............................................ 185
California Evaporative Emission Control........................ 187
EPA Noise Regulations.................................................. 187
Warranty/Service Information......................................... 187
Reporting Safety Defects ............................................... 188
NHTSA Statement.......................................................... 188
Harley-Davidson Limited Warranty ................................. 189
Limited Warranty Transfer Form (Sample)..................... 190
Harley-Davidson Emission Control System Warranty.... 191
Harley-Davidson Noise Control System Warranty ......... 192
Page No.
MAINTENANCE CHECK-OFF
COUPONS ............................................................193
500 Mile Maintenance .................................................... 193
2500 Mile Maintenance .................................................. 195
5000 Mile Maintenance .................................................. 197
7500 Mile Maintenance .................................................. 199
10,000 Mile Maintenance ............................................... 201
12,500 Mile Maintenance ................................................203
15,000 Mile Maintenance ................................................205
17,500 Mile Maintenance ................................................207
20,000 Mile Maintenance ................................................209
22.500 Mile Maintenance ................................................211
25,000 Mile Maintenance ................................................213
27,500 Mile Maintenance ................................................215
30,000 Mile Maintenance ................................................217
32,500 Mile Maintenance ................................................219
35,000 Mile Maintenance ................................................221
37,500 Mile Maintenance ................................................223
40,000 Mile Maintenance ................................................225
42,500 Mile Maintenance ................................................227
45,000 Mile Maintenance ................................................229
47,500 Mile Maintenance ................................................231
50,000 Mile Maintenance ................................................233
SERVICE LITERATURE .......................... 235
INDEX .......................................................................237
viii.
99466-98
LIST OF
Page ILLUSTRATIONS
No.
Figure
Page No.
FLHTC Ultra/I - Left Side View ......................................... 4
FLHTC Ultra/I - Right Side View....................................... 5
FLHTC/I - Left Side View.................................................. 6
FLHTC/I - Right Side View ............................................... 7
FLHT - Left Side View ...................................................... 8
FLHT - Right Side View.................................................... 9
FLHR - Left Side View.................................................... 10
FLHR - Right Side View ................................................. 11
FLHRC-I - Left Side View ................................................ 12
FLHRC-I - Right Side View.............................................. 13
FLTR/I - Left Side View ................................................... 14
FLTR/I - Right Side View................................................. 15
FLSTC - Left Side View.................................................. 28
FLSTC - Right Side View ............................................... 29
FLSTF - Left Side View .................................................. 30
FLSTF - Right Side View................................................ 31
FLSTS - Left Side View .................................................. 32
FLSTS - Right Side View................................................ 33
FXSTC - Left Side View ................................................. 34
FXSTC - Right Side View ............................................... 35
FXSTS - Left Side View.................................................. 36
FXSTS - Right Side View ............................................... 37
FXDL - Left Side View .................................................... 38
FXDL - Right Side View.................................................. 39
FXDWG - Left Side View................................................ 40
Figure
Page No.
Page No.
FXDWG - Right Side View.............................................. 41
FXDS-CONV - Left Side View ........................................ 42
FXDS-CONV - Right Side View ...................................... 43
FXD - Left Side View ...................................................... 44
FXD - Right Side View .................................................... 45
XLH 1200 - Left Side View.............................................. 60
XLH 1200 - Right Side View ........................................... 61
XLH 1200C - Left Side View ........................................... 62
XLH 1200C - Right Side View......................................... 63
XLH 1200S - Left Side View ........................................... 64
XLH 1200S - Right Side View......................................... 65
XLH 883 - Left Side View (Typical)................................. 66
XLH 883 - Right Side View (Typical) .............................. 67
Figure 1. Ignition/Light Key Switch............................... 83
Figure 2. Handlebar Controls....................................... 87
Figure 3. Setting the Enrichener .................................. 88
Figure 4. Gear Shifter .................................................. 89
Figure 5. Cruise, Speakers, Acc.,
Passing Lamp Controls................................. 92
Figure 6. Sound System/Cruise Control Handlebar
Controls ........................................................ 96
Figure 7. Indicator Lights ............................................. 97
Figure 8. Indicator Lamps .............................................99
Figure 9. Speedometer, Odometer, Trip-odometer,
Tachometer................................................... 99
ix.
99466-98
Figure
Figure 10.
Figure 11.
Figure 12.
Figure 13.
Figure 14.
Figure 15.
Figure 16.
Figure 17.
Figure 18.
Figure 19.
Figure 20.
Figure 21.
Figure 22.
Figure 23.
Figure 24.
Figure 25.
Figure 26.
Figure 27.
Figure 28.
Figure 29.
Figure 30.
Figure 31.
Figure 32.
Figure 33
PageNo.
No.
Page
Mirror.......................................................... 100
Jiffy Stand (Typical).................................... 101
Fork Lock - Softail, XLH Models................. 102
Dyna Glide Fork Lock................................. 103
Road King Fork Lock................................... 103
Fuel Supply Valve ...................................... 104
Fuel Filler Cap............................................ 105
Air Suspension Components FLT Models ................................................ 108
Shock Adjustment - Softail Models ............. 109
Shock Adjustment - XLH, FX/DL/DWG ...... 110
XL Sport Preload Measurement.................. 112
Front Suspension Adjustments ................... 113
Rear Suspension Adjustments.................... 114
Tour-Pak Lock and Drawcatch................... 117
Tour-Pak Installation - FLT......................... 118
FLT Models Saddlebags ............................ 120
Road King Windshield................................. 121
FXDS Convertible Saddlebag Frame
Attachment .................................................. 123
FXDS-CON Windshield............................... 125
Seat Mounting Hole Plug ............................ 126
5 - Speed Shifting Sequence ..................... 134
Fill Plug Dipstick & Oil Tank Drains............ 143
Engine Oil Level - XLH/Softail Models ....... 143
Engine Oil Filter.......................................... 145
Figure
Figure 34.
Figure 35.
Figure 36.
Figure 37.
Figure 38.
Figure 39.
Figure 40.
Figure 41.
Figure 42.
Figure 43.
Figure 44.
Figure 45.
Figure 46.
Figure 47.
Figure 48.
Figure 49.
Figure 50.
Figure 51.
Figure 52.
Figure 53.
Figure 54.
Figure 55.
x.
99466-98
Page
Page No.
No.
Hydraulic Lifter Filter Screen ...................... 146
Transmission Lubricant Dipstick - 1340cc.. 147
Primary Chaincase ..................................... 149
Belt Deflection ............................................ 151
Air Cleaner ................................................. 154
Clutch Control Cable (Typical) ................... 155
Brake Pad - Side View ............................... 156
Measuring Rear Brake Outer
Pad - 1340cc Models.................................. 157
Measuring Rear Brake Outer Pad - 883cc,
1200cc Models ........................................... 157
Headlamp ................................................... 161
Voltage Regulator....................................... 162
Battery ........................................................ 163
Jump Start Cable Connections................... 166
Seat and Mounting Hardware (Typical)...... 167
Dyna Glide Battery Tray and
Mounting Hardware .................................... 168
Left Side cover Removed ........................... 170
Fuse Blocks................................................ 171
Fuse Block Cover ....................................... 171
XL Side Cover ............................................ 173
XL Fuse Block ............................................ 174
FLT Models Saddlebag Latch .................... 177
Owner’s Warranty Identification Card......... 185
PageTABLES/CHARTS
No.
LIST OF
Table
Table 1.
Table 2.
Table 3.
Table 4.
Table 5.
Chart
Page No.
Ignition/Light Switch ......................................... 84
Suspension Adjustments................................ 106
FLT Air Suspension Pressure ........................ 107
Maximum Recommended RPM ..................... 127
Gear Changes - All......................................... 133
Lubrication Summary ......................................138
Table
Page No.
Page No.
Chart
Regular Maintenance Intervals...................... 138
Table 6. Recommended Engine Oils........................... 142
Table 7. Checking Oil Level......................................... 144
Table 8. Belt Deflection .............................................. 151
Table 9. Battery Location............................................. 162
Table 10. Battery Self Discharge Rate at 77°F............. 164
xi.
99466-98
NOTES
xii.
99466-98
The Touring section contains the vehicle specifications for the
following Harley-Davidson models:
FLHTCU-I.......................... Ultra Electra Glide Classic
FLHTC/I............................. Electra Glide Classic
FLHT ................................. Electra Glide Standard
FLHR................................. Road King
FLHRC-I ............................Road King Classic
FLTR/I ............................... Road Glide
T
O
U
R
I
N
G
1
99466-98
NOTES
2
99466-98
VEHICLE IDENTIFICATION NUMBER (V.I.N.)
NOTE
The full 17 digit serial, or Vehicle Identification Number
(V.I.N.) is stamped on the steering head and on a label
located on the right front frame downtube. An abbreviated
V.I.N. is stamped on the left side crankcase above the timing
inspection hole plug.
Model Designation
Engine Type (L=Carburetor, R=EFI)
Varies - 1 thru 8
Model Year - 1998
IDENTIFICATION
Always give the full 17 digit Vehicle Identification Number
when ordering parts or making any inquiry about your
motorcycle.
DP - FLHTC Ultra
DJ - FLHTC
DD - FLHT
DG - FLHTC Shrine
FB - FLHR-I
FC - FLHTCU-I
FD - FLHR
FR - FLHRCI
FF - FLHTC-I
FS - FLTR-I
Sequential Number
1 HD 1
FB R
*Varies - can be 0 thru 9 or X
1
*
W
Y
600000
Sample V.I.N. as it appears on the steering head - 1HD1FBR11WY600000
Sample abbreviated V.I.N. as it appears on the left crankcase - FBRW600000
3
99466-98
6365
17
1 2 3 4
5
16
15 14 13
1.
1.
2.
2.
3.
3.
4.
4.
5.
5.
6.
6.
7.
Ignition/light
Ignition/light switch/fork
switch/fork lock
lock
Ignition coil
coil
Ignition
Enrichener
Enrichener knob
knob (Carb.
(Carb. only)
only)
Fuel supply
supply valve
valve (Carb.
(Carb. only)
only)
Fuel
Fuses
Fuses
Rear
Rear axle
axle adjuster
adjuster
Rear sprocket and drive
8.
7.
9.
8.
10.
9.
11.
10.
11.
12.
13.
12
11 10 9 8
Transmission
plug
Rear sprocket drain
and drive
Primary drain plug
Transmission
drain plug
Clutch
Primaryinspection
drain plugcover
Primaryinspection
chain inspection
Clutch
cover
cover
Primary chain inspection
Primary
cover chain cover
Timing inspection hole plug
7
14.
filtercover
12. Engine
Primaryoil
chain
15.
regulator hole plug
13. Voltage
Timing inspection
16.
lamps
14. Passing
Engine oil
filter
17.
signal
module
15. Turn
Voltage
regulator
16. Passing/Fog lamps
17. Turn signal module
Ultra Electra Glide Classic (FLHTCU-I) - Left Side View
4
99466-98
6
6364
6
15
1
14
12
13
1.
2.
3.
4.
5.
Ignition module/ECM
Electric starter motor
Battery/main circuit breaker
(under seat)
Acc. connector (under seat)
Air cleaner
2
3 4 5
10 11
6.
7
9
Front brake master cylinder
reservoir
7. Speedometer/tachometer
8. Rear brake fluid reservoir
9. Rear brake master cylinder
10. Transmission fill plug
8
11.
12.
13.
14.
15.
Engine oil tank drain
Engine oil fill plug & dipstick
Rear axle adjuster
Shock absorber(s)
Front/rear suspension air valve
Ultra Electra Glide Classic (FLHTCU-I) - Right Side View
5
99466-98
5799
1
17
2 3
4
5
16
15 14 13
1.
2.
3.
4.
5.
6.
Ignition/light switch/fork lock
Ignition coil
Enrichener knob (Carb. only)
Fuel supply valve (Carb. only)
Sound system fuse board
Rear axle adjuster
7.
8.
9.
10.
11.
12.
12
11 10 9 8
Rear sprocket and drive
Transmission drain plug
Primary drain plug
Clutch inspection cover
Primary chain inspection cover
Primary chain cover
7
13.
14.
15.
16.
17.
Electra Glide Classic (FLHTC/I) - Left Side View
6
99466-98
6
Timing inspection hole plug
Engine oil filter
Voltage regulator
Passing/Fog lamps
Circuit breakers/fuses/turn
signal module
5798
6
1
2 3
7
4 5
15
14
13
1.
2.
3.
4.
5.
Ignition module/ECM
Electric starter motor
Battery/main circuit breaker
(under seat)
Acc. connector (under seat)
Air cleaner
12
11 10
6.
9
8
Front brake master cylinder
reservoir
7. Speedometer/tachometer
8. Rear brake fluid reservoir
9. Rear brake master cylinder
10. Transmission fill plug
11.
12.
13.
14.
15.
Engine oil tank drain
Engine oil fill plug & dipstick
Rear axle adjuster
Shock absorber(s)
Front/rear suspension air valve
Electra Glide Classic (FLHTC/I) - Right Side View
7
99466-98
5797
16
1
2 3
15
14 13 12
1.
2.
3.
4.
5.
6.
Ignition/light switch/fork lock
Ignition coil
Enrichener knob
Fuel supply valve
Rear axle adjuster
Rear sprocket and drive
7.
8.
9.
10.
11.
12.
11
4
10 9 8 7
Transmission drain plug
Primary drain plug
Clutch inspection cover
Primary chain inspection cover
Primary chain cover
Timing inspection hole plug
6
13.
14.
15.
16.
Electra Glide Standard (FLHT) - Left Side View
8
99466-98
5
Engine oil filter
Voltage regulator
Passing/Fog lamps
Turn signal module
5796
6
15
1 2 3
7
4 5
14
13
1.
2.
3.
4.
5.
Ignition module
Electric starter motor
Battery/main circuit breaker
(under seat)
Acc. connector (under seat)
Air cleaner
12
6.
10 11
9
Front brake master cylinder
& reservoir
7. Speedometer/tachometer
8. Rear brake fluid reservoir
(under side cover)
9. Rear brake master cylinder
10. Transmission fill plug
8
11.
12.
13.
14.
15.
Engine oil tank drain
Engine oil fill plug & dipstick
Rear axle adjuster
Shock absorber(s)
Front/rear suspension air valve
Electra Glide Standard (FLHT) - Right Side View
9
99466-98
6357
1 2 3 4
5
6
17
16 15 14 13
1.
2.
3.
4.
5.
6.
Fork lock
Ignition/light switch
Ignition coil
Enrichener knob (Carb. only)
Fuel supply valve (Carb. only)
Circuit breakers/relays
7.
8.
9.
10.
11.
12.
7
12 11 10 9
Rear axle adjuster
Rear sprocket and drive
Transmission drain plug
Clutch inspection cover
Primary drain plug
Primary chain inspection cover
Road King (FLHR) - Left Side View
10
99466-98
8
13.
14.
15.
16.
17.
Primary chain cover
Timing inspection hole plug
Engine oil filter
Voltage regulator
Passing lamps
6356
6
15
1
2
3
4
7
5
14
12 11 10
13
1.
2.
3.
4.
5.
Ignition module/ECM
Electric starter motor
Battery/circuit breakers
(under seat)
Acc. connector (under seat)
Air cleaner
9
8
6.
Front brake master cylinder &
reservoir
7. Speedometer
8. Rear brake fluid reservoir
9. Rear brake master cylinder
10. Engine oil tank drain
11.
12.
13.
14.
15.
Transmission fill plug
Engine oil fill plug & dipstick
Rear axle adjuster
Shock absorber(s)
Front/rear suspension air valve
Road King (FLHR) - Right Side View
11
99466-98
6361
1 2 3 4
6
5
17
16 15 14 13 12 9
1.
2.
3.
4.
5.
6.
Fork lock
Ignition/light switch
Ignition coil
Enrichener knob (Carb. only)
Fuel supply valve (Carb. only)
Circuit breakers/relays
7.
8.
9.
10.
11.
12.
7
11
10
Rear axle adjuster
Rear sprocket and drive
Transmission drain plug
Clutch inspection cover
Primary drain plug
Primary chain inspection cover
Road King Classic (FLHRC-I) - Left Side View
12
99466-98
8
13.
14.
15.
16.
17.
Primary chain cover
Timing inspection hole plug
Engine oil filter
Voltage regulator
Passing/Fog lamps
6360
6
15
1
2
3
4
5
14
12 11 10
13
1.
2.
3.
4.
5.
Ignition module/ECM
Electric starter motor
Battery/circuit breakers
(under seat)
Acc. connector (under seat)
Air cleaner
6.
7
9
8
Front brake master cylinder &
reservoir
7. Speedometer
8. Rear brake fluid reservoir
9. Rear brake master cylinder
10. Engine oil tank drain
11.
12.
13.
14.
15.
Transmission fill plug
Engine oil fill plug & dipstick
Rear axle adjuster
Shock absorber(s)
Front/rear suspension air valve
Road King Classic (FLHRC-I) - Right Side View
13
99466-98
6369
1
15
2
14 13 12
1.
2.
3.
4.
5.
6.
Ignition/light switch/fork lock
Ignition coil
Enrichener knob (Carb. only)
Fuel supply valve (Carb. only)
Rear axle adjuster
Rear sprocket and drive
7.
8.
9.
10.
11.
12.
3 4
8 10 7
9
11
Transmission drain plug
Primary drain plug
Clutch inspection cover
Primary chain inspection cover
Primary chain cover
Timing inspection hole plug
Road Glide (FLTR/I) - Left Side View
14
99466-98
5
6
13. Engine oil filter
14. Voltage regulator
15. Circuit breakers/fuses/turn
signal module
6368
15
1
2
3
4
5
14
12 11 10
13
1.
2.
3.
4.
5.
7
6
Ignition module
Electric starter motor
Battery/main circuit breaker
(under seat)
Acc. connector (under seat)
Air cleaner
9
8
6.
Front brake master cylinder
& reservoir
7. Speedometer/tachometer
8. Rear brake fluid reservoir
(under side cover)
9. Rear brake master cylinder
10. Transmission fill plug
11.
12.
13.
14.
15.
Engine oil tank drain
Engine oil fill plug & dipstick
Rear axle adjuster
Shock absorber(s)
Front/rear suspension air valve
Road Glide (FLTR/I) - Right Side View
15
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NOTES
16
99466-98
FLHT/C/U/I
Wheel Base....................... 63.50
Overall Length................... 93.70
Overall Width. ................... 39.00
Road Clearance ................ 5.12
Overall Height ................... 61.00
Saddle Height ................... 28.00
CAPACITIES (U.S.)
FLHR/C-I
63.50
93.70
34.45
5.12
55.06
28.20
FLHT/C/U/I FLHR/C/I FLTR-I
Fuel Tank
(Gallons) Total .......................5
5
5
Reserve .................................0.9
0.9
0.9
Oil Tank
(Quarts) w/filter ......................4
4
4
Transmission
(Ounces, approx.) ..................20-24
20-24 20-24
Front Fork
Each (Ounces, wet) ...............7.75
7.75
7.75
Primary Chaincase
(Ounces, approx.). .................38-44
38-44 38-44
FLTR-I
63.50
93.70
35.75
5.12
55.00
28.40
WEIGHT (LBS.)
FLHT/C/U/I
DRY WEIGHT
(as shipped from
the factory) ........................ 742/760/772
GVWR ............................... 1179
GAWR - Front ................... 410
GAWR - Rear .................... 769
NOTE
FLHR/C-I FLTR-I
IGNITION SYSTEM
707/694
1179
410
769
Timing Setting
715
1179
410
769
1050-1500 RPM .............. 20° BTDC
Battery.................................................. 12 Volt, 30 amp. hr.
Spark Plugs
Gross Vehicle Weight Rating (GVWR) (maximum allowable
loaded vehicle weight) and corresponding Gross Axle Weight
Ratings (GAWR) are given on a label located on the frame
down tube.
Type ..................................................................... HD-5R6A
Size ........................................................................... 14mm
Gap ....................................0.038-0.043 in. (0.97-1.09 mm)
17
99466-98
SPECIFICATIONS
DIMENSIONS (IN.)
ENGINE
OVERALL GEAR RATIOS
Number of Cylinders ......................................................... 2
Type ....................... 4-Cycle, 45 Degree V-Type, air cooled
Compression Ratio.................................................. 8.5 to 1
First (Low) Gear........................................................10.110
Second Gear.............................................................. 6.958
Third Gear...................................................................4.953
Fourth Gear ................................................................3.862
SAE Horsepower
Fifth Gear....................................................................3.150
Brake
Horse
power
@ RPM
Bore
in. (mm)
Stroke
in. (mm)
Displacement
cu. in. (cc)
Torque
lb-ft
@ RPM
70@5000
3.498
(88.8)
4.25 (108)
81.6 (1338.6)
80@4000
TIRE DATA
1WARNING
●
For your personal safety, tires, rims and air valves
must be correctly matched to wheel rims. See your
Harley-Davidson dealer. Mismatching tires, tubes,
rims and air valves may result in damage to the tire
bead during mounting or may allow the tire to slip on
the rim, possibly causing tire failure and/or personal
injury.
●
In addition, using tires other than those specified
may adversely affect motorcycle stability.
●
Tubeless tires fitted with the correct size inner tubes
may be used on all Harley-Davidson laced (wire
spoked) wheels. Protective rubber rim strips must be
used with tubeless tires (fitted with correct size inner
tubes) when mounted on laced (wire spoked) wheels.
TRANSMISSION
Type ........................................... Constant Mesh, Foot Shift
Speeds ................................................................ 5 Forward
NUMBER OF SPROCKET TEETH
Engine ............................................................................. 25
Clutch .............................................................................. 36
Transmission................................................................... 32
Rear Wheel ..................................................................... 70
18
99466-98
●
●
●
Inner tubes must not be used in radial tires and radial
tires must not be used on laced (wire spoked)
wheels.
Tubeless tires are used on all Harley-Davidson cast
and disc wheels.
Tire sizes are molded on the tire sidewall. Inner tube
sizes are printed on the tube.
Tire Pressure
1998 VEHICLES
DUNLOP® TIRES ONLY
Solo Rider
FLHT/C/Ultra/I
FLHR/C-I, FLTR/I
Rider & One FLHT/C/Ultra/I
Passenger FLHR/C-I, FLTR/I
TIRE PRESSURE
PSI (COLD)
Front
Rear
36
36
36
40
1WARNING
●
Dunlop® front and rear tires for Harley-Davidson
motorcycles are not the same. They are not interchangeable. Use the front tire ONLY for a front tire.
DO NOT put a rear tire on the front of a vehicle. Failure to follow this warning could result in personal
injury.
●
Maximum inflation pressure must not exceed specification on tire sidewall. Failure to follow this warning
could cause tire failure possibly resulting in personal injury.
19
99466-98
FUEL
Use a good quality unleaded gasoline. For a carburetor
equipped vehicle use at least 87 octane gasoline. For
sequential port injected vehicles use at least 91 octane
gasoline. Octane rating is usually found on the pump.
1WARNING
Remove fuel filler cap slowly. Fill fuel tank slowly to
prevent spillage. Do not overfill. Do not fill above the
bottom of the filler neck insert. Leave air space to allow
for fuel expansion. Expansion can cause an overfilled
tank to overflow gasoline through the filler cap onto
surrounding areas. After refueling, be sure fuel filler cap
is securely tightened. Failure to follow this warning could
result in an explosion and/or fire possibly resulting in
personal injury.
through whatever opening is available within the filler tube.
This may not only soil clothing, but may create a potential fire
hazard.
GASOLINE BLENDS
Your motorcycle was designed to obtain the best
performance and efficiency using unleaded gasoline. Some
fuel suppliers sell gasoline/alcohol blends as a fuel. The type
and amount of alcohol added to the fuel is important.
●
DO NOT USE GASOLINES CONTAINING METHANOL.
Using gasoline/methanol blends will result in starting and
driveability deterioration and damage to critical fuel
system components.
●
Gasolines containing METHYL TERTIARY BUTYL
ETHER (MTBE): Gasoline/MTBE blends are a mixture of
gasoline and as much as 15% MTBE. Gasoline/ MTBE
blends can be used in your motorcycle.
●
ETHANOL (Grain alcohol) is a mixture of 10% ethanol
and 90% unleaded gasoline. It is identified as “gasohol”,
“ethanol enhanced”, or “contains ethanol.” Gasoline/ethanol blends can be used in your motorcycle.
●
REFORMULATED OR OXYGENATED GASOLINES
(RFG): “Reformulated gasoline” is a term used to
describe gasoline blends that are specifically designed to
burn cleaner than other types of gasoline, leaving fewer
“tailpipe” emissions. They are also formulated to evaporate less when you are filling your tank. Reformulated
1CAUTION
●
Using gasoline that has an alcohol additive, such as
methanol, may cause fuel system rubber components’ failure and/or engine damage.
●
Gasohol spills can stain the paint on your HarleyDavidson.
Todays service station pumps are increasingly of the higher
capacity variety. With the high flow of gasoline into a
motorcycle tank, air entrapment and pressurization is a
possibility. The pressurized air may force gasoline to escape
20
99466-98
gasolines use additives to “oxygenate” the gas. Your
motorcycle will run normally using this type of gas and
Harley-Davidson recommends you use it when possible,
as an aid to cleaner air in our environment.
Because of their generally higher volatility, these blends may
adversely affect the starting, driveability and fuel efficiency of
your motorcycle. If you experience these problems, HarleyDavidson recommends you operate your motorcycle on
straight, unleaded gasoline.
CATALYTIC CONVERTERS
California and Swiss model 1340cc carbureted motorcycles
are equipped with catalytic converters.
1CAUTION
●
Do not operate catalytic converter-equipped vehicle with engine misfire or a non-firing cylinder. If
you operate the vehicle under these conditions,
the exhaust will become abnormally hot, which
can cause vehicle damage, including emission
control loss.
●
You must use ONLY unleaded fuel in California
and Swiss model catalytic converter-equipped
motorcycles. Using leaded fuel will damage the
emissions control system.
21
99466-98
BULB CHART - FLHT/C/ULTRA/I, FLHR/CI, FLTR/I
LAMP DESCRIPTION
ALL LAMPS 12 VOLT
Headlamp
FLTR/I
FLHT/C/ULTRA/I, FLHR/I
Position Lamp (HDI)
Tail and Stop Lamp
Tail Lamp
Stop Lamp
Tail Lamp (HDI)
Stop Lamp (HDI)
Passing Lamp
Fog Lamp (HDI)
Turn Signal Lamp
Front/Running
Front (HDI)
Rear
Rear (HDI)
Tour-Pak Side Lamps - FLHTC/ULTRA/I
Fender Tip Lamps
License Plate Lamp (HDI)
NUMBER OF
BULBS
(REQUIRED)
CURRENT
DRAW
(AMPERAGE)
HARLEY-DAVIDSON
PART NUMBER
2
1
1
1 (Ultra - 3)
4.58(Lo),5.0(Hi)
4.58(Lo),5.0(Hi)
0.32
67697-81
67697-81
53438-92
68168-89
2
2
0.59
2.25
0.42
1.75
2.5
2.92
2
2
2
2
4
2
1
2.25/0.59
1.75
2.25
1.75
0.30
0.30
0.37
68168-89
68163-84
68572-64B
68163-84
53439-79
53439-79
53436-97
22
99466-98
68169-90
68674-69
68847-98
BULB CHART - FLHT/C/ULTRA/I, FLHR/CI, FLTR/I
LAMP DESCRIPTION
ALL LAMPS 12 VOLT
Instrument Panel Lamps - FLHR/I, FLHT/C/U, FLTR/I
High Beam Indicator
Oil Pressure Indicator
Neutral Indicator
Turn Signal Indicators
Gauge Lamps - FLHR/I
Speedometer
Odometer
Fuel Gauge
Engine (FLHR-I only)
Gauge Lamps - FLHT/C/ ULTRA/I, FLTR/I
Speedometer
Tachometer
Voltmeter
Oil Pressure Indicator (FLHTC/U, FLTR/I)
Air Temp. Gauge (FLHTC/U, FLTR/I)
Fuel Gauge
NUMBER OF
BULBS
(REQUIRED)
CURRENT
DRAW
(AMPERAGE)
HARLEY-DAVIDSON
PART NUMBER
1
1
1
2
0.15
0.15
0.15
0.15
68024-94
68024-94
68024-94
68024-94
1
1
1
1
0.3
0.19
0.19
0.15
53439-79
67136-85
67136-85
68024-94
2
1
1
1
1
1
0.12
0.24
0.24
0.24
0.24
0.24
75048-96
75045-96
75045-96
75045-96
75045-96
75045-96
23
99466-98
NOTES
24
99466-98
The Custom section contains the vehicle specifications for
the following Harley-Davidson models:
FLSTS .............................................Heritage Springer
FLSTC .............................................Heritage Softail Classic
C
U
S
T
O
M
FXSTC ............................................Softail Custom
FXSTS ............................................Springer Softail
FLSTF .............................................Fat Boy
FXDWG .......................................... Dyna Wide Glide
FXDL ...............................................Dyna Low Rider
FXDS-CONV .................................. Dyna Convertible
FXD ................................................ Dyna Super Glide
25
99466-98
NOTES
26
99466-98
VEHICLE IDENTIFICATION NUMBER (V.I.N.)
NOTE
The full 17 digit serial, or Vehicle Identification Number
(V.I.N.) is stamped on the steering head and on a label
located on the right front frame downtube. An abbreviated
V.I.N. is stamped on the left side crankcase above the timing
inspection hole plug.
Model Designation
Engine Type
Varies - 1 thru 8
Model Year - 1998
IDENTIFICATION
Always give the full 17 digit Vehicle Identification Number
when ordering parts or making any inquiry about your
motorcycle.
BJ - FLSTC
BK - FXSTC
BL - FXSTS
BR - FLSTS
BM - FLSTF
GE - FXDWG
GD - FXDL
GG - FXDS-CONV
GH - FXD
Sequential
Number
1 HD 1
BR L
*Varies - can be 0 thru 9 or X
1
*
W
Y
110000
Sample V.I.N. as it appears on the steering head - 1HD1BJL1LWY110000
Sample abbreviated V.I.N. as it appears on the engine - BRLW110000
27
99466-98
5783
16
1 2 3 4
5
15
14 13 12
1.
2.
3.
4.
5.
6.
Ignition/light key switch
Carburetor enrichener knob
Fuel supply valve
Ignition coil
Ignition module (under seat)
Rear sprocket and drive
7.
8.
9.
10.
11.
11 10
9
6
8
Rear axle adjuster
Clutch inspection cover
Primary drain plug
Primary chain cover
Primary chain inspection cover
7
12.
13.
14.
15.
16.
Heritage Softail Classic (FLSTC) - Left Side View
28
99466-98
Timing inspection hole plug
Engine oil filter
Voltage regulator
Passing/Fog lamp
Fuel filler cap
5782
5
14
1.
2.
3.
4.
5.
Battery (under seat)
Engine oil fill plug & dipstick
Carburetor/air cleaner
Speedometer
Front brake master cylinder &
reservoir
6.
7.
8.
9.
1 2 3
4
13 12 11 10
9
Passing/Fog lamp
Fork lock brackets
Rear brake master cylinder &
reservoir
Transmission fill plug
6
7
8
10.
11.
12.
13.
14.
Transmission drain plug
Electric starter motor
Shock absorber
Engine oil tank drain
Rear axle adjuster
Heritage Softail Classic (FLSTC) - Right Side View
29
99466-98
5787
1 2 3 4
5 6 7
16
15
1.
2.
3.
4.
5.
6.
Fuel filler cap
Ignition/light key switch
Carburetor enrichener knob
Fuel supply valve
Timing inspection hole plug
Ignition coil
7.
8.
9.
10.
11.
14
13 12
11
Ignition module (under seat)
Rear sprocket and drive
Rear axle adjuster
Clutch inspection cover
Primary drain plug
Fat Boy (FLSTF) - Left Side View
30
99466-98
8
10 9
12.
13.
14.
15.
16.
Primary chain inspection cover
Primary chain cover
Engine oil filter
Voltage regulator
Clutch cable adjuster
5786
4
5
1
2
3
6
13
1.
2.
3.
4.
Battery (under seat)
Engine oil fill plug & dipstick
Carburetor/air cleaner
Front brake master cylinder &
reservoir
12 11 10 9
5.
6.
7.
8.
8
7
Speedometer
Fork lock brackets
Rear brake master cylinder &
reservoir
Transmission fill plug
9.
10.
11.
12.
13.
Transmission drain plug
Electric starter motor
Shock absorber
Engine oil tank drain
Rear axle adjuster
Fat Boy (FLSTF) - Right Side View
31
99466-98
6343
1 2 3 4 5
15
14 13 12
1.
2.
3.
4.
5.
Ignition/light key switch
Carburetor enrichener knob
Fuel supply valve
Ignition coil
Ignition module (under seat)
6.
7.
8.
9.
10.
11
10
9
8
Rear sprocket and drive
Rear axle adjuster
Clutch inspection cover
Primary drain plug
Primary chain inspection cover
6
7
11.
12.
13.
14.
15.
Heritage Springer (FLSTS) - Left Side View
32
99466-98
Primary chain cover
Timing inspection hole plug
Engine oil filter
Voltage regulator
Clutch cable adjuster
6342
4
5
1
12 11 10
13
1.
2.
3.
4.
Battery (under seat)
Engine oil fill plug & dipstick
Carburetor/air cleaner
Front brake master cylinder &
reservoir
5.
6.
7.
8.
3
2
9
6
8
Speedometer
Fork lock brackets
Rear brake master cylinder &
reservoir
Transmission fill plug
7
9.
10.
11.
12.
13.
Transmission drain plug
Electric starter motor
Shock absorber(s)
Engine oil tank drain
Rear axle adjuster
Heritage Springer (FLSTS) - Right Side View
33
99466-98
5789
1 2 3 4 5 6 7
16
14
15
1.
2.
3.
4.
5.
6.
Fuel filler cap
Ignition/light key switch
Carburetor enrichener knob
Fuel supply valve
Timing inspection hole plug
Ignition coil
7.
8.
9.
10.
11.
13 12
8
11 10 9
Ignition module (under seat)
Rear sprocket and drive
Rear axle adjuster
Clutch inspection cover
Primary drain plug
Softail Custom (FXSTC) - Left Side View
34
99466-98
12.
13.
14.
15.
16.
Primary chain inspection cover
Primary chain cover
Engine oil filter
Voltage regulator
Clutch cable adjuster
5788
4
5
1 2
14
1.
2.
3.
4.
Battery (under seat)
Engine oil fill plug & dipstick
Carburetor/air cleaner
Front brake master cylinder &
reservoir
13
5.
6.
7.
8.
9.
3
12 11 10 9
6
8
7
Speedometer
Fork lock brackets
Rear brake fluid reservoir
Rear brake master cylinder
Transmission fill plug
10.
11.
12.
13.
14.
Transmission drain plug
Electric starter motor
Engine oil tank drain
Shock absorber(s)
Rear axle adjuster
Softail Custom (FXSTC) - Right Side View
35
99466-98
5791
1 2 3 4 5 6
15
14 13
1.
2.
3.
4.
5.
Ignition/light key switch
Carburetor enrichener knob
Fuel supply valve
Timing inspection hole plug
Ignition coil
6.
7.
8.
9.
10.
12 11 10
9
Ignition module (under seat)
Rear sprocket and drive
Rear axle adjuster
Clutch inspection cover
Primary drain plug
7
8
11.
12.
13.
14.
15.
Springer Softail (FXSTS) - Left Side View
36
99466-98
Primary chain inspection cover
Primary chain cover
Engine oil filter
Voltage regulator
Clutch cable adjuster
5790
4
5
1
14
1.
2.
3.
4.
Battery (under seat)
Engine oil fill plug & dipstick
Carburetor/air cleaner
Front brake master cylinder &
reservoir
2
3
13 12 11 10 9
5.
6.
7.
8.
9.
6
8
7
Speedometer
Fork lock brackets
Rear brake fluid reservoir
Rear brake master cylinder
Transmission fill plug
10.
11.
12.
13.
14.
Transmission drain plug
Engine oil tank drain
Electric starter motor
Shock absorber
Rear axle adjuster
Springer Softail (FXSTS) - Right Side View
37
99466-98
5777
1
2 3 4
5
6
17
7
16 15
1.
2.
3.
4.
5.
Fuel gauge
Carburetor enrichener knob
Fuel supply valve
Ignition coil
Electrical enclosure (contains
ignition module, circuit breakers
and starter relay)
14 13
12 11 10
9
6.
7.
8.
9.
Shock absorber
Rear axle adjuster
Rear sprocket and drive
Engine oil tank drain (under
transmission)
10. Primary drain plug
11. Clutch inspection cover
Dyna Low Rider (FXDL) - Left Side View
38
99466-98
8
12.
13.
14.
15.
16.
17.
Primary chain inspection cover
Primary chain cover
Timing inspection hole plug
Engine oil filter
Voltage regulator
Clutch cable adjuster
5776
3
2
4
5
6
7
8
1
14
1.
2.
3.
4.
5.
Shock absorber
Ignition/light key switch
Battery
Carburetor/air cleaner
Fuel filler cap
13 12 11 10 9
6.
Front brake master cylinder &
reservoir
7. Speedometer/tachometer
8. Fork lock
9. Engine oil fill plug & dipstick
10. Transmission fill plug
11. Transmission drain plug (under
transmission)
12. Electric starter motor
13. Rear brake master cylinder &
reservoir
14. Rear axle adjuster
Dyna Low Rider (FXDL) - Right Side View
39
99466-98
5779
1
2 3
4
5
17
6
7
16 15
1.
2.
3.
4.
5.
Fuel gauge
Carburetor enrichener knob
Fuel supply valve
Ignition coil
Electrical enclosure (contains
ignition module, circuit breakers
and starter relay)
14 13 12
11 10
6.
7.
8.
9.
9
Shock absorber
Rear axle adjuster
Rear sprocket and drive
Engine oil tank drain (under
transmission)
10. Primary drain plug
11. Clutch inspection cover
8
12.
13.
14.
15.
16.
17.
Dyna Wide Glide (FXDWG) - Left Side View
40
99466-98
Primary chain inspection cover
Primary chain cover
Timing inspection hole plug
Engine oil filter
Voltage regulator
Clutch cable adjuster
5778
6
3
4
2
5
7
8
1
14
1.
2.
3.
4.
5.
Shock absorber
Ignition/light key switch
Battery
Carburetor/air cleaner
Fuel filler cap
13 12 11 10 9
6. Front brake master cylinder &
reservoir
7. Speedometer
8. Fork lock
9. Engine oil fill plug & dipstick
10. Transmission fill plug
11. Transmission drain plug (under
transmission)
12. Electric starter motor
13. Rear brake master cylinder &
reservoir
14. Rear axle adjuster
Dyna Wide Glide (FXDWG) - Right Side View
41
99466-98
5781
1 2 3 4
5
6
17
7
16 15 14 13
1.
2.
3.
4.
5.
Fuel gauge
Carburetor enrichener knob
Fuel supply valve
Ignition coil
Electrical enclosure (contains
ignition module, circuit breakers
and starter relay)
12 11
10 9
6.
7.
8.
9.
Shock absorber
Rear axle adjuster
Rear sprocket and drive
Engine oil tank drain (under
transmission)
10. Primary drain plug
11. Clutch inspection cover
8
12.
13.
14.
15.
16.
17.
Primary chain inspection cover
Primary chain cover
Timing inspection hole plug
Engine oil filter
Voltage regulator
Clutch cable adjuster
Dyna Glide Convertible (FXDS-CONV) - Left Side View
42
99466-98
5780
6
2
3 4 5
7
8
1
14
1.
2.
3.
4.
5.
Shock absorber
Ignition/light key switch
Battery
Carburetor/air cleaner
Fuel filler cap
13 12 11 10 9
6. Front brake master cylinder &
reservoir
7. Speedometer/tachometer
8. Fork lock
9. Engine oil fill plug & dipstick
10. Transmission fill plug
11. Transmission drain plug (under
transmission)
12. Electric starter motor
13. Rear brake master cylinder &
reservoir
14. Rear axle adjuster
Dyna Glide Convertible (FXDS-CONV) - Right Side View
43
99466-98
5775
1 2
3
4
5
6
17
7
16 15
1.
2.
3.
4.
5.
Fuel gauge
Carburetor enrichener knob
Fuel supply valve
Ignition coil
Electrical enclosure (contains
ignition module, circuit breakers
and starter relay)
14 13
12 11 10
6.
7.
8.
9.
Shock absorber
Rear axle adjuster
Rear sprocket and drive
Engine oil tank drain (under
transmission)
10. Primary drain plug
11. Clutch inspection cover
9
8
12.
13.
14.
15.
16.
17.
Dyna Super Glide (FXD) - Left Side View
44
99466-98
Primary chain inspection cover
Primary chain cover
Timing inspection hole plug
Engine oil filter
Voltage regulator
Clutch cable adjuster
5774
6
2
3
4
5
8
1
14
1.
2.
3.
4.
5.
Shock absorber
Ignition/light key switch
Battery
Carburetor/air cleaner
Fuel filler cap
7
13 12 11 10 9
6. Front brake master cylinder &
reservoir
7. Speedometer
8. Fork lock
9. Engine oil fill plug & dipstick
10. Transmission fill plug
11. Transmission drain plug (under
transmission)
12. Electric starter motor
13. Rear brake master cylinder &
reservoir
14. Rear axle adjuster
Dyna Super Glide (FXD) - Right Side View
45
99466-98
NOTES
46
99466-98
FLSTC
FXSTC
FXSTS
FLSTF
FLSTS
FXDWG
FXDSCONV
FXDL
FXD
Wheel
Base
63.90
66.50
64.41
63.89
63.07
66.10
Overall
Length
94.02
94.92
92.52
93.85
94.00
94.50
Overall Road
Width Clr’nc
38.00 5.47
29.00 5.94
29.00 5.59
38.00 5.47
36.60 5.00
28.50 5.62
Overall
Height
59.40
47.00
47.00
48.00
44.00
47.50
Saddle
Height
26.50
26.70
26.12
26.50
25.75
26.75
63.88
92.88
28.95
6.98
59.25
27.75
65.60
62.80
94.00
91.00
28.50
28.50
5.62
5.62
47.50
47.50
26.50
26.50
WEIGHT (LBS.)
Dry
Weight
FLSTC
704
FXSTC
613
FXSTS
625
FLSTF
631
FLSTS
690
FXD/L/WG
598
FXDS-CONV 621
Ratings (GAWR) are given on a label located on the frame
down tube.
CAPACITIES
FLSTC/F
1118
1084
1084
1118
1135
1085
1085
GAWR
Front
402
390
390
402
405
390
390
GAWR
Rear
716
694
694
716
730
695
695
FXSTS
FXD/L/
FLSTS
WG
FXDS
-CONV
Fuel Tank
(Gallons)
Total ...............4.2
5.2
4.2
4.9/5.2
4.9
Reserve ..........0.4
0.6
0.4
1.1
1.1
3.0
3.0
3.0
3.0
24
24
24
24
10.2
None
9.2
9.2
38-44
38-44
38-44 38-44
Oil Tank
(Quarts)
w/Filter............3.0
GVWR
FXSTC
Transmission
(Ounces,
approx.) ..........24
Front Fork
Each (Ounces,
wet).................11.5
Primary
NOTE
Chaincase
Gross Vehicle Weight Rating (GVWR) (maximum allowable
loaded vehicle weight) and corresponding Gross Axle Weight
(Ounces,
approx.) ......... 38-44
47
99466-98
SPECIFICATIONS
DIMENSIONS (IN.)
IGNITION SYSTEM
NUMBER OF SPROCKET TEETH
Timing Setting
20°
BTDC
1050-1500 RPM ..............
Battery................... Maintenance Free, 12 Volt, 18 amp. hr.
Engine ............................................................................. 25
Clutch .............................................................................. 36
Transmission................................................................... 32
Rear Wheel - Softail/Dyna.......................................... 65/70
Spark Plugs
OVERALL GEAR RATIOS
Type ..................................................................... HD-5R6A
Size ........................................................................... 14mm
Gap .....................................0.038-0.043 in. (0.97-1.09mm)
Softail Models
ENGINE
Number of Cylinders ......................................................... 2
Type ....................... 4-Cycle, 45 Degree V-Type, air cooled
Compression Ratio.................................................. 8.5 to 1
SAE Horsepower
First (Low) Gear ....... 9.388 Fourth Gear ................. 3.586
Second Gear ............ 6.461 Fifth Gear..................... 2.925
Third Gear ................ 4.599
DYNA Models
First (Low) Gear ..... 10.110 Fourth Gear ................. 3.862
Second Gear ............ 6.958 Fifth Gear..................... 3.150
Third Gear ................ 4.953
TIRE DATA
Brake
Horse
power
@ RPM
Bore
in. (mm)
Stroke
in. (mm)
Displacement
cu. in. (cc)
Torque
lb-ft
@ RPM
67@5000
3.498
(88.8)
4.25 (108)
81.6 (1338.6)
78@4000
●
For your personal safety, tires, rims and air valves
must be correctly matched to wheel rims. See your
Harley-Davidson dealer. Mismatching tires, tubes,
rims and air valves may result in damage to the tire
bead during mounting or may allow the tire to slip on
the rim, possibly causing tire failure and/or personal
injury.
●
In addition, using tires other than those specified may
TRANSMISSION
Type ...........................................Constant Mesh, Foot Shift
Speeds ................................................................ 5 Forward
1WARNING
48
99466-98
adversely affect motorcycle stability.
●
●
Tubeless tires fitted with the correct size inner tubes
may be used on all Harley-Davidson laced (wire
spoked) wheels. Protective rubber rim strips must be
used with tubeless tires (fitted with correct size inner
tubes) when mounted on laced (wire spoked) wheels.
Inner tubes must not be used in radial tires and radial
tires must not be used on laced (wire spoked)
wheels.
●
Tubeless tires are used on all Harley-Davidson cast
and disc wheels.
●
Tire sizes are molded on the tire sidewall. Inner tube
sizes are printed on the tube.
1998 VEHICLES
DUNLOP TIRES ONLY
Solo Rider
FLSTC/F/N
Solo Rider & One
Passenger
FLSTC/F/S
Solo Rider
FXSTC/S
Solo Rider & One
Passenger
FXSTC/S
Solo Rider FXD/L/WG/CONV
Solo Rider & One
Passenger FXD/L/WG/CONV
TIRE PRESSURE
PSI (COLD)
FRONT
36
REAR
36
36
30
40
36
30
40
30
36
30
40
49
99466-98
1CAUTION
1WARNING
●
●
Dunlop front and rear tires for Harley-Davidson
motorcycles are not the same. They are not interchangeable. Use the front tire ONLY for a front tire.
DO NOT put a rear tire on the front of a vehicle. Failure to follow this warning could result in personal
injury.
Maximum inflation pressure must not exceed specification on tire sidewall. Failure to follow this warning
could cause tire failure possibly resulting in personal injury.
FUEL
Use a good quality unleaded gasoline, at least 87 pump
octane. Octane rating is usually found on the pump.
1WARNING
Remove fuel filler cap slowly. Fill fuel tank slowly to
prevent spillage. Do not overfill. Do not fill above the
bottom of the filler neck insert. Leave air space to allow
for fuel expansion. Expansion can cause an overfilled
tank to overflow gasoline through the filler cap onto
surrounding areas. After refueling, be sure fuel filler cap
is securely tightened. Failure to follow this warning could
result in an explosion and/or fire possibly resulting in
personal injury.
●
Using gasoline that has methanol, can cause fuel
system rubber components’ failure and/or engine
damage.
●
Gasohol spills can stain the paint on your Harley
Davidson.
Todays service station pumps are increasingly of the higher
capacity variety. With the high flow of gasoline into a
motorcycle tank, air entrapment and pressurization is a
possibility. The pressurized air may force gasoline to escape
through whatever opening is available within the filler tube.
This may not only soil clothing, but may create a potential fire
hazard.
GASOLINE BLENDS
Your motorcycle was designed to get the best performance
and efficiency using unleaded gasoline. Most gasolines sold
in the United States are blended with alcohol and/or ether to
create “oxygenated” blends. The type and amount of alcohol
or ether added to the fuel is important.
●
DO NOT USE GASOLINES CONTAINING METHANOL.
Using gasoline/methanol blends will result in starting and
driveablility deterioration and damage to critical fuel system components.
●
ETHANOL is a mixture of 10% ethanol (Grain alcohol)
and 90% unleaded gasoline. Gasoline/ethanol blends
50
99466-98
can be used in your motorcycle if the ethanol content
does not exceed 10%.
●
●
Gasolines containing ETHER: Gasoline/ether blends are
a mixture of gasoline and as much as 15% ether. Gasoline/ether blends can be used in your motorcycle if the
ether content does not exceed 17%.
REFORMULATED OR OXYGENATED GASOLINES
(RFG): “Reformulated gasoline” is a term used to
describe gasoline blends that are specifically designed to
burn cleaner than other types of gasoline, leaving fewer
“tailpipe” emissions. They are also formulated to evaporate less when you are filling your tank. Reformulated
gasolines use additives to “oxygenate” the gas. Your
motorcycle will run normally using this type of gas and
Harley-Davidson recommends you use it when possible,
as an aid to cleaner air in our environment.
CATALYTIC CONVERTERS
California and Swiss model 1340cc motorcycles are equipped
with catalytic converters.
1CAUTION
Do not operate catalytic converter-equipped vehicle with
engine misfire or a non-firing cylinder. If you operate the
vehicle under these conditions, the exhaust will become
abnormally hot, which can cause vehicle damage,
including emission control loss.
1CAUTION
You must use ONLY unleaded fuel in California and
Swiss model catalytic converter-equipped motorcycles.
Using leaded fuel will damage the emissions control
system.
You may find that some gasoline blends adversely affect the
starting, driveability or fuel efficiency of your bike. If you
experience one or more of these problems, we recommend
you try a different brand of gasoline or higher octane rating.
51
99466-98
BULB CHART - FLSTC/F/S, FXSTC/S
LAMP DESCRIPTION
ALL LAMPS 12 VOLT
NUMBER OF
CURRENT
HARLEY-DAVIDSON
BULBS
DRAW
PART NUMBER
(REQUIRED) (AMPERAGE)
Headlamp
FLSTC/F/S
FXSTC/S
1
1
4.7/4.3
4.7/4.3
67713-86
67697-81
Position Lamp (HDI)
1
0.32
53438-92
Tail and Stop Lamp
Tail Lamp
Stop Lamp
Tail Lamp (HDI)
Stop Lamp (HDI)
1
0.59
2.25
0.42
1.75
68168-89
Passing Lamp FLSTC/FLSTS
Fog Lamp (HDI)
2
2
2.5
2.92
68674-69
68847-98
Turn Signal Lamp
Front/Running
Front (HDI)
Rear
Rear (HDI)
2
2
2
2
2.25/0.59
1.75
2.10
1.75
68168-89
68163-84
68572-64B
68163-84
License Plate Lamp
FLSTS
FLSTS (HDI)
1
1
0.35
0.37
52441-95
53436-97
Fender Tip Lamps FLSTC
2
0.10
53439-79
52
99466-98
68169-90
BULB CHART - FLSTC/F/S, FXSTC/S
NUMBER OF
CURRENT
HARLEY-DAVIDSON
BULBS
DRAW
PART NUMBER
(REQUIRED) (AMPERAGE)
LAMP DESCRIPTION
ALL LAMPS 12 VOLT
Instrument Panel Lamps
High Beam Indicator
Oil Pressure Indicator
Neutral Indicator
Turn Signal Indicator
Speedometer
Odometer
1
1
1
2
1
1
0.15
0.15
0.15
0.15
0.3
1.9
68024-94
68024-94
68462-64
68462-64
53439-79
67136-85
Front Fender Lamp FLSTS
1
0.35
52441-95
53
99466-98
BULB CHART - FXD/L/WG/CONV
LAMP DESCRIPTION
ALL LAMPS 12 VOLT
Headlamp
High Beam / Low Beam
NUMBER OF
BULBS
(REQUIRED)
CURRENT
DRAW
(AMPERAGE)
HARLEY-DAVIDSON
PART NUMBER
1
5.0 / 4.58
67697-81
0.59
2.10
0.42
1.75
68168-89
Tail and Stop Lamp
Tail Lamp
Stop Lamp
Tail Lamp (HDI)
Stop Lamp (HDI)
1
Position Lamp
1
0.32
53438-92
Turn Signal Lamp
Front/Running
Front (HDI)
Rear
Rear (HDI)
2
2
2
2
2.25/0.59
1.75
2.25
1.75
68168-89
68163-84
68572-64B
68163-84
54
99466-98
68169-90
BULB CHART - FXD/L/WG/CONV
LAMP DESCRIPTION
ALL LAMPS 12 VOLT
NUMBER OF
BULBS
(REQUIRED)
Instrument Panel Lamps
High Beam Indicator
Oil Pressure Indicator
Neutral Indicator
Turn Signal Indicator
Speedometer
Odometer
Tachometer
Fuel Gauge FXD/L
FXD CONV
FXDWG
1
1
1
2
1
1
1
1
1
1
CURRENT
DRAW
(AMPERAGE)
FXD/CONV
0.15
0.15
0.15
0.15
0.3
0.19
0.35
0.19
0.3
0.12
FXDL
0.08
0.08
0.08
0.08
0.3
0.19
0.35
0.19
HARLEY-DAVIDSON
PART NUMBER
FXD/CONV
68024-94
68024-92
68024-94
68024-92
53439-79
52439-94
52441-95
67136-85
53439-79
67136-85
FXDL
68023-92A
68020-92A
68024-92A
68021-92A
53439-79
67136-85
52441-94
67136-85
55
99466-98
NOTES
56
99466-98
The Sportster section contains the vehicle specifications for
the following Harley-Davidson models:
XLH 883
XLH 883 Hugger
XLH 1200
XL 1200C Custom
XL 1200S Sport
S
P
O
R
T
S
T
E
R
57
99466-98
NOTES
58
99466-98
VEHICLE IDENTIFICATION NUMBER (V.I.N.)
NOTE
The full 17 digit serial, or Vehicle Identification Number
(V.I.N.) is stamped on the steering head and on a label
located on the right front frame downtube. An abbreviated
V.I.N. is stamped on the left side crankcase at the base of the
rear cylinder.
IDENTIFICATION
Always give the full 17 digit Vehicle Identification Number
when ordering parts or making any inquiry about your
motorcycle.
CAM - XLH 883
CEM - XLH 883 Hugger
CAP - XLH 1200
CGP - XL 1200 Custom
CHP - XL 1200 Sport
Model Designation
Engine Type
Varies - 1 thru 8
Model Year - 1998
Y - Manufactured in York, PA
K - Manufactured in Kansas City, MO
Sequential Number
1 HD 1
CA M
*Varies - can be 0 thru 9 or X
1
*
W
Y
110000
Sample V.I.N. as it appears on the steering head - 1HD1CAM19WY110000
Sample abbreviated V.I.N. as it appears on the engine - CAMW110000
59
99466-98
5769
1 2
3
4
5
13
6
12
1.
2.
3.
4.
Fuel supply valve
Carburetor enrichener knob
Battery
Ignition module (under
side cover)
5.
6.
7.
8.
11 10
9
8
7
Engine oil tank drain hose
Rear axle adjuster
Primary & transmission drain
plug
Clutch inspection cover
Sportster XLH 1200 - Left Side View
60
99466-98
9.
10.
11.
12.
13.
Primary chain cover
Primary chain inspection cover
Engine oil filter
Voltage regulator
Ignition coil
5768
3
2
1
4
5
6
12
11
10
1.
2.
3.
4.
Engine oil fill plug & dipstick
Carburetor/air cleaner
Front brake master cylinder &
reservoir
Speedometer/tachometer
9
5.
6.
7.
8.
8
7
Ignition/light key switch
Fork lock brackets
Timing inspection hole plug
Rear brake master cylinder &
reservoir
Sportster XLH 1200 - Right Side View
99466-98
9.
10.
11.
12.
Electric starter motor
Rear axle adjuster
Rear sprocket & drive
Shock absorber(s)
61
5773
1
2
3
4
12
5
11
1.
2.
3.
4.
5.
62
Fuel supply valve
Carburetor enrichener knob
Battery)
Engine oil tank drain hose
Rear axle adjuster
6.
7.
8.
10 9
8
7
6
Primary & transmission drain
plug
Clutch inspection cover
Primary chain cover
9.
10.
11.
12.
Primary chain inspection cover
Engine oil filter
Voltage regulator
Ignition coil
Sportster XL 1200C Custom - Left Side View (Typical)
99466-98
5772
3
4
2
1
5
6
12
11
10
9
1.
2.
3.
4.
Engine oil fill plug & dipstick
Carburetor/air cleaner
Front brake master cylinder &
reservoir
Speedometer
5.
6.
7.
8.
8
7
Ignition/light key switch
Fork lock brackets
Timing inspection hole plug
Rear brake master cylinder &
reservoir
9.
10.
11.
12.
Electric starter motor
Rear axle adjuster
Rear sprocket & drive
Shock absorber(s)
Sportster XL 1200C Custom- Right Side View (Typical)
63
99466-98
6327
1
2
3
4
5
13
6
12 11 10 9
1.
2.
3.
4.
Fuel supply valve
Carburetor enrichener knob
Battery
Ignition module (under
seat)
5.
6.
7.
8.
8
7
Engine oil tank drain hose
Rear axle adjuster
Primary & transmission drain
plug
Clutch inspection cover
9.
10.
11.
12.
13.
Primary chain cover
Primary chain inspection cover
Engine oil filter
Voltage regulator
Ignition coil
Sportster XL 1200S Sport - Left Side View (Typical)
64
99466-98
6326
3
4
1
12
2
5
6
11
10
1.
2.
3.
4.
9
Engine oil fill plug & dipstick
Carburetor/air cleaner
Front brake master cylinder &
reservoir
Speedometer/tachometer
5.
6.
7.
8.
7
8
Ignition/light key switch
Fork lock brackets
Timing inspection hole plug
Rear brake master cylinder &
reservoir
9.
10.
11.
12.
Electric starter motor
Rear axle adjuster
Rear sprocket & drive
Shock absorber(s)
Sportster XL 1200S Sport - Right Side View (Typical)
65
99466-98
5765
3
1 2
4
12
5
11
1.
2.
3.
4.
5.
Fuel supply valve
Carburetor enrichener knob
Battery
Engine oil tank drain hose
Rear axle adjuster
6.
7.
8.
9.
10 9 8
7
6
Primary & transmission drain
plug
Clutch inspection cover
Primary chain cover
Primary chain inspection plug
10. Engine oil filter
11. Voltage regulator
12. Ignition coil
Sportster XLH 883 - Left Side View (Typical)
66
99466-98
5764
3
4
5
2
1
12
6
11
10
1.
2.
3.
4.
Engine oil fill plug & dipstick
Carburetor/air cleaner
Front brake master cylinder &
reservoir
Speedometer
9
5.
6.
7.
8.
8
7
Ignition/light key switch
Fork lock brackets
Timing inspection hole plug
Rear brake master cylinder &
reservoir
9.
10.
11.
12.
Electric starter motor
Rear axle adjuster
Rear sprocket & drive
Shock absorber(s)
Sportster XLH 883 - Right Side View (Typical)
67
99466-98
NOTES
68
99466-98
XLH
1200
Wheel Base......... 60.20
Overall Length..... 88.10
Overall Width....... 35.00
Road Clearance ... 6.70
Overall Height ..... 49.75
Saddle Height...... 28.90
XL
1200
Custom
59.00
88.00
35.00
4.70
49.75
27.12
CAPACITIES (U.S.)
XL
1200
Sport
60.20
88.50
33.00
6.70
47.50
28.00
XLH
883
60.00
88.10
33.00
6.70
47.50
28.00
XLH
883
Hugger
59.00
88.00
35.00
4.70
49.75
27.12
WEIGHT (LBS.)
XLH
1200
DRY WEIGHT
(as shipped from
the factory) ...........491
GVWR ..................948
GAWR - Front ..... 353
GAWR - Rear ...... 595
Fuel Tank - All Models
(Gallons) Total ........................................................... 3.30
Reserve ..................................................................... 0.50
Oil Tank
(Quarts) w/filter ................................................................3
Transmission/Primary chaincase
(Ounces, approx.)..........................................................32
Front Fork
XL
1200
Custom
XL
1200
Sport
XLH
883
XLH
883
Hugger
Each (Ounces, wet) ...................................................... 9*
*Hugger/Custom .........................................................10.7
Sport..................................... follow applicable procedure
IGNITION SYSTEM
491
948
353
595
501
948
353
595
489
948
353
595
486
948
353
595
Timing Setting
1050-1500 RPM...............20° BTDC
Battery .................. Maintenance Free, 12 Volt, 18 amp. hr.
Spark Plugs
NOTE
Gross Vehicle Weight Rating (GVWR) (maximum allowable
loaded vehicle weight) and corresponding Gross Axle Weight
Ratings (GAWR) are given on a label located on the frame
steering head.
Type ......................................................................HD-6R12
Size ............................................................................12mm
Gap ..................................... 0.038-0.043 in. (0.97-1.09mm)
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SPECIFICATIONS
DIMENSIONS (IN.)
ENGINE
NUMBER OF SPROCKET TEETH
Number of Cylinders ......................................................... 2
Type ....................... 4-Cycle, 45 Degree V-Type, air cooled
Compression Ratio (all except XL Sport) ................ 9.0 to 1
Compression Ratio - XL Sport .................................10.0 to 1
Motorcycle
883
1200
SAE Horsepower
Brake
Horse
power
@ RPM
Bore
in. (mm)
Stroke
in. (mm)
Displacement
cu. in. (cc)
Torque
lb-ft
@ RPM
XLH 1200/C
66@5200
3.50 (88.9)
3.812
(96.8)
73.4 (1200)
72@4000
73.4 (1200)
76@4000
XLH 1200S
69@ 5500
XLH 883
57@6000
3.50 (88.9)
3.00 (76)
3.812
(96.8)
3.812
(96.8)
53.9 (883)
Rear Wheel
61
61
OVERALL GEAR RATIOS
Gear
883
1200
First (Low) ......................... 9.717 ............................... 9.047
Second .............................. 7.120 ............................... 6.629
Third .................................. 5.180 ............................... 4.823
Fourth................................ 4.267 ............................... 3.973
Fifth ................................... 3.615 ............................... 3.366
TIRE DATA
1WARNING
●
For your personal safety, tires, rims and air valves
must be correctly matched to wheel rims. See your
Harley-Davidson dealer. Mismatching tires, tubes,
rims and air valves may result in damage to the tire
bead during mounting or may allow the tire to slip on
the rim, possibly causing tire failure and/or personal
injury.
●
In addition, using tires other than those specified
may adversely affect motorcycle stability.
●
Tubeless tires fitted with the correct size inner tubes
may be used on all Harley-Davidson laced (wire
spoked) wheels. Protective rubber rim strips must be
53@4500
TRANSMISSION
Type ...........................................Constant Mesh, Foot Shift
Speeds ................................................................ 5 Forward
NUMBER OF SPROCKET TEETH
(Primary Chain)
Transmission
27
29
Engine ............................................................................. 35
Clutch .............................................................................. 56
70
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used with tubeless tires (fitted with correct size inner
tubes) when mounted on laced (wire spoked) wheels.
●
●
Inner tubes must not be used in radial tires and radial
tires must not be used on laced (wire spoked)
wheels.
Tubeless tires are used on all Harley-Davidson cast
and disc wheels.
Tire sizes are molded on the tire sidewall. Inner tube sizes
are printed on the tube.
1WARNING
Maximum inflation pressure must not exceed
specification on tire sidewall. Failure to follow this
warning could cause tire failure possibly resulting in
personal injury.
1998 VEHICLES
DUNLOP TIRES ONLY
Solo Rider
Rider & One
Passenger
XLH - All
XLH - All
TIRE PRESSURE
PSI (COLD)
Front
30
Rear
36
30
40
FUEL
Use a good quality unleaded gasoline. Use at least 87 pump
octane. Octane rating is usually found on the pump.
1WARNING
Remove fuel filler cap slowly. Fill fuel tank slowly to
prevent spillage. Do not overfill. Do not fill above the
bottom of the filler neck insert. Leave air space to allow
for fuel expansion. Expansion can cause an overfilled
tank to overflow gasoline through the filler cap onto
surrounding areas. After refueling, be sure fuel filler cap
is securely tightened. Failure to follow this warning could
result in an explosion and/or fire possibly resulting in
personal injury.
1CAUTION
●
Using gasoline that has methanol, can cause fuel
system rubber components’ failure and/or engine
damage.
●
Gasohol spills can stain the paint on your HarleyDavidson.
Todays service station pumps are increasingly of the higher
capacity variety. With the high flow of gasoline into a
motorcycle tank, air entrapment and pressurization is a
possibility. The pressurized air may force gasoline to escape
71
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through whatever opening is available within the filler tube.
This may not only soil clothing, but may create a potential fire
hazard.
GASOLINE BLENDS
“tailpipe” emissions. They are also formulated to evaporate less when you are filling your tank. Reformulated
gasolines use additives to “oxygenate” the gas. Your
motorcycle will run normally using this type of gas and
Harley-Davidson recommends you use it when possible,
as an aid to cleaner air in our environment.
Your motorcycle was designed to get the best performance
and efficiency using unleaded gasoline. Most gasolines sold
in the United States are blended with alcohol and/or ether to
create “oxygenated” blends. The type and amount of alcohol
or ether added to the fuel is important.
You may find that some gasoline blends adversely affect the
starting, driveability or fuel efficiency of your bike. If you
experience one or more of these problems, we recommend
you try a different brand of gasoline or higher octane rating.
●
CATALYTIC CONVERTERS
●
DO NOT USE GASOLINES CONTAINING METHANOL.
Using gasoline/methanol blends will result in starting and
driveability deterioration and damage to critical fuel system components.
ETHANOL is a mixture of 10% ethanol (Grain alcohol)
and 90% unleaded gasoline. Gasoline/ethanol blends
can be used in your motorcycle if the ethanol content
does not exceed 10%.
●
Gasolines containing ETHER: Gasoline/ether blends are
a mixture of gasoline and as much as 15% ether. Gasoline/ether blends can be used in your motorcycle if the
ether content does not exceed 17%.
●
REFORMULATED OR OXYGENATED GASOLINES
(RFG): “Reformulated gasoline” is a term used to
describe gasoline blends that are specifically designed to
burn cleaner than other types of gasoline, leaving fewer
Swiss model XLH motorcycles are equipped with catalytic
converters.
1CAUTION
You must use ONLY unleaded fuel in Swiss model
catalytic converter-equipped motorcycles. Using leaded
fuel will damage the emissions system.
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BULB CHART - XLH
NUMBER OF
CURRENT
HARLEY-DAVIDSON
BULBS
DRAW
PART NUMBER
(REQUIRED) (AMPERAGE)
LAMP DESCRIPTION
ALL LAMPS 12 VOLT
Headlamp
1
4.58/5.0
67697-81
Position Lamp (HDI)
1
0.32
53438-92
Tail and Stop Lamp
Tail Lamp
Stop Lamp
Tail Lamp (HDI)
Stop Lamp (HDI)
1
0.59
2.25
0.42
1.75
68168-89
Turn Signal Lamp
Front/Running
Rear
Front (HDI)
Rear (HDI)
2
2
2
2
2.25/0.59
2.25
1.75
1.75
Instrument Panel Lamps
High Beam Indicator
Oil Pressure Indicator
Neutral Indicator
Turn Signal Indicator
Speedometer
Odometer
Tachometer*
1
1
1
2
1
1
1
0.15
0.15
0.15
0.15
0.30
0.19
0.35
68169-90
68168-89
68572-64B
68163-84
68163-84
68024-94
68024-94
68024-94
68024-94
53439-79
67136-85
52441-94
*If applicable
73
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NOTES
74
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SAFE OPERATING RULES
●
Know and respect the rules of the road (see RULES OF THE
ROAD). Also read and observe the MOTORCYCLE SAFETY
booklets that come with this Owner’s Manual. You should also
read and know the contents of the MOTORCYCLE HANDBOOK for your state.
●
Use only Genuine Harley-Davidson approved parts and
accessories. Use of certain Screamin’ Eagle® or other manufacturer’s performance parts will void your new motorcycle
warranty. See your dealer for details.
●
Gasoline is extremely flammable and is explosive under certain conditions. Refuel in a well ventilated area with the engine
turned off. Remove fuel filler cap slowly. Do not smoke or allow
open flames or sparks when refueling or servicing the fuel system. Always close the fuel supply valve when the engine is not
running to prevent flooding of the carburetor and the surrounding area with gasoline. Do not fill fuel tank above the bottom of
the filler neck insert. Leave air space to allow for fuel
expansion.
●
Motorcycle exhaust contains poisonous carbon monoxide gas.
Do not inhale exhaust gases and never run the engine in a
closed garage or confined area.
●
Before starting engine, check for proper operation of
●
Be sure jiffy stand is fully retracted before riding the
motorcycle. If jiffy stand is not fully retracted during vehicle operation, it could contact the road surface causing a
momentary disturbance before retracting. This momentary disturbance could distract the rider, possibly causing
loss of vehicle control.
●
A new motorcycle must be operated according to special
break-in procedure. (See Break-in - The First 500 Miles.)
●
Operate motorcycle only at moderate speed and out of
traffic until you have become thoroughly familiar with its
operation and handling characteristics under all conditions. If you are an inexperienced rider we recommend
that you obtain information and formal training in correct
motorcycle riding technique.
●
Do not exceed 80 mph (130 km/h) carrying a passenger
or cargo.
●
Do not exceed the legal speed limit or drive too fast for
existing conditions. Always reduce speed when poor
driving conditions exist. High speed increases the influence of any other condition affecting stability and
possibility of loss of control.
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SAFETY FIRST
Before operating your new motorcycle it is your responsibility to
read and follow operating and maintenance instructions in this manual, and follow these basic rules for your personal safety.
brake, clutch, shifter, throttle controls, correct fuel and oil
supply.
●
●
●
Pay strict attention to road surfaces and wind conditions.
Any two wheeled vehicle may be subject to upsetting
forces. Wind blasts from passing trucks, holes in the
pavement, rough road surfaces, rider control error, etc.,
may influence the handling characteristics of your motorcycle. If this happens, reduce speed and guide the
motorcycle with a relaxed grip to a controlled condition.
Do not brake abruptly or force the handlebar because
this may aggravate an unstable condition. New riders
should gain experience under various conditions while
driving at moderate speeds.
Operate your motorcycle defensively. Remember, a
motorcycle does not afford the same protection as an
automobile in an accident. One of the most common
accident situations occurs when the driver of the other
vehicle fails to see or recognize a motorcycle and turns
left into the on-coming motorcyclist. Operate only with
headlamp on.
Wear an approved helmet, clothing and footgear suited
to motorcycle riding. Bright or light colors are best for
greater visibility in traffic, especially at night. Avoid loose,
flowing garments and scarves.
●
The exhaust pipes and mufflers get very hot when the
engine is running and remain too hot to touch for some
time after the engine is turned off. Wear clothing that will
completely cover the legs when riding. Avoid contact with
the exhaust system.
●
When carrying passengers, it is your responsibility to
instruct them on proper riding procedures. (See Riding
Tips for Motorcyclist included in your Owner’s Kit.)
●
Do not allow others, under any circumstances, to operate
your motorcycle unless you are certain that they are
experienced, licensed riders and are familiar with the
operation of your particular motorcycle.
●
When leaving motorcycle unattended, lock the steering
head and remove ignition key from switch. Protect your
motorcycle against theft.
●
Safe motorcycle operation requires mental awareness
and good judgment combined with a defensive driving
attitude. Don’t allow fatigue, alcohol or drugs to endanger
your safety or the safety of others. Vehicles equipped
with a sound system should have the volume adjusted to
a nondistracting level before operating vehicle.
76
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●
Maintain your motorcycle in proper operating condition in
accordance with the MAINTENANCE INTERVALS chart
in this Owner’s Manual. Particularly important to motorcycle stability is proper tire inflation pressure, tread
condition, and proper adjustment of wheel bearings and
steering head bearings. Do not operate motorcycle with
a loose, worn or damaged steering system or front and
rear suspension system because handling will be
adversely affected. Contact your dealer for repair of
steering or suspension system wear or damage.
●
Be sure all equipment required by federal, state, and
local law is installed and in good operating condition.
●
Maintain proper tire pressure and wheel and tire balance.
Improper tire and wheel balance and abnormal tread
wear can cause poor handling. Inspect your tires periodically. Replace tires with approved tires only. (See your
Harley-Davidson dealer.)
●
Do not exceed the Gross Vehicle Weight Rating of your
motorcycle. Maximum allowable vehicle weights with
rider and passenger are specified on the Identification
Label affixed to your vehicle. Overloading, particularly at
the rear of a motorcycle, can cause instability. Carefully
check any approved accessories for the maximum
weight capacities.
●
Do not tow a trailer. Trailers may contribute to motorcycle instability and/or tire overload.
●
Regularly inspect shock absorbers and front forks.
Check for leaks. Worn parts can affect stability. If you
have questions as to how these should function, see
your Harley-Davidson dealer.
●
Keep hazardous substances such as brake and battery
fluids and cleaning compounds away from eyes and skin
and out of mouth. Keep all hazardous substances out of
the reach of children.
●
Consult your dealer regarding any questions you may
have about your motorcycle. Should any abnormality
occur in the operation of your motorcycle, immediately
contact your Harley-Davidson dealer for correction of the
problem. Continued operation of a misperforming motorcycle will probably aggravate an initial problem, cause
repairs to be more costly and perhaps affect your personal safety.
●
The front and/or rear guard(s) may provide limited leg
protection and cosmetic vehicle protection under unique
circumstances (i.e., fall to the side while stopped, very
slow speed slide). They are not made nor intended to
provide protection in a collision with another vehicle or
an object.
●
The quality fasteners used in Harley-Davidson motorcycles have specific strength, finish and type requirements
to perform properly in the assembly and its environment.
Use only Genuine Harley-Davidson replacement fasten77
99466-98
ers, tightened to the proper torque. Substitution could
cause fastener failure which may result in personal
injury.
●
California vehicles, equipped with Evaporative Emission
controls, have a plugged carburetor overflow fitting. The
fuel supply valve on the vehicle should be turned off
when the vehicle is not operating. If the fuel supply valve
is not turned off when the vehicle is not operating, fuel
can drain into the engine, dilute the engine oil and cause
engine damage.
●
Do not tow a disabled motorcycle with another vehicle.
The steering and handling of the disabled motorcycle will
be impaired because of the force on the tow line.
Impaired handling can cause loss of control and possible
personal injury. If a disabled motorcycle must be transported, use a truck or trailer.
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RULES OF THE ROAD
Keep on the right side of the road centerline when meeting
other vehicles coming in the opposite direction. Ride to left of
center of your lane to avoid possible oily pavement.
● Always sound your horn, actuate your turn signals and
pass on the left side when passing other vehicles going
in the same direction. Never try to pass another vehicle
going in the same direction at street intersections, on
curves, or when going up or down a hill.
●
At street intersections give the right-of-way to the vehicle on
your right. Do not presume too much when you have the
right-of-way; the other driver may not know you have it.
●
Always signal when preparing to stop, turn, or pass.
●
All traffic signs, including those used for the control of
traffic at intersections, should be obeyed promptly.
SLOW DOWN signs near schools and caution signs at
railroad crossings should always be observed and your
actions governed accordingly.
●
When intending to turn to the left, signal at least 100 feet
before reaching the turning point. Move over to the centerline of the street (unless local rules require otherwise),
slow down, enter the intersection of the street and then
turn carefully to the left.
●
Never anticipate a traffic light. When a change is indicated from GO to STOP (or vice versa) in the traffic
control systems at intersections, await the change.
●
While turning either right or left, watch for pedestrians as
well as vehicles.
●
Do not leave the curb or parking area without signaling
and being sure that your way is clear to enter moving
traffic. A moving line of traffic has the right-of-way.
●
Be sure that your license plate is installed in the position
specified by law and that it is clearly visible under all conditions. Keep it clean.
●
Ride at a safe speed, a speed consistent with the type of
highway you are on, and always note whether the road is
dry, oily, icy or wet. Each varying condition on the highway means adjusting your speed and driving habits
accordingly.
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ACCESSORIES AND CARGO
●
Keep cargo weight concentrated close to the motorcycle and as low as possible to minimize the change in
the motorcycle’s center of gravity. Distribute weight
evenly on both sides of the vehicle and do not load
bulky items too far behind the rider or add weight to the
handlebars or front forks. Do not exceed 15 pounds
maximum load in each saddlebag (12 pounds, FXDSConv.) or 25 pounds maximum in Tour-Pak®. Improper
loading can cause vehicle handling problems, leading
to personal injury.
●
Luggage racks are designed for lightweight items - do
not overload racks.
●
Be sure cargo is secure and will not shift while riding.
Recheck load periodically.
●
Accessories that change the operator’s riding position
may increase reaction time and affect handling.
●
Additional electrical equipment may overload the
motorcycle’s electrical system and cause an unsafe
operating condition.
●
The front and rear guard may provide limited leg protection and cosmetic vehicle protection under unique
circumstances (i.e., fall to the side while stopped, very
slow speed slide). It is not intended to provide protection in a collision with another vehicle or other object.
1WARNING
The addition of accessories and additional weight to this
motorcycle can affect the motorcycle’s stability, handling
characteristics, and safe operating speed. Because HarleyDavidson cannot test and make specific recommendations
concerning every accessory or combination of accessories
sold, the rider must be responsible for safe operation of the
motorcycle when installing accessories or carrying additional weight. The following guidelines should be used
when equipping a motorcycle and carrying passengers and
cargo.
●
●
The Gross Vehicle Weight Rating (GVWR) is shown on
the information plate located on the frame steering
head. GVWR is the sum of the weight of the motorcycle
and accessories and the maximum weight of the rider,
passenger and cargo that may be safely carried. Do not
tow a trailer with this motorcycle. Do not exceed the
Gross Vehicle Weight Rating as indicated on the frame
label. Overloading the motorcycle or towing a trailer
will cause unstable handling and reduced braking efficiency which could result in an accident and personal
injury.
Never exceed 80 MPH (130 km/h) when carrying a passenger or cargo.
80
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●
Large surfaces such as fairings, windshields, backrests, and luggage racks can adversely affect handling.
These items should be designed and approved by Harley-Davidson specifically for the motorcycle model and
be properly installed.
1WARNING
1WARNING
The front end components of the Springer and their
design relationships to each other are very important.
Altering these relationships by modifying the Springer
front end could adversely affect the handling of the
motorcycle and result in personal injury.
Softail models are special edition, custom motorcycles. They have been carefully designed and
engineered to be ridden in the original configuration. DO NOT alter the handling characteristics of
these motorcycles by adding weight, such as fairings or radios. Do not attempt “custom” alterations
such as extended front forks. Present Softail models are not designed for and must NEVER be used
with a sidecar. Use of the vehicle for this purpose
could cause personal injury. FXSTS and FLSTS
motorcycles were NOT designed for sidecar use.
The Springer ® fork was NOT designed for sidecar
use. DO NOT use either the motorcycle or the
Springer fork for this purpose. Use of the vehicle or
the fork for this purpose could cause personal
injury.
The above constitute vehicle misuse. Vehicle misuse
could adversely affect handling, posing a potential hazard to the rider possibly resulting in personal injury.
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1WARNING
The Springer front suspension was designed as a
system and the shock absorber: FLSTS P/N 54482-97;
FXSTS P/N 54483-88A has specific characteristics that
make it an integral part of the suspension system.
Replacing this shock absorber with anything other than a
Harley-Davidson replacement part or altering the
suspension system, may affect handing, resulting in
personal injury.
Harley-Davidson has designed and manufactured this
special, custom front end according to our very stringent
and well-tested standards. If you modify the Springer
front end in any way that changes our original design,
Harley-Davidson cannot and does not assume responsibility for mishaps resulting from these changes.
DO NOT:
●
Alter the fender brackets to lower the fender. Doing
this could allow the front wheel to bind on the fender
during hard stops or big bumps.
●
Replace the O.E.M. tire with a higher-aspect ratio
tire. Doing this could allow the front wheel to bind on
the fender during hard stops or big bumps.
●
Replace the FXSTS tire with a traditional-looking 16
in. front wheel, tire and front fender. In addition to
above, this could adversely affect the handling characteristics of this motorcycle.
82
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●
NOTE
This Owner’s Manual covers 1998 Harley-Davidson
motorcycles. Some features explained are unique to
certain models. These features may be available as
accessories for your Harley-Davidson motorcycle. See
your Harley-Davidson dealer for a complete list of
accessories that will fit your model.
omf1c
Refer to the side-view photographs in the front of the
manual to locate the items discussed in this manual.
OFF
FORK
LOCK
OFF
CONTROLS AND INDICATORS
●
ACC. IGNITION
IGNITION
ACCESS
UNLOCK
LOCK
IGNITION/LIGHT KEY SWITCH
1WARNING
FXD/L/CONV
DO NOT modify the ignition/light switch wiring to circumvent the automatic-on headlight feature. High visibility is
an important safety consideration for motorcycle riders.
To reduce the risk of vehicle damage and personal injury,
ensure that headlight is on at all times.
Be sure to record all your key numbers in the space provided at
the front of this book on page ii.
See Figure 1 and Table 1. The ignition/light key switch controls
electrical functions of the motorcycle.
1CAUTION
●
To deter theft of your motorcycle, always lock ignition
and remove key when motorcycle is left unattended.
●
Do not lubricate barrel locks with petroleum based
lubricants or graphite. Inoperative locks may result.
FLT Models
ACC.
F
OF
Softail Models,
Dyna Wide Glide &
Road King
IG
NI
TI
O
N
XLH Models
Figure 1. Ignition/Light Key Switch
83
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1CAUTION
Turn switch to OFF position and remove key before locking bike. If you leave the ignition in the ACC. position, the
instrument lights will discharge the battery.
Table 1. Ignition/Light Switch (1 of 2)
MODEL
FLT
LOCATION
SWITCH POSITIONS/FUNCTIONS
At bottom of To unlock the switch and the front fork, push the key in and turn it counterclockwise (clockwise on
instrument
HDI). Press the lever/key (HDI) down and turn it to the off position. Be sure you push key in to
panel
move key to either position. Press the lever/key (HDI) down to move it to any position.
To lock the fork, move fork to the full left position. Push down on lever and turn it to the left, to the
FORK LOCK position. Remove the key.
ACC. - Accessories and hazard warning flasher can be turned on. Instrument lights are on.
Brake light and horn can be activated. Key may be removed (except HDI).
The ignition, lights and accessories work when the switch is in the IGNITION position, as required
by law in some localities.
NOTE
Harley-Davidson recommends removing key from ignition/fork lock before operating motorcycle. If
you do not remove key, key can fall out during operation (except HDI).
FLHR/C-I On fuel tank Switch is locked or unlocked by lifting switch cover, inserting key and turning key counterclockwise
instrument
to lock, clockwise to unlock. Key may be removed in any position.
panel
LOCK - Ignition, lights and accessories are off.
ACC. - Accessories are on. Hazard warning flashers can be operated. Instrument lights are on.
Brake light and horn can be activated.
LIGHTS and IGNITION - Ignition, lights and accessories are on.
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Table 1. Ignition/Light Switch (2 of 2)
MODEL
XLH
Softail
FXDWG
FXD/L/
CONV
LOCATION
SWITCH POSITIONS/FUNCTIONS
Behind frame OFF - Ignition and lights are off. Key may be removed.
steering neck ACC. - Hazard warning flasher can be turned on. Instrument lights are on. Brake light and horn
(right
hand can be activated. Key may be removed.
side)
IGNITION - Push in and turn key. Ignition and lights are on.
On fuel tank Switch is locked or unlocked by lifting switch cover, inserting key and turning key counterclockwise
instrument
to lock, clockwise to unlock. Key may be removed in any position.
panel
LOCK - Ignition, lights and accessories are off.
ACC. - Accessories are on. Hazard warning flashers can be operated. Instrument lights are on.
Brake light and horn can be activated.
IGNITION - Ignition, lights and accessories are on. Switch cannot be locked.
On fuel tank Switch is locked or unlocked by lifting switch cover, inserting key and turning key counterclockwise
instrument
to lock, clockwise to unlock. Key may be removed in any position.
panel
LOCK - Ignition, lights and accessories are off.
ACC. - Accessories are on. Hazard warning flashers can be operated. Instrument lights are on.
Brake light and horn can be activated.
IGNITION - Ignition, lights and accessories are on.
Below seat
OFF - Ignition and lights are off. Key may be removed.
(right hand
ACC. - Hazard warning flasher can be turned on. Instrument lights are on. Brake light and horn
side)
can be activated.
IGNITION - Push in and turn key. Ignition, lights and accessories are on.
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ELECTRIC STARTER SWITCH
See Figure 2. The electric starter switch (8) is located on the
right handlebar control group. Put engine stop switch (9) in
RUN position and transmission in neutral. Turn ignition ON
and push the START switch to operate starter motor.
ENGINE STOP SWITCH
See Figure 2. Engine stop switch (9) is located on the right
handlebar control. The engine stop switch turns ignition ON
or OFF and should be used at all times to stop the engine,
especially in an emergency. To stop engine, push switch to
position marked OFF - then turn key to OFF.
A spring loaded friction adjusting screw is located at the bottom of the throttle grip clamp on all models except Ultras.
Unscrew the knob (12) so throttle returns to idle position
when hand is removed from throttle grip. Screw the knob in to
increase friction on grip to provide a damping effect on throttle motion. This reduces rider fatigue on long trips, where
steady speeds are maintained. The throttle friction screw
should not be used under normal stop and go operating
conditions.
1WARNING
NOTE
Switch must be in RUN position to operate engine.
THROTTLE CONTROL GRIP
See Figure 2. The throttle control grip (10) is located on the
right handlebar control group. Turn control grip clockwise to
close throttle; turn control grip counterclockwise to open
throttle.
Do not overtighten the friction adjustment screw. Operation with the friction screw overtightened is not
recommended because of the possible hazard involved
when the engine will not return to idle automatically in an
emergency. This could lead to loss of control of motorcycle, resulting in possible personal injury.
86
99466-98
1.
2.
3.
4.
5.
6.
7
Headlamp dimmer switch
Horn switch
P.T.T. switch*
Audio control*
Left turn signal switch
Clutch hand lever
* If equipped
f1368x8x
11
9
8
12
14
15
f1367x8x
6
2
10
1
5
4
13
3
7.
8.
9.
10.
11.
12.
Master cylinder
Electric starter switch
Engine stop/run switch
Throttle control grip
Brake hand lever
Friction adjusting screw knob*
(Not shown)
13. Mode Select
14. Right turn signal switch
15. Cruise control function switch*
Figure 2. Handlebar Controls
87
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ENRICHENER
1.
CONSTANT VELOCITY (C.V.) CARBURETOR
ENRICHENER - CARBURETED MODELS
When starting a cold engine, the throttle control MUST
BE CLOSED for the enrichener to work properly.
2.
The enrichener does not have detents. The enrichener
knob position can be adjusted from full in to full out.
A constant velocity carburetor uses an “enrichener” instead of
a “choke”. An enrichener is operated almost the same way as
a choke. There are two differences:
Pull enrichener knob all the way out for cold engine starting.
Change the enrichener knob position between full out or full
in as the situation requires.
OMF3
1st position
(Normal
running
position)
See Figure 3. Engine speed increases as the enrichener
knob is pulled out. By moving the enrichener knob, you adjust
the air/fuel mixture to start a cold or warm engine.
Enrichener
1/2 way
position
Full out
position
NOTE
●
See OPERATION for detailed starting procedures.
●
Fuel injected models do not use an enrichener. See
OPERATION for detailed starting procedures.
CLUTCH HAND LEVER
1WARNING
Be sure fingers are not positioned between hand control
levers and handlebar grips or operation of these controls
could be impaired. This may cause loss of control of the
motorcycle, resulting in possible personal injury.
Figure 3. Setting the Enrichener
See Figure 2. The clutch hand lever (6) is located on the left
handlebar where it is operated with the fingers of the left
hand. Pull lever in against handlebar grip to disengage clutch;
release the lever slowly to its outward position to engage
clutch.
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GEAR SHIFTER
See Figure 4. The gear shifter is located on the left side,
where it is operated with the toe of the left foot.
OMF4
Front of Motorcycle
Pushing lever all the way down (full stroke) shifts transmission to
the next lower gear, while lifting lever all the way up (full stroke)
shifts transmission into the next higher gear.
The operator must release the shift lever after each gear change
to allow lever to return to its central position before another gear
change can be made.
Neutral position is between first (low) and second gears. First gear
is the last gear position that can be found by pushing lever full
strokes downward. To shift from first gear to neutral, lift lever half
its full stroke.
NOTE
●
The gear shifter mechanism on 1340cc 5-speed motorcycles
does not permit shifting the transmission to neutral from second gear. Neutral can only be engaged from first gear.
●
The XLH 5-speed transmission can be shifted to neutral from
either first or second gear.
With the motorcycle standing still and the engine not running, it
usually will be necessary to roll the motorcycle backward and forward with the clutch fully disengaged while maintaining a slight
pressure on the foot shift lever before a shift from one gear to
another can be made.
Figure 4. Gear Shifter
NOTE
Some motorcycles have a “heel-toe” shifter lever. With this
shift lever, upshifts can be made with the heel of the left foot.
Downshifts can be made with the toe.
Even with the engine running and the motorcycle standing still, difficulty may be experienced in shifting gears. This difficulty arises
when transmission gears are not turning and shifting parts are
not lined up to permit engagement.
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When this difficulty is experienced, do not under any circumstances, attempt to force the shift. The results of such abuse
will be a damaged or broken shifter mechanism.
Either roll the motorcycle as indicated above, or if the engine
is running, engage the clutch very slightly while applying light
pressure to the shifter lever to make the shift. Both of these
procedures set transmission gears in motion and then the
shift can be made easily. See Shifting Gears in the OPERATION section.
BRAKES
The brake pedal controls the rear wheel brake and is located
on the motorcycle’s right side. It is operated by the right foot.
See Figure 2. The brake hand lever (11) controls the front
wheel brake and is located on the right handlebar. It is operated by the fingers of the right hand.
Brakes should be applied uniformly and evenly to prevent
wheels from locking up. A balance between rear and front
braking is generally best.
1WARNING
Do not apply either brake strongly enough to lock the
wheel. This may cause loss of control of the motorcycle,
resulting in possible personal injury.
HEADLAMP DIMMER SWITCH
See Figure 2. The headlamp dimmer switch (1) on the left
handlebar controls the headlamp high and low beams.
NOTE
The beam (blue) indicator light remains lit when high beam is on.
PASSING/FOG LAMP SWITCH - FLT,
FLHR/C-I, FLSTC, FLSTS MODELS
See Figure 5. Use the passing lamp switch to turn on the
passing lamps as required.
NOTE
●
On the FLHT/C/Ultra/I, the passing/fog lamp switch is on
the left side of the ignition switch on inner fairing panel.
●
On the FLSTC, the passing/fog lamp switch is on the left,
inside of the triple clamp shroud.
●
On the FLHR/C-I, the passing /fog lamp switch is on the
right, inside of the triple clamp shroud.
●
On the FLSTS, the passing/fog lamp switch is under the
left fuel tank next to the enrichener knob.
●
The passing/fog lamps do not work when the headlamp
is on high beam (except Australian models).
HORN SWITCH
See Figure 2. The horn is operated by the horn switch (2) on
the left handlebar control group.
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●
CRUISE CONTROL - ULTRA
MODELS
Theory of Operation
The Harley-Davidson cruise control is designed to be safely
operated with minimum movement by the rider. It has been
designed so all rider control actions are natural and easy.
NOTE
Controls (Figures 2 and 5 and Table 1)
There are two rider-operated control switches:
●
FLTR/C-I models are “cruise ready”, see your dealer for
information.
●
The rider always over-rides and controls the system.
●
The system will not work at vehicle speeds below 30
MPH.
●
The system is managed by a small computer that gets its
operation information from VEHICLE SPEED, via the
speedometer. The tachometer provides information to
disengage the system if engine RPM’s suddenly
increase (disengage clutch, slippery or icy roads).
●
The system will allow rider to increase speed 10 MPH or
more (depending on how hard the rider rolls on the throttle and the condition of the bike) over the “SET” point
before de-activating. This feature allows the rider to
momentarily increase speed, if necessary. Rolling on the
throttle to greatly increase speed may de-activate the
system.
1.
An “ON/OFF” switch located on the right of the ignition
switch. This switch turns the system ON or OFF.
NOTE
The red light on the CRUSE ON/OFF switch will come on to
indicate the system is ON. If the red light does NOT come on,
the system is NOT ON, you cannot “SET” cruise speed - see
your Dealer.
2.
“RESUME/SET” switch located in the right handlebar
control group:
Besides the computer, the system has other components: a stepper-motor (controlled by the computer),
which operates the throttle during CRUISE operation, a
clutch which disengages the stepper-motor during noncruise operation and several internal switches, all sending information to the computer.
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f1250x2x
See OPERATION. This switch controls several system functions, including: SET, RESUME, ACCELERATE and
DECELERATE.
FLHTC Ultra/I
SPO
Acc.
switch
T
SPK
R
CRU
The switch is “self-centering”. After you press the switch to
the desired function it will return to the center (ready) position.
ISE
ACC
Passing/Fog
lamp
Helmet
speakers
NOTE
OPERATION
1WARNING
Cruise
Figure 5. Cruise, Speakers, Acc., Passing Lamp Controls
The cruise control system is not intended for use:
●
In heavy traffic.
●
On roads with sharp or blind curves.
●
On slippery roads of any kind.
Using the cruise control in these circumstances can
cause personal injury.
TURN ON THE SYSTEM:
Turn the fairing mounted “ON/OFF” switch to the ON position.
See Figure 5. The RED lamp on or near the switch, indicating
CRUISE ON, will light.
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2.
Activate the System:
Set:
1.
Increase motorcycle speed to the desired cruise speed.
2.
Momentarily press the “RESUME/SET” switch to the
right to set the speed. The system will quickly (approximately 1 1/2 seconds or less) begin to maintain the
desired motorcycle speed.
3.
See Figures 5 and 9. The GREEN lamp on the gauge
panel, indicating CRUISE SET, will light.
Resume:
If the system has been deactivated (see DE-ACTIVATE/
TURN OFF THE SYSTEM), you can resume the previously
set speed by pressing the RESUME/SET switch to the left.
NOTE
The system has a “decelerate” function. If you are at your
SET speed, press the switch to the right and release to
reduce speed in 1 MPH increments. Press and hold
switch down to decrease speed continuously at approximately 1 MPH increments. System takes approximately
2 seconds to react.
NOTE
The system will not accelerate more than 10 MPH above the
set speed. The system will decelerate until the set switch is
released or is de-activated when speed goes below 30 MPH.
DE-ACTIVATE/TURN OFF THE SYSTEM
De-Activate the System:
There are several ways to de-activate the system without
turning it OFF:
The computer will hold the SET speed in its memory for the
RESUME function until the system is turned to the left. If
vehicle speed drops more than 15 MPH below SET speed,
speed can no longer be RESUMED.
●
Roll the throttle OFF - TO THE STOP.
●
Pull in the clutch lever (disengage the clutch).
●
Engage either or both brake(s).
Accelerate, Decelerate:
The above actions temporarily de-activate (disengage) the
system. The system will still be ON and ready to operate if
you RESUME or SET it again. The pre-set speed will remain
in memory, ready for RESUME function. The GREEN lamp
on the gauge panel, indicating CRUISE SET, will turn off. The
RED cruise control lamp will remain lit, indicating CRUISE
ON.
1.
The system has an “accelerate” function. If you are at
your SET speed, press the switch to the left and release
to increase speed in 1 MPH increments. Press and hold
switch up to increase speed continuously at approximately 1 MPH increments. System takes approximately
2 seconds to react.
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Turn Signal Switch Operation
Turn Off the System:
Turn the fairing mounted “ON/OFF” switch OFF or turn OFF
vehicle ignition. These actions turn the system OFF until you
turn it ON again. Turning the system/ignition OFF also erases
the previously set cruise speed from memory so you can program a new cruise speed when you next turn the system ON.
Both the green and red cruise control indicator lamps will be
off.
NOTE
System WILL NOT work if:
●
An uphill grade is so long and/or steep, the throttle
cables are pulled their full length when the system tries
to maintain vehicle speed. This feature prevents
stretching the cables.
●
Rider operates bike at vehicle speeds below 30 MPH.
●
Brake light bulbs are burned out.
●
Throttle cables are too tight. (See Dealer.)
●
Brake lights are on constantly. (See Dealer.)
TURN SIGNAL SWITCHES - General
See Figure 2. The right handlebar turn signal switch (14)
operates the right front and right rear flashing lamps. The left
handlebar turn signal switch (5) operates the left front and left
rear flashing lamps. Front turn signal lamps also function as
running lamps.
The turn signal switches are controlled by a small microprocessor which gets its operation information from the
speedometer and turn signal switches.
Momentarily depress the desired turn signal switch. The turn
signal lamps will begin and continue flashing. When the
microprocessor senses enough forward movement (a time
period of approximately 6-10 seconds) from the speedometer, it cancels the turn signal lamps. If you are not moving
forward, (for example; stopped at a stoplight) the turn signals
will flash indefinitely.
NOTE
●
If you want the turn signals on longer, hold the switch in.
The turn signals will begin flashing immediately, but the
microprocessor will not begin computing distance until
you release the switch.
●
If you are signaling to turn in one direction and you
depress the switch for the opposite turn signal, the first
signal is canceled and the opposite side begins flashing.
If you want to stop the lamps from flashing, briefly depress
the turn signal switch a second time. The turn signal lamps
will stop flashing.
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HAZARD WARNING 4-WAY
FLASHER (Turn Signal Switches)
The hazard warning 4-way flasher operates all four turn signal lamps at the same time. It is controlled by the turn signal
switch microprocessor. The hazard warning flasher will operate when the ignition switch is in the ignition, lights or access
position.
Turn ON the hazard warning 4-way flasher by momentarily
(approximately 1 1/2 seconds) depressing BOTH turn signal
switches at once. Turn OFF the 4-way flasher the same way.
ACC. SWITCH
See Figure 5. All FLT models, including the FLHR, have an
accessory switch for the owner’s use. There is an accessory
connector, located under the seat, that can be activated with
the ACC. switch. The switch is located on the left side of the
fairing or triple clamp shroud. See your dealer for possible
uses.
SOUND SYSTEM CONTROLS
See Figures 2, and 5 thru 4 for sound system controls. For a
more detailed explanation of the sound system controls,
read the Harley-Davidson Premium Sound System Handbook (P/N 99464-98.)
1WARNING
On ULTRA-GLIDES, if the C.B. is ON to monitor incoming transmissions and turned to low volume at the same
time the stereo is ON, the C.B. can mute the stereo. If
you have compensated for the muting effect by turning
up the stereo, turning off C.B. will stop the muting effect
and the stereo will be loud. This can distract you from
motorcycle operation, resulting in possible personal
injury. Turn music DOWN before turning OFF C.B.
NOTE
FLTR/C-I models have wiring and switches for sound system
upgrades. See your dealer for information.
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f1367x8x
INDICATOR LIGHTS
See Figure 7. Five or seven indicator lights are provided.
The green TURN indicators will flash when turn signals are
activated. Whichever indicator flashes indicates chosen turn
direction. When the 4-way hazard flashers are operating,
both turn indicators will flash simultaneously.
The blue BEAM indicator light, when lit, signals that the high
beam headlamp filament is operating.
The green NEUTRAL light turns on to indicate when transmission is in neutral.
The red OIL indicator light, when lit, signals that oil is not circulating through the engine. The OIL indicator light will glow
when the ignition is turned on prior to starting engine. With
engine running, light should be off when engine speed is
above idle.
If the oil pressure indicator light does not go off at speeds
above idling, it is usually because of an empty oil tank or
diluted oil. In freezing weather the oil feed may clog with ice
and sludge, preventing oil circulation. A grounded oil signal
switch wire, faulty signal switch, damaged or improperly
installed check valve and/or trouble with the pump will also
cause the light to remain illuminated.
Figure 6. Sound System/Cruise Control Handlebar
Controls
NOTE
On Sportster models, if the ignition is turned on immediately
after the engine is stopped, the oil light may not come back
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XL Sport Indicator Lights
OMF9
Left turn
High beam
Engine Lamp
Right turn
See Figure 8. The engine lamp is located at the lower center
of the tachometer. Its purpose is to indicate whether or not
the engine/engine management system is operating normally.
The engine lamp color is RED.
The engine lamp normally comes on when the bike’s ignition
is first turned on and remains on for approximately 4 seconds,
as the engine management system runs a series of selfdiagnostics.
Neutral
If the engine lamp comes on at any other time, see your
Harley-Davidson dealer.
Oil
Figure 7. Indicator Lights (Typical)
on because of oil pressure retained in the filter housing.
1CAUTION
If the oil pressure indicator light fails to go off, always
check the oil supply first. If oil supply is normal and the
light still does not operate normally, stop the engine at
once and do not ride further until the trouble is located
and the necessary repairs are made.
Ultra Models Indicator Lights
See Figures 5 and 9. Ultra models have two additional indicator lights: a red light on the cruise control switch, indicating
cruise control ON or OFF, and a green light on the tachometer, indicating cruise control set or not set. See CRUISE
CONTROL - ULTRA MODELS.
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SEQUENTIAL PORT FUEL
INJECTED HARLEY-DAVIDSONS
INDICATOR LAMPS, Sequential Port Fuel Injected HarleyDavidsons (Figure 8)
Compared to other Harley-Davidsons, fuel injected models
have two additional indicator lamps; an ENGINE LAMP and a
LOW FUEL L.E.D.
Engine Lamp
The engine lamp is located at the lower right side of the
tachometer (FLHTCU-I) or speedometer. Its purpose is to
indicate whether or not the engine/engine management
system is operating normally. The engine lamp color is RED.
The engine lamp normally comes on when the bike’s ignition
is first turned on and remains on for approximately 4 seconds,
as the engine management system runs a series of selfdiagnostics.
cruise and engine L.E.D. lamps on FLHTC/U-I and FLTR-I
models or above and to the left of the fuel gauge on FLHR-I
models. The low fuel L.E.D. lights up to indicate that you have
approximately 1/2 gallon of gasoline left in the tank. The low
fuel lamp color is AMBER.
TACHOMETER
See Figure 9. If vehicle is so equipped, the tachometer registers the engine speed in revolutions per minute (RPM).
1CAUTION
Do not operate the engine above maximum safe RPM as
shown in Table 4, OPERATION (red zone on tachometer).
Engine damage may occur. Lower the RPM by upshifting
to a higher gear or reducing the amount of throttle.
SPEEDOMETER/ODOMETER
If the engine lamp comes on at any other time, see your
Harley-Davidson dealer.
See Figure 9. The speedometer registers miles per hour of
forward speed. The odometer registers the number of miles
the vehicle has traveled.
A blinking or continuously lit engine lamp indicates that an
“event” has occurred relating to the engine/engine
management system. See your Harley-Davidson dealer.
1WARNING
Low Fuel L.E.D.
There is a low fuel L.E.D., below the tachometer, between the
Never travel at a speed faster than the posted speed
limit. Excessive speed could cause loss of control resulting in possible personal injury.
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o0023aox
o0023aox
FLHTC/U-I
FLTR/I
H
AR
MPH
LE
Y-D
P
CERTIFIED
OM
AVI
DSON MOTOR C
40
30
50
FLHTC/U-I
FLTR/I
60
20
70
10
0
80
RPM
x100
Y
AN
CR
U IS
Odometer
INE
ENG
E
E
F
50 60 70
40
30
20
10
0
MPH
000001
HA
Engine
lamp
80
90
100
110
120
N
RL
PA
EY
CERTIFIED
- DA
OM
VI DS ON M OTOR C
50 60 70
80
40
30 0 0 0 0 0 1 90
20
100
10
110
0
120
0001
Y
AR
L
MPH
H
Trip
odometer
Low fuel
indicator
Tachometer
Speedometer
EY
MP
-DA CERTIFIED
CO
V ID S
ON MOTOR
FLHR/C-I
E
F
60
70
0
Y
AN
40
30
20
10
0
AR
LE
Y-D
50 60 70
MPH
000001
UIS
E
INE
ENG
80
90
100
110
120
P
CERTIFIED
M
AV I
CO
DSO N M O T O R
P
80
RPM
x100
CR
H
Speedometer
50
10
FLHR/C-I
ENG
40
30
20
Y
50 60 70
80
40
30 0 0 0 0 0 1 90
20
100
10
110
0
120
0001
AN
ENG
Odometer
50 60 70
80
40
90
30
20
100
10
110
0
0 0 0 0 0 1 120
MPH
LE
YDA
V ID S
Y
AN
MP
CO
ON MOTOR
50
Engine
lamp
60
20
70
10
0
RPM x100
80
ENGINE
AR
H
H
AR
40
30
LE
YDA
V ID S
ON MOTOR
Y
AN
MP
CO
XL SPORT
Figure 9. Speedometer, Odometer, Trip-odometer,
Tachometer
Figure 8. Indicator Lamps
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1CAUTION
1CAUTION
Never attempt to tamper with or alter the vehicle odometer. This is illegal and the speedometer will be damaged.
Objects in mirrors are closer than they appear.
TRIP-ODOMETER (MECHANICAL)
Adjust the mirrors to clearly reflect the area behind the
motorcycle.
Use the trip-odometer to register number of miles traveled on
a trip or between refueling. Use the knurled knob on the dash
panel to reset the trip odometer to zero.
ELECTRONIC SPEEDOMETER
The electronic speedometer has a single display window for
both the odometer and trip-odometer.
Press the speedometer control (rubber covered) button, to
change the display window on the speedometer face to either
odometer or trip-odometer. To reset the trip-odometer to
zero, press button to reset speedometer display to the
ODOMETER mode and hold the button in for approximately 2
to 3 seconds. The speedometer will switch to the tripodometer mode and reset the display to zero.
NOTE
Adjust mirrors so you can see a small portion of your shoulders in each mirror. This will help you establish the relative
distance of vehicles to the rear of your motorcycle.
OMF11
MIRRORS (CONVEX)
See Figure 10. Your vehicle is equipped with convex mirrors.
A convex mirror has a curved surface. This type of mirror is
designed to give a much wider view to the rear than a flat mirror; however, cars and other objects seen in this type of
mirror will look smaller and farther away than when seen in a
flat mirror. Therefore you must use care when judging the
size or distance of objects seen in these mirrors.
Figure 10. Mirror
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OIL PRESSURE GAUGE
JIFFY STAND
The oil pressure gauge indicates engine oil pressure. Engine
oil pressure will normally vary from 5 PSI at idle speed to 12 15 PSI at 50 MPH when engine is at normal operating
temperature.
See Figure 11. The jiffy stand is located on the left side of the
motorcycle and swings outward to support the motorcycle for
parking.
VOLTMETER
The voltmeter indicates electrical system voltage. With the
engine running above 1500 RPM, the voltmeter should register 13 - 14.5 volts with battery at full charge.
1CAUTION
Always park the motorcycle on a level, firm surface.
Vehicle weight could cause motorcycle to fall over. Cosmetic damage could occur.
OMF12
CLOCK (In Radio)
The clock runs continuously as long as there is battery power.
See the Harley-Davidson Premium Sound System Handbook
(P/N 99464-98) to reset clock.
FUEL GAUGE
The fuel gauge indicates the approximate amount of fuel in
the fuel tank(s).
Figure 11. Jiffy Stand (Typical)
NOTE
The Dyna Glide Low Rider, Dyna Wide Glide and Road King
models’ left-side fuel cap is a fuel gauge only. Do not remove.
AIR TEMPERATURE GAUGE
The air temperature gauge indicates the ambient air temperature in °F.
1WARNING
●
Your vehicle is equipped with a jiffy stand that locks
when placed in the full forward (down) position and
the vehicle weight is rested on it. Without vehicle
weight resting on the jiffy stand, any movement of
the vehicle could cause the jiffy stand to retract
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slightly from the full forward position. If the jiffy
stand is not in the full forward (lock) position when
vehicle weight is rested on it, the vehicle could fall
over, possibly causing injury.
●
o0006ax
Be sure jiffy stand is fully retracted before riding the
motorcycle. If jiffy stand is not fully retracted during
vehicle operation, it could contact the road surface
causing a momentary disturbance before retracting.
This momentary disturbance could distract the rider,
possibly causing loss of vehicle control and possible injury.
FORK LOCK
1WARNING
Do not operate vehicle with forks locked. This will
restrict the vehicle’s turning ability and could cause personal injury.
See Figure 12. The XLH and Softail models fork lock is
located on the center of the lower front fork bracket. Turning
fork to the left aligns hole in bracket with hole in steering
head. A high strength padlock is available from your dealer to
lock the fork in this position. Order Part No. 45737-72A.
Using the padlock will discourage unauthorized use or theft
when parking your motorcycle.
See Figure 1. FLT models, excluding the FLHR, have the fork
lock incorporated in the Ignition/Light switch. See Table 1,
IGNITION/LIGHT SWITCH.
Figure 12. Fork Lock - Softail, XLH Models
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Clamp
shroud
90
0
10
20
MP
30
CK
H
40 5
0
LO
LO
CK
UN
70
Fork
lock
80
OMF51
60
OMF14b
Figure 13. Dyna Glide Fork Lock
See Figure 13. Dyna Glide models have the fork lock incorporated in the steering head on the right hand side.
See Figure 14. The FLHR/C-I has a fork lock at the top of the
steering head, behind the headlamp nacelle and inset in the
handlebar clamp shroud.
Accessory.
switch
Passing lamp
switch
Figure 14. Road King Fork Lock
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FUEL SUPPLY VALVE CARBURETED MODELS ONLY
See Figure 15. The fuel supply valve is located under the fuel
tank. Fuel supply to carburetor is shut off when handle is in
horizontal position or engine is turned OFF. Turning the handle down to vertical position turns ON the main fuel supply;
turning handle up to vertical position turns ON reserve supply.
Valve is vacuum-operated and will open and close when
engine is turned ON or OFF. The fuel supply valve on the
vehicle should be turned OFF when the vehicle is not
operating.
1CAUTION
OMF15a
Fuel
strainer
Handle position for
reserve supply on
Handle in
off position
California vehicles, equipped with Evaporative Emission
controls, have a plugged carburetor overflow fitting. The
fuel supply valve on the vehicle should be turned off
when the vehicle is not operating. If the fuel supply valve
is not turned off when the vehicle is not operating, fuel
can drain into the engine, dilute the engine oil and cause
engine damage.
NOTE
●
Sequential port fuel injected models do not have a fuel
supply valve.
●
To always maintain a reserve supply, do not operate the
motorcycle with the valve in the reserve (RES) position
after refueling.
Handle position for
main supply on
Figure 15. Fuel Supply Valve
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FUEL FILLER CAP (Figure 16)
NOTE
To open, turn cap counterclockwise and lift up. To close turn
cap clockwise until it clicks. The ratchet action of the fuel cap
prevents overtightening.
●
Fuel filler cap turns approximately 3/4 turn before it starts
unscrewing.
●
FLT models filler caps are located beneath a door and
has a ratchet action. The filler cap should be fully closed
before closing the fuel door.
●
Softail models have a dual tank configuration. The left
side tank cap has a left hand thread. Right hand fuel filler
cap has a right hand thread.
OMF16
Fuel
cap
Fuel
cap
1WARNING
FLT
models
(excluding
Road King)
All models
except FLT
(Including
Road King)
Remove fuel filler cap slowly. Fill fuel tank slowly to
prevent spillage. Do not overfill. Do not fill above the
bottom of the filler neck insert. Leave air space to allow
for fuel expansion. Expansion can cause an overfilled
tank to overflow gasoline through the filler cap onto
surrounding areas. After refueling, be sure fuel filler cap
is securely tightened. Failure to follow this warning could
result in an explosion and/or fire possibly resulting in
personal injury.
1WARNING
Do not use decorative “spinner” or “bullet” type fuel cap
covers, which may possibly cause the cap to loosen from
the tank upon impact. Personal injury can also result
from direct contact with cap covers.
Figure 16. Fuel Filler Cap
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1CAUTION
●
Gasohol spills can stain the paint on your HarleyDavidson.
●
You must use ONLY unleaded fuel in California and
Swiss model catalytic converter-equipped motorcycles. Using leaded fuel will damage the emissions
control system.
SUSPENSION ADJUSTMENTS
Table 2 shows where to find instructions for suspension
adjustments to your motorcycle.
Table 2. Suspension Adjustments
MODEL
ADJUSTMENT PROCEDURE
FLT Models
FLSTC/F/S,
FXSTC/S Models
XLH,
FXD Models
XLH Sport Model
Procedure A
PROCEDURE A
AIR SUSPENSION ADJUSTMENTS
FLT Models
See Figure 17. The FLT models feature air-adjustable suspension. Air pressure may be varied to suit your own
personal comfort. Lower pressure gives a softer ride and high
pressure gives a firmer ride.
Table 3 shows recommended pressures for your riding
comfort.
1CAUTION
Front suspension pressures over 25 PSI are not
recommended. Damage to air control components can
result. This may cause loss of control of the motorcycle,
resulting in possible personal injury.
1WARNING
Procedure B
Procedure C
Procedure D
Exercise caution when bleeding air from the air valves.
Moisture combined with lubricant (either from shock
assembly or a drip oiler in the air compressor lines) may
be ejected onto the rear wheel, tire and/or brake components, adversely affecting traction and possibly resulting
in personal injury.
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Table 3. FLT Air Suspension Pressure
Loading
RECOMMENDED
PRESSURES (PSI)
Shocks
Rider weight up to 150 lbs., add:
Forks
0
0
For each extra
25 lbs., add:
1.0
1.0
Passenger weight for each 50 lbs., add:
1.5
-
Luggage weight for each 10 lbs., add:
Maximum Pressures
3.0
35
1.0
25
See Figure 17. On all FLT models the front and rear suspension air pressure is adjusted by adding or removing air from
the air valves located at the right side of the motorcycle below
the frame cover, above right saddlebag. Refer to Table 4 for
the recommended air pressure.
The preferred pressure for your personal riding comfort can
be selected from Table 4. Lower pressure gives a softer ride
and higher pressure gives a firmer ride. Setting the pressure
outside the recommended range for your loading will result in
a reduction of available suspension travel and reduced ride
comfort. Pressures should be adjusted with the vehicle on the
jiffy stand.
1CAUTION
●
Maximum air pressure should not be exceeded. All
air components fill rapidly and we recommend low
air line pressure be used to avoid damage to the
components.
●
Use a no-loss air gauge to check air pressure. A
small hand pump is the best way to add air to suspension components.
1CAUTION
Maximum air pressure for rear suspension is 35 PSI. Air
components fill rapidly. To avoid possible damage to
components, use low air line pressure. Pressure in front
forks and air shocks should be checked weekly if in daily
use or before each trip if used occasionally.
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PROCEDURE B - REAR SHOCK
ABSORBER SPRING ADJUSTMENT
Softail Models
See Figure 18. The rear shock absorber springs can be
adjusted for the weight the motorcycle is to carry. The shock
absorbers’ springs are variable over a wide range. A spanner
wrench for this purpose is available from your Harley-Davidson dealer.
To change the spring compression:
1.
Loosen the locknuts.
2.
Use the spanner wrench and extend or compress the
springs to the desired position.
NOTE
Figure 17. Air Suspension Adjustment Valves - FLT
Models
●
Turning the adjuster plates OUT (toward the locknut)
increases the spring preload to carry a heavier load.
Turning the adjuster plates IN (away from the locknut)
decreases the spring preload to carry a lighter load.
●
Mark the adjuster plates so you adjust both springs to the
same position.
3.
Tighten the locknuts against the adjuster plates.
1WARNING
Both shock absorber adjuster plates must be adjusted to
the same position. Not having the springs adjusted to the
same length could adversely affect handling. This could
lead to loss of control of the motorcycle possibly resulting in personal injury.
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OMF19
PROCEDURE C - REAR SHOCK
ABSORBER SPRING ADJUSTMENT
Adjuster plate
DYNA, XLH Models
See Figure 19. The rear shock absorber spring preload can
be adjusted for the weight the motorcycle is to carry. Hugger,
XL Custom and Dyna Glide model shock absorbers have five
preload positions. XLH models, except Hugger, and XL Custom have three preload positions. The average weight solo
rider might use the extended spring preload position (off cam
or first cam step). A heavy solo rider might require additional
preload (second or middle cam step); a rider and passenger
may require maximum preload (fifth/third cam step).
Spanner
1WARNING
Figure 18. Shock Adjustment - Softail Models
The average weight solo rider might use the extended (fully
IN) spring position. A heavy solo rider might require the position with springs slightly compressed; a rider and passenger
may require the compressed spring position (fully OUT).
Experimentation will show you what the best spring positions
are for you.
Both shock absorber spring adjusting cams must be
adjusted to the same position. Not having the cams
adjusted to the same position could adversely affect handling. This could lead to loss of control of the motorcycle
possibly resulting in personal injury.
To adjust the rear shock absorber springs, turn spring adjusting cam to the desired position with a spanner wrench.
When returning to off-cam position, cams should be backed
off in opposite direction. Spanner wrenches for this purpose
are available from your Harley-Davidson dealer.
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PROCEDURE D - SUSPENSION
ADJUSTMENT XL Sport Models
OMF20
Spanner
Definitions:
Damping: Resistance to movement. Damping affects how easily
the suspension can move and limits oscillations of the system
once movement has begun.
Compression: Suspension is compressed when the wheel
moves up.
Rebound: The suspension is rebounding when it is moving back
from being compressed.
Cam
Figure 19. Shock Adjustment XLH, DYNA
Preload: The spring is compressed somewhat during assembly.
This initial compression provides a “loaded” condition in the
spring. This initial compression is referred to as preload.
Your XL1200S motorcycle has a front suspension with cartridge
valve 39mm forks that adjust for compression, rebound damping
and spring preload.
The rear suspension features gas canister piggyback shock
absorbers that adjust for compression and rebound damping as
well as spring preload.
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The front and rear suspension preload setting will need to be
adjusted for your weight. This setting should be made before the
motorcycle is ridden any distance. Your Harley-Davidson dealer
can assist you in setting this when you take delivery of the
motorcycle.
If the preload adjustment is correct, and you have the
rebound and compression damping set at the factory
recommended points, the motorcycle should ride properly. If
you are unhappy with these settings they can be changed.
Evaluating and changing the rebound and compression
damping is a very subjective process with many variables
and should be approached carefully.
Damping is set at the factory for the average rider under
normal riding conditions. The rider may wish to adjust these
settings to compensate for individual riding styles, weight
variations, or when carrying a passenger.
Spring Preload
Front and rear suspension spring preload must be adjusted
before any other adjustments can be attempted. This
adjustment assures that the suspension has the proper
amount of travel.
Spring preload is the most important suspension adjustment
offered on your XL1200S motorcycle. Correct setting of
preload will result in a motorcycle that suits the rider’s size
and weight.
You will need two people to carry out this adjustment.
Take the motorcycle off the jiffy stand and bounce the rear up
and down a few times to be sure the suspension is free and
not binding. With the motorcycle unloaded, take the following
measurements. See Figure 20. At the rear shock, measure
the distance A, from the upper shock bolt center to the lower
shock bolt center. At the front fork, measure the distance B,
from the front axle center to the bottom of the lower triple
clamp.
With the help of an assistant take the same measurements
with the rider in full gear on the motorcycle. The assistant
should help balance the motorcycle so the rider can keep
both feet on the footpegs. Bounce a few times on the seat to
be sure the suspension is free and not binding.
Subtract the second measurement from the first. The
difference, which is the squat, must be in the range of 0.5 in.
to 1.0 in. If it is not, adjustment is necessary.
See Figure 22. To adjust the rear shock spring preload, turn
spring adjusting cam to the desired position with a spanner
wrench. When returning to off-cam position, cams should be
backed off in opposite direction. A spanner wrench (HD-
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94700-52C) for this purpose is available from your HarleyDavidson dealer.
See Figure 21. To adjust the front fork spring preload, turn
spring adjusting nut with a 7/8 in. wrench. Turning nut
clockwise increases preload. Turning nut counterclockwise
decreases preload.
o0011ax
A
B
NOTE
●
●
Changes in load will require changes in the preload
setting. Carrying less weight than was used for setting up
the suspension will require a reduction in the preload.
Increasing the load will require an increase in the
preload.
Figure 20. XL Sport Preload Measurment
The GVWR of the XL1200S is given in the specifications
and under no circumstance is it to be exceeded.
1WARNING
Both shock absorber adjusting cams and front fork
spring adjusting nuts must be adjusted to the same
position. Not having the preload adjusted equally from
side to side could adversely affect handling. This could
lead to loss of control of the motorcycle possibly
resulting in personal injury.
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Front Suspension Adjustments
o0007bx
Rebound Damping
Adjuster
Mechanical Preload
Adjusting Nut
1WARNING
The front forks allow multiple compression and rebound
adjustments. Settings on both fork legs for compression
and rebound damping must be identical or handling can
be adversely affected. This could lead to loss of control
of the motorcycle possibly resulting in personal injury.
Make all suspension adjustments in one or two click increments. Adjusting more than one or two clicks at a time may
cause you to skip the best adjustment. Test ride after each
adjustment. When an adjustment makes no difference, return
to the previous adjustment and try a different approach
The fork compression damping adjuster has 14 possible settings. Equal adjustments are made to the adjuster knobs at
the base of each fork leg. Rotating the adjuster in the “H”
direction (clockwise) gives a harder setting and rotating in the
“S” direction (counterclockwise) yields softer damping.
Compression
Damping Adjuster
Located on top of each fork leg, the fork rebound adjuster
knobs have 15 positions. Turning the adjuster knobs clockwise until they lock yields maximum rebound damping. Forks
set in this position will have the slowest rebound. Adjusters
turned fully counterclockwise will have the least amount of
rebound damping. This adjustment will produce the fastest
rebound. Make adjustments by counting the clicks while turning the adjuster knob(s).
Figure 21. Front Suspension Adjustments
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Rear Suspension Adjustments
Make all suspension adjustments in one or two click increments. Adjusting more than one or two clicks at a time may
cause you to skip the best adjustment. Test ride after each
adjustment. When an adjustment makes no difference, return
to the previous adjustment and try a different approach.
Compression
Damping
Adjuster
Rebound
Damping
Adjuster
Adjust compression damping by using the knob on the top of
the piggyback canister. Rotate toward “H” (Clockwise) to
increases compression damping. Rotate toward “S” (Counter
clockwise) to decrease compression damping.
Adjust rebound damping using the dial in the lower shock eye
casting. Rotating the knob in the” H” (Clockwise) direction
gives a harder setting and rotating in the “S” (Counterclockwise) direction yields softer rebound damping.
There are 12 click stops between hard (position 1) and soft
(position 15) settings for both compression and rebound
shock damping adjusters.
o0008bx
Mechanical
Preload
Adjusting
Cam
If the preload adjustment is correct and you have the rebound
and compression damping set at the factory recommended
points the motorcycle should handle and ride properly.
Figure 22. Rear Suspension Adjustments
If you are unhappy with these settings they can be changed.
Evaluating and changing the rebound and compression
damping is a very subjective process with many variables
and should be approached carefully.
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To achieve the proper settings you will need the preload
adjusted properly, the tires inflated properly, and a familiar
bumpy road. It is useful if the road contains a variety of
different kinds of bumps.
Begin the process by putting all the damping adjustments at
the factory recommended settings and riding the bike over a
variety of surfaces and bumps at different speeds. If the
suspension is set properly the motorcycle will be stable and
comfortable.
Factory Recommend Suspension Settings
(From Maximum Hard)
Fork Rebound
position 8
Fork Compression
position 13
Rear Shock Compression
position 8
Rear Shock Rebound
position 6
If you are not satisfied with the factory settings the following
table should help you achieve settings that suit your riding
style. Remember that any setting chosen is a compromise.
NOTE
Rotate adjusters to full clockwise (position 1) or maximum
hard position first, then back-off to desired setting.
.
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Suspension Troubleshooting
Troubleshooting Condition
Adjustment Solution
Bike wallows through turns.
Feels loose or vague after bumps.
Wheel tends to “pogo” after passing over a bump. This is noticeable
by watching the bike continue to bounce as it travels over multiple
bumps.
Increase rebound damping.
Wheel responds to bump, but doesn’t return to ground quickly after
bumps. This is more pronounced over a series of bumps and is
often referred to as “packing down.”
Reduce rebound damping.
The bike bottoms out or dips while cornering.
Bike has excessive brake dive.
Increase compression damping.
Harsh ride particularly over washboard surfaces.
Bumps kick through handlebars or seat.
Suspension seems not to respond to bumps. This is evidenced by
tire chattering (a movement with short stroke and high frequency)
through corners or by jolting the rider over rough roads.
Reduce compression damping.
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LUGGAGE
FLT Models
OMF21
1WARNING
Keep cargo weight concentrated close to the motorcycle
and as low as possible to minimize the change in the
motorcycle’s center of gravity. Distribute weight evenly
on both sides of the vehicle and do not load bulky items
too far behind the rider or add weight to the handlebars
or front forks. Do not exceed 15 pounds maximum load
in each saddlebag or 25 pounds maximum in Tour-Pak.
Improper loading can adversely affect handling, leading
to personal injury.
Tour-Pak Removal (Figures 23 and 24)
1.
Unlock lock and open drawcatch.
2.
Remove the map pouch by removing the nuts holding it
in place.
3.
Open Tour-Pak and remove Tour-Pak mat or liner,
exposing bolt heads.
1CAUTION
Do not pull on the wires. Pulling on the wires may break
them.
4.
Lock
Unplug the wiring harness leading from the Tour-Pak to
the motorcycle. Depress latch, grasp both ends of the
molded connector and pull apart.
Key
Drawcatch
Figure 23. Tour-Pak Lock and Drawcatch
5.
Disconnect the antenna(e) and remove the speakers, if
equipped.
6.
Remove bolts and washers with wrench at inside of
Tour-Pak. Remove Tour-Pak from luggage rack.
1WARNING
The Tour-Pak supports the passenger backrest. Check
the Tour-Pak mounting bolts periodically for tightness.
Be sure that they are in good condition and tightened
properly when installing the Tour-Pak. Failure to do so
could cause the rider and/or passenger to lose control
resulting in possible personal injury.
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FLT Models Saddlebag Operation
(Figure 25)
OMF22
NOTE
The FLT and FLHR saddlebag lids are designed to stay
attached to the bags at all times.
Bolt
OPEN
Washer
Figure 24. Tour-Pak Installation - FLT
1.
Unlock latch.
2.
Place fingers under latch and lift.
3.
Place one hand at OUTSIDE CORNER of cover and
other hand at opposite outside corner.
4.
Lift outside edge of cover, pivoting inside edge of cover
in brackets.
5.
Lift inside edge of cover to disengage brackets.
6.
Bring cover towards you, over saddlebag.
7.
As you bring cover toward you, let it flip over, so the
inside faces up. Let cover rest against rub bars and nylon
check strap.
NOTE
●
When installing King Tour-Pak, be sure to connect lights,
antennae and/or speakers at the connectors.
●
Tour-Pak drawcatches should be closed and locked
whenever motorcycle is in operation.
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CLOSE
1.
2.
Use both hands to hold OUTSIDE corners of cover up
and slide inside edge back into place so brackets slide
together.
Close lid and secure latch. Brackets will engage
automatically.
NOTE
Saddlebag latch and Tour-Pak drawcatches should be closed
and locked whenever motorcycle is in operation.
REMOVE (Figure 25)
The saddlebags are secured to the support brackets by 1/4
turn fasteners called “Bail Head Studs”.
NOTE
If your vehicles does not have the wire form “bail”, use a flat
bladed screwdriver to turn the studs.
1.
Unscrew saddlebag fasteners by turning 1/4 turn
counterclockwise.
2.
Remove saddlebag.
INSTALL (Figure 25)
1.
Carefully place saddlebag in position on saddlebag rail
and align the bail head studs with the support bracket
fasteners.
2.
Fasten studs by pushing into support bracket fasteners
and turning 1/4 turn clockwise. Be sure studs are
securely fastened.
ADJUSTMENTS
See Figure 25. If the latches become loose, you can adjust
the latch “fingers”. See ACCESSORIES MAINTENANCE,
HINGES, LATCHES, FUEL DOOR, SADDLEBAGS - FLT
MODELS.
1CAUTION
Adjust the latch “fingers” only enough to enable them to
properly engage the latch hinge. Bending them back and
forth can overstress the metal and weaken them.
Bend the fingers until they firmly engage the hinge.
FLHRC-I Road King Classic Saddlebag
Operation (Figure 25)
OPEN
To use the quick disconnect strap feature, lift up the strap end
to expose the quick release buckle and press on the lock tabs
as shown in Figure 25. The straps may also be opened and
closed using the buckle in a conventional manner.
CLOSE
Insert the male strap end into the receptacle on the bag and
push until a positive “click” is felt.
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Road King Classic
FLT Models
Push to release
Saddlebags
latch
“fingers”
For proper saddlebag maintenance,
See ACCESSORIES MAINTENANCE.
o0024aox/omf23b
Figure 25. FLT Models Saddlebags
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Bail head studs
FLHR/C-I WINDSHIELD
OMF53
Windshield
REMOVAL
1.
See Figure 26. Insert your fingers into the wireform latch
springs at either side of the windshield and move the
TOP of the windshield assembly forward, until the TOP
bracket notches slide away from the grommets.
2.
Carefully lift the windshield bracket BOTTOM notches off
the bottom grommets. Remove windshield.
Wireform latch
spring
For proper windshield maintenance, See ACCESSORIES
MAINTENANCE.
INSTALLATION
1CAUTION
Be sure you position the windshield bracket between the
rubber grommets. Windshield may be damaged by
incorrect installation.
1.
2.
See Figure 26. Insert your fingers into the wireform latch
springs at either side of the windshield and slide the
BOTTOM windshield bracket notches onto the bottom
grommets.
Slide the TOP bracket notches onto the top grommets.
Clutch cable
Grommet
Figure 26. FLHR/C-I Windshield
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FXDS-CONV SADDLEBAG
REMOVAL/INSTALLATION
1WARNING
2.
Lift the bag up and slightly forward, so the slotted frame
slides off the mounting studs.
Keep cargo weight concentrated close to the motorcycle
and as low as possible to minimize the change in the
motorcycle’s center of gravity. Distribute weight evenly
on both sides of the vehicle. Do not exceed 12 pounds
maximum load in each saddlebag. Improper loading can
adversely affect handling, possibly leading to personal
injury.
The knobbed screws are designed to stay in place on the
saddlebag frame.
NOTE
INSTALLATION
1.
Put the saddlebag in position at the top support points.
1CAUTION
2.
Slide the slots in the frame onto the mounting studs.
Be sure saddlebag frame(s) is fully seated on mounting
studs and knobbed screw(s) is securely tightened.
Failure to do could result in the saddlebags becoming
detached and/or damaged.
3.
Screw the knobbed screw into the screw hole in the
fender until it is snug.
See Figure 27. The saddlebags are fastened to the bike at
three points each by an integral frame. At the rear of each
frame is a screw with a large knob and at the top of each
frame are two slots that slide onto mounting studs on the
fender brace. The saddlebags have handles for carrying.
The saddlebag handles are not intended to serve as
“grab handles” for the passenger. DO NOT allow them to
be used as “grab handles.” When riding with
passengers, make certain a grab strap, designed for
passengers to hold onto while vehicle is in motion, is
installed. Failure to do so could result in possible injury.
REMOVAL
1.
Use the handle to support the saddlebag and unscrew
the knobbed screw from the rear fender.
1WARNING
For proper saddlebag maintenance, See ACCESSORIES
MAINTENANCE.
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o0001bx
Screw
hole
Mounting
studs
Knobbed
screw
Slots
Saddlebag
frame
Figure 27. FXDS Convertible Saddlebag Frame Attachment (Saddlebag Removed For Illustration Purposes)
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FXDS-CONV WINDSHIELD
REMOVAL/INSTALLATION
1CAUTION
When removing or installing the windshield, protect the
headlamp housing, bracket, and front turn signals with
rags to prevent scratches.
NOTE
The socket head bolts (1) on the windshield brackets (2)
permit minor windshield adjustments.
INSTALLATION
NOTE
With practice, you will be able to install the windshield with
the hinges in place. However, initially you may find it easier to
install by removing the left side hinge assemblies from the
bracket (2), then installing them once the right side hinges are
in place.
1.
1CAUTION
●
Be sure that the lower part of the windshield is positioned BEHIND the front turn signals.
●
Do not bend or damage front brake line.
2.
Close the hinges on the slider tubes.
REMOVAL
See Figure 28. The windshield brackets have a hinge and
toggle design for quick removal.
1.
Loosen the toggles’ socket head (toggle) bolts (3)
enough to easily slip the toggle stops (4) out of their
notches. Use the allen wrench provided.
2.
Carefully support the windshield and unhinge the hinges
(5) from the slider tubes. The toggle stops and bolts
remain with the hinges.
3.
Remove windshield assembly from the motorcycle.
Place the windshield on the motorcycle’s front fork and
move the hinges (5) into position on the slider tube.
NOTE
The hinges will not close properly if you close them around a
wiring harness or the clutch cable. Be sure they are closing
only on the slider tubes.
3.
Slide the toggle stops (4) into their notches in the hinges,
with the lip facing outward. As each hinge is fastened,
tighten the toggle bolts (3) finger tight, to hold the
windshield in position.
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OMF49
4
5
3
1
2
Figure 28. FXDS-CONV Windshield
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4.
Check the position of the windshield. Carefully position
the windshield so no part of the windshield touches any
part of the motorcycle.
1CAUTION
Tighten the toggle bolts with the supplied “key-ring”
allen wrench. DO NOT use a long handled allen wrench
or over-tighten. Over-tightening could cause the toggle
bolts to work loose. The hinges are designed to produce
their maximum clamp load when the toggle bolts are
snug.
5.
Tighten the toggle bolts and socket head bolts.
6.
For proper windshield maintenance, See ACCESSORIES
MAINTENANCE in the MAINTENANCE Section.
Heritage Springer and Road King
Passenger Seat
4.
The chrome plug is a press-fit. To remove plug from
passenger seat, grasp with fingers and pull straight up.
5.
Insert plug in seat nut hole by pressing into position with
finger pressure.
Installation
1.
Remove chrome plug from rear seat nut hole and press
into hole on underside of passenger seat.
2.
Slide slots on leading edge of passenger seat into seat
mounting studs.
3.
Position seat bracket over seat nut and install mounting
screw.
o0016aox
The FLSTS and FLHR seat is designed to be converted to
solo configuration by removing the passenger section.
Removal
1.
Remove screw from rear seat bracket.
2.
Lift rear of seat up slightly and carefully slide toward rear
of motorcycle. This will detach passenger seat from seat
mounting studs.
3.
See Figure 29. Under the passenger seat is a chrome
plug on the seat frame.
Figure 29. Seat mounting hole plug
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OPERATING RECOMMENDATIONS
1CAUTION
●
Do not run the engine at extremely high RPM with clutch
disengaged or transmission in neutral. Do not exceed
maximum safe RPM specified in Table 4 under any conditions or serious engine damage may result.
The 1340cc ignition module has an ignition retard feature
which will automatically begin to retard the spark
advance if the engine exceeds 5000 RPM (5600 RPM for
EFI models).
●
The XLH ignition module has an ignition retard feature
which will automatically begin to retard the spark
advance if the engine exceeds 6000 RPM.
MODEL
MAXIMUM RECOMMENDED
ENGINE SPEED (RPM)
XLH Models
5800
All Other Models
5000
An engine run long distances at high speed must be given
closer than ordinary attention to avoid overheating and possible damage. Have the engine checked regularly and keep it
well tuned. This applies particularly to a motorcycle equipped
with windshield, fairing and lowers.
1CAUTION
1WARNING
All Harley-Davidson V2 engines are air-cooled and
consequently require air movement over the cylinders
and heads to maintain proper operating temperature.
Extended periods of idling or parade duty may overheat
the engine, resulting in serious engine damage.
When riding on wet roads or under rainy conditions,
braking efficiency is greatly reduced. Caution must be
used when applying the brakes, accelerating and turning.
This is especially true immediately after the rain begins
and the oil from the road surface combines with the
water. Failure to observe these precautions may result in
personal injury.
When descending a long, steep grade, downshift and use
engine compression together with intermittent application of
both brakes to slow the motorcycle. Avoid continuous use of
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OPERATION
Table 4. Maximum Recommended RPM
NOTE
the brakes which may overheat them and cause reduced
braking efficiency.
PRE-RIDING CHECKLIST
1WARNING
Do not coast for a long distance with the engine off because
the transmission is properly lubricated only when the engine
is running. To prevent transmission damage, do not tow the
motorcycle.
Read CONTROLS AND INDICATORS section before
riding your motorcycle. Failure to do so may result in
personal injury.
BREAK-IN - THE FIRST 500 MILES
Before riding your motorcycle at any time, make a general
inspection to be sure it is in safe riding condition.
The sound design, quality materials, and workmanship that is
built into your new Harley-Davidson will give you optimum
performance right from the start.
However, for the first 500 miles, to wear-in critical parts,
observe the few simple riding rules below. This will assure
future performance and durability.
1.
Check amount of fuel in tank and add fuel if required.
1WARNING
Remove fuel filler cap slowly. Fill fuel tank slowly to prevent fuel spillage. Do not fill above the bottom of filler
neck insert. Leave air space to allow for fuel expansion.
Expansion can cause an overfilled tank to overflow fuel
through the filler cap vent to surrounding areas. After
refueling, be sure filler cap is securely tightened. Failure
to observe this warning may result in personal injury.
1.
During the first 50 miles, keep the engine speed below
2500 RPM in any gear, however, do not lug the engine.
2.
Up to 500 miles, vary the engine speed, avoiding any
steady speed for long distances. Engine speed up to
3000 RPM is permissible in any gear.
3.
Avoid fast starts at wide open throttle. Drive slowly until
engine warms up.
1CAUTION
4.
Avoid running the engine at extremely low RPM in higher
gears.
DO NOT exceed 50 MPH for the first 50 miles.
DO NOT exceed 55 MPH for the first 50 - 500 miles.
Gasohol spills can stain the paint on your HarleyDavidson.
2.
Check oil tank oil level. See MAINTENANCE AND
LUBRICATION section.
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3.
Check controls to be sure they are operating properly;
operate the front and rear brakes, throttle, clutch and
shifter.
4.
Check steering for smoothness by turning the handlebars through the full operating range.
5.
Check tire condition and pressure. Incorrect pressure will
result in poor riding characteristics and can affect handling and stability. See TIRE DATA, for correct inflation
pressures to use.
6.
Check all electrical equipment and switches including
the stoplamp, turn signals and horn for proper operation.
7.
Check for any fuel, oil or hydraulic fluid leaks.
8.
Check rear belt adjustment. Service as necessary.
to warm up and let oil reach all surfaces needing lubrication. Extended idling with enrichener in the full out
position for a period longer than 30 seconds is not
recommended.
NOTE
Engine stop switch on the right handlebar control group
must be in RUN (ignition on) position to start engine.
Use recommended oil for extended expected temperatures. See engine lubrication table in the MAINTENANCE
AND LUBRICATION section.
If you read this section and still have questions about the
correct operation of your motorcycle, talk to your authorized Harley-Davidson dealer.
CARBURETED MODELS
STARTING THE ENGINE
NOTE
GENERAL
1WARNING
Before starting engine, always shift transmission to neutral to prevent accidental movement which could
possibly cause personal injury.
1CAUTION
Never accelerate the engine above 2500 RPM immediately after a cold start. The engine should be allowed to
run slowly for 15-30 seconds. This will allow the engine
●
H-D CV carburetors have an enrichener circuit that
will cause the engine to idle at approximately 2000
RPM with the engine at normal operating temperature and the enrichener knob pulled fully out.
●
The increase in idle speed is intended to alert the
rider that the engine is warmed up to normal operating temperature and the enrichener knob should be
pushed all the way in.
●
Continuing to use the enrichener when the engine is at
129
99466-98
full operating temperature WILL CAUSE FOULED
SPARK PLUGS.
1CAUTION
You must pay close attention to the vehicle's warm-up
time. Either excessive or insufficient use of the
enrichener may cause poor performance, erratic idle,
poor fuel economy and spark plug fouling.
NOTE
The following starting and operating instructions for all HarleyDavidson motorcycles are recommendations. They may be
modified for individual vehicles.
COOL ENGINE
Outside Temperature Cooler than 60°F
Turn the fuel valve to the ON position (carbureted models). BE
SURE THROTTLE IS CLOSED. Pull enrichener knob to full out
position. Turn the ignition switch ON and press starter switch to
operate the electric starter.
1.
See Figure 3. After initial 15-30 second warm-up, ride for 3
minutes or 2 miles with enrichener knob in full out position.
2.
After 3 minutes or 2 miles, push the enrichener knob in to the
1/2 way position. Ride 2 minutes or 2 miles.
3.
After 2 minutes or 2 miles, push the enrichener knob fully in.
NOTE
If outside temperature is cooler than 20°F it may be
necessary to pump the throttle 2 or 3 times.
COOL ENGINE
Outside Temperature Warmer than 60°F
Turn the fuel valve to the ON position (carbureted models). BE
SURE THROTTLE IS CLOSED. Pull enrichener knob to full
out position. Turn the ignition switch on and press starter
switch to operate the electric starter.
1.
See Figure 3. After initial 15-30 second warm-up, ride for
1 minutes or 1/2 mile with enrichener knob in full out
position.
2.
After 1 minutes or 1/2 mile, push the enrichener knob in
to the 1/2 way position. Ride 1 minutes or 1/2 miles.
3.
After 1 minutes or 1/2 mile, push the enrichener knob
fully in.
WARM OR HOT ENGINE
Turn the fuel valve to the ON position (carbureted models). Open
throttle 1/8 - 1/4. Turn on ignition switch and operate electric
starter. DO NOT USE ENRICHENER.
NOTE
If the engine does not start after a few turns or if one cylinder
fires weakly but engine does not start, it is usually because of
an over-rich (flooded) condition. This is especially true of a
hot engine. If the engine is flooded, push enrichener knob in
all the way, turn ignition on and operate starter with throttle
wide open. DO NOT “pump” the throttle while turning the
engine over.
130
99466-98
SEQUENTIAL PORT FUEL
INJECTED HARLEY-DAVIDSONS
Starting
1.
Turn ignition ON. Do not “pump” the throttle.
NOTE
General
There are some differences between a carbureted HarleyDavidson and a fuel injected Harley-Davidson. The
sequential port fuel injection system simplifies the starting
procedure, compared to carbureted Harley-Davidsons.
Do not “pump” the throttle before starting. Rolling the throttle
before starting the motorcycle is unnecessary.
There is no “choke” or “enrichener” on a fuel injected HarleyDavidson. The engine management system handles starting
and running the engine at all temperatures and conditions.
There is no fuel valve.
If the sound system is not on, you may occasionally hear a
slight fuel pump purr, as the fuel pump operates to maintain
the proper pressure in the fuel lines.
The engine lamp will light for approximately 4 seconds and
you will hear the fuel pump purr for approximately 2 seconds
as it operates to fill the fuel lines with gasoline.
2.
Press the starter button to start the motorcycle.
3.
When the engine has started, you can operate your
motorcycle as you normally would.
NOTE
If the fuel tank becomes completely dry, it may take a few
seconds longer to start the motorcycle after filling the tank. It
will not be necessary to take any extraordinary measures
before starting the motorcycle.
STOPPING THE ENGINE
See Figure 2. Stop the engine by turning OFF the engine
stop switch (10) on right handlebar, then turn OFF the ignition
key switch. If the engine should be stalled or stopped in any
way, turn off the key switch at once to prevent battery discharge. Turn the fuel valve to the OFF position (carbureted
models).
131
99466-98
SHIFTING GEARS
1CAUTION
The clutch must be fully disengaged before attempting a
gear shift or engine damage may occur.
NOTE
until you reach neutral. Neutral is 1/2 stroke up from first gear
on 1340cc models. On XLH models, neutral is 1/2 stroke up
from first gear and 1/2 stroke down from second gear.
See Figures 4, 30 and Table 5. Gear shift pattern is first gear
down; next four gears up.
1WARNING
Always start motorcycle in motion in first gear.
See Figure 2. To start moving with motorcycle upright and
engine idling, pull the clutch lever (6) to fully disengage
clutch. See Figure 30. Push shifter lever down firmly, but
gently, to end of its travel to engage first gear. Then release
the clutch lever slowly to engage the clutch and at the same
time, open throttle gradually.
Engage second gear after the motorcycle has run a few
yards, as follows: Close the throttle, disengage the clutch, lift
the gear shifter pedal up to the end of its travel and release.
Engage the clutch and operate the throttle gradually. Repeat
the same operation to engage third, fourth, and fifth gears.
To shift to lower gears, reverse the movement of the gear
shifter lever, disengage the clutch completely before each
gear change and only partially close the throttle so the engine
will not drag when clutch is again engaged.
Keep in mind that by lifting the gear shifter lever up, a higher
gear is engaged; by pushing the gear shifter lever down a
lower gear is engaged. When stopping, operate gear shift
When shifting to lower gears with the motorcycle in
motion, do not downshift at speeds higher than those
listed in the table. Shifting to lower gears when speed is
too high may severely damage the transmission or cause
the rear wheel to lose traction. This may cause loss of
vehicle control resulting in personal injury.
1CAUTION
Do not shift gears without fully disengaging the clutch or
engine damage may occur.
Shift to neutral before stopping engine. Shifting mechanism
can be damaged by shifting gears while engine is stopped.
NOTE
Always start motorcycle in motion in first gear.
When engine speed decreases, as in climbing a hill or running at a reduced speed, shift to the next lower gear while
partially closing the throttle so the engine accelerates as soon
as the clutch lever is pulled.
132
99466-98
See Gear Shifter in the CONTROLS AND INDICATORS section. The recommended shift points are as follows:
Table 5. Gear Changes - All Models
GEAR CHANGE
Acceleration (Upshift)
First to Second
Second to Third
Third to Fourth
Fourth to Fifth
Deceleration (Downshift)
Fifth to Fourth
Fourth to Third
Third to Second
Second to First
SPEED
15 MPH (25 km/h)
25 MPH (40 km/h)
35 MPH (55 km/h)
45 MPH (70 km/h)
40 MPH (65 km/h)
30 MPH (50 km/h)
20 MPH (30 km/h)
10 MPH (15 km/h)
133
99466-98
NOTE
OMF26
●
The gear shifter mechanism on 1340cc 5-speed motorcycles does not permit shifting the transmission to
neutral from second gear. Neutral can only be engaged
from first gear.
●
The XLH 5-speed transmission can be shifted to neutral
from either first or second gear.
Shift sequence - neutral
to higher gears
Shift sequence to lower
gears
Figure 30. 5 - Speed Shifting Sequence
134
99466-98
Good maintenance means a safe machine. A careful check of
certain equipment must be made after periods of storage and
frequently between the regular service intervals to determine
if additional maintenance is necessary.
The following items should be checked:
1. Tires for correct pressure, abrasions or cuts.
BREAK-IN MAINTENANCE
NOTE
The performance of new motorcycle initial service is required
to keep your new motorcycle warranty in force, and to assure
proper emissions system operation.
2.
Belt and primary chain for proper tension.
3.
Brakes, steering and throttle for responsiveness.
4.
Brake fluid level and condition. Hydraulic lines and fittings for leaks. Also, check brake pads and discs for
wear.
5.
Cables for fraying or crimping and free operation.
After a new motorcycle has been ridden its first 500 miles the
motorcycle should be taken to the dealer from whom it was
purchased for initial service operations. If it is impossible to
take the motorcycle to a dealer at the mileage intervals noted,
the owner should give the following checklist attention, or
arrange to have it checked, and take the motorcycle to the
dealer for more complete servicing as soon as it is
convenient.
6.
Engine oil, primary chaincase and transmission fluid
levels.
We recommend the following maintenance procedures be
performed by your Harley-Davidson dealer.
7.
Wheel spoke tightness, if applicable.
8.
Headlamp, tail lamp, brake lamp and directional lamp
operation.
1WARNING
●
Stop the engine and support the motorcycle securely
before performing all service procedures. Service
should be performed using proper tools, in an adequately lighted and ventilated work area.
●
When working on the motorcycle, do not support
motorcycle by placing supports under the brake
pedal. Damage to the brake system could occur
causing possible malfunction and personal injury.
1WARNING
For your personal welfare, all the listed service and maintenance recommendations should be performed. Lack of
regular maintenance, at the suggested intervals, may
affect the safe operation of your motorcycle and could
lead to personal injury.
135
99466-98
MAINTENANCE AND LUBRICATION
SAFE OPERATING MAINTENANCE
1WARNING
1CAUTION
For your personal welfare, all the listed service and maintenance recommendations should be followed because
they may affect the safe operation of your motorcycle.
Failure
to
follow
service
and
maintenance
recommendations may result in personal injury.
DO NOT lubricate the enrichener cable on C.V. carburetors; the cable must have sliding resistance to work
properly.
CHECK AT FIRST 500 MILES
NOTE
The following is an overview. For a complete listing, see the
500 mile checklist (coupon) at rear of manual.
11. Lubricate the following: front brake hand lever, throttle
control cables, clutch control cable (and hand lever*).
12. Check operation of throttle and enrichener* controls.
13. Check engine idle speed.
14. Check battery electrolyte level (FLT only); check and
clean connections.
1.
Change engine oil.
2.
Replace oil filter.
3.
Change primary chaincase lubricant and clean magnetic
drain plug. See Dealer.
16. Check cruise control disengage switch and other
components.*
4.
Inspect air cleaner and service as required.
5.
Check/adjust primary chain. See Dealer.
17. Check tightness of all fasteners, except engine head
bolts.
6.
Check clutch adjustment. See Dealer.
7.
Check rear brake pedal height adjustment. See Dealer.
8.
Inspect brake pad linings and discs for wear.
19. Check tire pressure and inspect tread.
9.
Check brake fluid level and condition. See Dealer.
20. Check wheel spoke tightness.* See Dealer.
10. Inspect oil lines and brake system for leaks.
15. Check operation of all electrical equipment and switches.
18. Check stabilizer links* and engine mounts. See Service
Manual.
* If applicable.
136
99466-98
21. Check rear fork pivot nut tightness.* See Dealer.
26. Check front fork bearing adjustment. See Dealer.
22. Check/adjust rear drive belt.
27. Check and adjust air suspension system.*
23. Change transmission lubricant and clean magnetic drain
plug.
28. Lubricate jiffy stand.
24. Inspect fuel valve, lines and fittings for leaks.
29. Road test.
25. Check rear shock absorbers.
* If applicable.
137
99466-98
LUBRICATION SUMMARY
P
r
e
r
i
d
e
Service Operation
1.
2.
3.
4.
5.
6.
7.
8.
Wheel bearings
Steering head bearings
Speedometer cable
Throttle grip sleeve, throttle control
cables, front brake hand lever
Rear brake pedal grease fitting
Engine oil
(pre-ride check)
Transmission lubricant
Rear fork bearings
5
0
0
√
√
√
√
√
√
√
√
√
OM L P.
2
1
14
13
3
4
12
9.
10.
11.
12.
13.
14.
*
√
*
* If applicable
Service Operation
√
√
√
*
*
1
0
0
0
0
5
0
0
0
Primary chaincase lubricant
Jiffy stand
Clutch control cable (and hand lever, if
necessary)
Shifter pivot fitting
Oil filter
Front fork oil
Hinges, latches - fuel door, Tour-Pak,
saddlebags
*
*
* If applicable
Lubrication Points
6 7
5
11
P
r
e
r
i
d
e
10
138
99466-98
5
0
0
0
√
√
√
√
√
√
√
√
√
√
8
1
9
5
0
0
1
0
0
0
0
√
√
REGULAR SERVICE INTERVALS
NOTE
Regular lubrication and maintenance will help keep your new
Harley-Davidson operating at peak performance. Your Harley-Davidson dealer knows best how to service your
motorcycle with factory approved methods and equipment
assuring you of thorough and competent workmanship.
Regular maintenance interval operations are required to keep
your new motorcycle warranty in force. The use of other than
Harley-Davidson approved parts and service procedures may
void the warranty. Any alterations to the emission system
components, such as the carburetor and exhaust system,
may be in violation of Federal and State laws.
1CAUTION
The regular maintenance intervals given in this manual are intended to be guidelines.
If you operate your motorcycle under adverse conditions, (severe cold, extreme heat, very dusty environment, very bad
roads, through standing water, etc.) you should perform the regular maintenance intervals more frequently to ensure
the safe operation of your motorcycle.
139
99466-98
REGULAR MAINTENANCE INTERVALS
ODOMETER READING
SERVICE OPERATIONS
(see chart code below)
Engine oil*
Oil filter
Air cleaner
Hydraulic lifter oil screen**
Rear belt
Primary chain
Clutch adjustment
Primary chaincase lubricant
Transmission lubricant
Brake fluid level and condition*
Brake pad linings and discs for wear
Condition of rear brake caliper mounting pins & boots
Grease fittings (2), shift and brake lever
pivots**, rear brake linkage**
Front brake hand lever, throttle control cables,
clutch control cables (and hand lever**)
Throttle control grip sleeve, speedometer cable**
Fuel valve**, lines and fittings for leaks
Fuel tank filter screen (Carburetor only)
Engine idle speed
Operation of throttle and enrichener** controls
Battery fluid level, connections (FLT only)*
Spark plugs
Operation of all electrical equipment and switches
P
r
e 5
r 0
i 0
d mi
e
I
R
R
I
I
A
I
A
R
R
I
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2
5
0
0
mi
5
0
0
0
mi
7
5
0
0
mi
I
R
R
I
I
IA
I
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R
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I
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IL
I
I
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L
I
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I
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I
I
I
1
0
0
0
0
mi
1
2
5
0
0
mi
1
5
0
0
0
mi
1
7
5
0
0
mi
2
0
0
0
0
mi
2
2
5
0
0
mi
2
5
0
0
0
mi
2
7
5
0
0
mi
3
0
0
0
0
mi
3
2
5
0
0
mi
3
5
0
0
0
mi
3
7
5
0
0
mi
4
0
0
0
0
mi
4
2
5
0
0
mi
4
5
0
0
0
mi
R
R
I
I
IA
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A
R
R
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IL
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4 5
7 0
5 0
0 0
0 0
mi mi
I
I
I
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R
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I
IA
I
A
R
R
I
I
IL
IL
IL
IL
IL
IL
IL
IL
IL
IL
IL
L
L
L
L
L
L
L
L
L
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L
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I
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140
99466-98
L
I
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L
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P
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e
ODOMETER READING
SERVICE OPERATIONS
(see chart code below)
Ignition timing and vacuum operated
electric switch (V.O.E.S.) (Carburetor only)
Cruise control components**
Air suspension components**
Condition of rear shock absorbers
Rear fork pivot nut**
Rear fork bearings**
Front fork oil*, **
Front fork bearing adjustment
Wheel bearings*
Wheel spoke tightness**
Springer rocker bearings**
Springer steering head bearings
Tire pressure and inspect tires for wear/damage
Engine mounts**
Stabilizer links**
Vehicle alignment*
All fasteners except engine head bolts
Hinges, latches - fuel door, Tour-Pak, saddlebags**
Road King windshield bushings
Jiffy stand
Road test
perform prior to storage, or annually.
*Also
**If applicable.
I
I
2
5
0
0
mi
5
0
0
0
mi
7
5
0
0
mi
1
0
0
0
0
mi
1
2
5
0
0
mi
1
5
0
0
0
mi
1
7
5
0
0
mi
2
0
0
0
0
mi
I
I
I
I
I
I
I
I
I
I
I
I
I
I
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IL
A
A
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I
I
I
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I
IL
R
AL
IL
I
A
IL
I
I
I
I
T
L
I
L
X
I
I
I
I
IL
R
AL
IL
I
A
IL
I
I
I
I
T
L
I
L
X
L
I
I
I
L
I
L
I
I
T
L
T
X
L
I
I
X
L
X
X
A
I
L
I
L
I
I
L
I
I
T
L
X
L
X
X
Chart Code:
I - Inspect, & if necessary correct, clean or replace.
A - Adjust.
R - Replace or change.
2
2
5
0
0
mi
2
5
0
0
0
mi
2
7
5
0
0
mi
I
I
I
I
IL
A
I
L
I
L
I
I
L
I
I
T
L
X
L
X
X
3
0
0
0
0
mi
3
2
5
0
0
mi
3
5
0
0
0
mi
3
7
5
0
0
mi
4
0
0
0
0
mi
4
2
5
0
0
mi
4
5
0
0
0
mi
4 5
7 0
5 0
0 0
0 0
mi mi
I
I
I
I
I
I
I
I
I
IL
R
AL
IL
I
A
IL
I
I
I
I
T
L
I
L
X
I
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I
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IL
I
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IL
R
AL
IL
I
A
IL
I
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T
L
I
L
X
I
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IL
I
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I
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IL
R
ILA
IL
I
A
IL
I
I
I
I
T
L
I
L
X
A
I
L
I
L
I
I
L
I
I
T
L
X
L
X
X
I
I
L
I
L
I
I
L
I
I
T
L
X
L
X
X
T - Tighten to proper torque.
L - Lubricate with specified lubricant.
X - Perform.
141
99466-98
ENGINE LUBRICATION
Engine oil is a major factor in the performance and service life
of the engine. Always use the proper grade of oil for the lowest temperature expected before the next scheduled oil
change.
See Table 6. If it is necessary to add oil and Harley-Davidson
oil is not available, use an oil certified for diesel engines.
Acceptable diesel engine oil designations include CE, CF,
CF-4 and CG-4. The preferred viscosities for the diesel
engine oils, in descending order, are 20W-50, 15W-40 and
10W-40. At the first opportunity, see a Harley-Davidson
dealer to change back to 100 percent H-D oil.
Table 6. Recommended Engine Oils
HarleyDavidson
Type
Viscosity
HarleyDavidson
Rating
Lowest
Ambient
Temperature
Cold
Weather
Starts
Below 50˚F
(10˚C)
HD Multigrade
SAE
10W40
HD 240
Below 40˚F
(4˚C)
Excellent
HD Multigrade
SAE
20W50
HD 240
Above 40˚F
(4˚C)
Good
HD Regular
Heavy
SAE
50
HD 240
Above 60˚F
(16˚C)
Poor
HD Extra
Heavy
SAE
60
HD 240
Above 80˚F
(27˚C)
Poor
CHECKING OIL LEVEL (Figures 31,
32, 34 & 35, Table 7)
Engine oil level should be checked only when engine is at
normal operating temperature. The engine will require a
longer warm up period in colder weather. The motorcycle
should be ridden to ensure oil is hot and is at normal operating oil pressure. When the above conditions are met, turn the
engine off. See Table 7.
NOTE
●
To remove all dipstick/oil plugs, pull steadily on the plug
while moving it back and forth.
●
Sidecar-equipped vehicles should have oil level 1/2 in.
higher on dipstick.
All motorcycles except Softails and Sportster models should
be on the jiffy stand. Softails and Sportster models should be
upright and level. Wipe off dipstick and insert into tank with
plug pushed completely into filler neck.
1CAUTION
Do not allow hot oil level to fall below lower mark on dipstick. Do not overfill oil tank. Overfilling may cause oil
carryover to the air cleaner.
142
99466-98
OMF27
OMF28
Full
Fill plug
dipstick
Add oil
Drain
plug
Figure 32. Engine Oil Level - XLH and Softail Models
Drain
hose
Figure 31. Fill Plug Dipstick & Oil Tank Drains
143
99466-98
Remove dipstick and note oil level. If oil level is down to or
below lower “fill” mark on dipstick add only enough oil to bring
level to upper mark on dipstick. See Figure 32.
1CAUTION
Do not switch brands indiscriminately because some
oils interact chemically when mixed. Use of inferior oils
or non-detergent oils can damage the engine.
Table 7. Checking Oil Level
MODEL
DRAIN
FLT
Models
Drain plug at front of oil
pan.
Softail
Models
XLH
Models
Drain hose right side of
oil tank.
Drain hose, rear of
frame, under rear fork.
Drain plug, under
transmission, forward,
left corner.
Dyna Glide
Models
FILL
Plug on right side, top,
rear of transmission
case.
Plug, right side of oil
tank.
Plug, right side, below
seat.
Plug, right side, top,
front of transmission
case.
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DIPSTICK
VEHICLE POSITION
On fill plug.
Resting on jiffy stand.
On fill plug.
Straight up and level.
On fill plug.
Straight up and level.
On fill plug.
Resting on jiffy stand.
Check engine oil supply at each complete fuel refill. Oil
should be changed after the first 500 miles for a new engine,
and thereafter at 5000 mile intervals in normal service at
warm or moderate temperatures. Oil change intervals should
be shorter in cold weather - see WINTER LUBRICATION.
Completely drain oil tank of used oil and refill with fresh oil. If
service is extremely hard or on dusty roads, drain and refill at
shorter intervals. Draining should be done after a ride while
oil is hot. It is not necessary to drain the crankcase because it
does not accumulate used oil. The oil filter should be
replaced every time the oil is changed.
1WARNING
Be sure no oil gets on rear tire when changing the filter.
Traction will be adversely affected. This could lead to
loss of control of the motorcycle, resulting in possible
personal injury.
OMF31
Oil filter
Mounting
plate
ENGINE OIL FILTER (Figure 33)
Oil filters are located on an oil filter mount in front of the
engine.
Completely drain engine oil tank before removing oil filter.
Clean filter gasket contact surface on mounting plate. Surface should be smooth and free of any debris or old gasket
material. Apply a thin film of oil to gasket contact surface on
mounting plate and to gasket on new oil filter.
Figure 33. Engine Oil Filter
Winter Lubrication
NOTE
On XLH models pour four ounces of clean oil into filter.
Screw filter onto adapter until gasket contacts plate surface.
On all models except Dyna Glides, apply another 1/2 to 3/4
turn by hand. On Dyna Glide models, apply another 3/4 to 1
full turn.
Combustion in any engine produces water vapor. When starting and warming up in cold weather, much of the vapor
condenses to water on the relatively cool metal surfaces. If
the engine is driven enough to get the crankcase thoroughly
warmed up frequently, most of this water is again vaporized
and blown out through the breather.
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A moderately driven engine, making only short runs and seldom getting thoroughly warmed up, is likely to accumulate an
increasing amount of water in the oil tank. In freezing weather
this water will become slush or ice and if allowed to accumulate too long, may block the oil lines and cause damage to
the engine.
OMF32
Water mixed with oil for some time forms sludge that is harmful to the engine and causes undue wear of various working
parts. Therefore, in winter the oil change interval should be
shorter than normal for all engines, and any engine used only
for short runs must have oil drained frequently along with a
thorough tank flush-out before new oil is put in tank.
The further below freezing the temperature drops, the shorter
the oil change interval should be.
Hydraulic Lifter Oil Filter Screen
(Figure 34) (1340cc Engines Only)
The hydraulic lifter oil filter screen is located in the crankcase
above the oil pump. Your dealer will inspect the screen every
5000 miles. Oil screen is installed with closed end up.
Figure 34. Hydraulic Lifter Oil Filter Screen
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TRANSMISSION LUBRICATION
OMF50
1340cc Models
The transmission lubricant level should be checked monthly.
When filling the transmission, use Harley-Davidson TRANSMISSION LUBRICANT, Part No. 99903-93 (qt.), 99904-93
(gal.).
NOTE
●
Keep motorcycle upright for a short period of time to
equalize
lubricant
level
in
the
transmission
compartments.
When the engine reaches normal operating temperature, turn
the engine off and position motorcycle STRAIGHT UP and
LEVEL.
See Figure 35. Remove the threaded filler plug. Clean dipstick. Put dipstick filler plug back into hole, but do not screw
in. Remove dipstick and take reading. Lubricant level should
be between the two marks on the dipstick. Add lubricant if
necessary.
Do not overfill or leakage may occur. The transmission
capacity is approximately 24 ounces. When reinstalling the
filler plug, tighten it to 25-75 in-lbs (2.8 - 8.5 Nm)(finger tight).
F
When checking the transmission lubricant level,
motorcycle should be standing STRAIGHT UP, not
leaning on the jiffy stand.
A
●
Figure 35. Transmission Lubricant Dipstick - 1340cc
The transmission should be drained and refilled with fresh
lubricant after the first 500 miles and thereafter seasonally or
every 5000 miles, whichever comes first.
On FLT models, the transmission magnetic drain plug is
located underneath the transmission, on right side of vehicle.
When installing the drain plug, tighten to 14-21 ft-lbs (19-28.5
Nm).
On Dyna Glide models, the transmission magnetic drain plug
is located underneath the transmission, in the middle, right
side of the case. When installing the drain plug, tighten it to
14-21 ft-lbs (19-28.5 Nm) torque.
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On the Softail models, the transmission magnetic drain plug
is located at the right side of the transmission housing. Install
drain plug so it projects 0.16-0.18 in. above surface of
housing.
CHECKING CHAINCASE
LUBRICANT
On all models, remove foreign material from end of plug.
1.
Position motorcycle STRAIGHT UP and LEVEL.
2.
See Figure 36. Remove screws and washers that secure
clutch inspection cover.
3.
Remove clutch inspection cover carefully to avoid damaging O-ring or finish on cover.
4.
Primary chaincase lubricant should be at the bottom of
the clutch diaphragm spring. Use only PRIMARY
CHAINCASE LUBRICANT, Part No. 99887-84.
1WARNING
Do not overtighten drain plug. When draining and refilling the transmission, be careful that dirt and debris do
not get into the case. Do not allow draining lubricant to
get on rear wheel, tires or brakes. Traction could be
adversely affected, possibly resulting in personal injury.
1340cc Models
NOTE
1CAUTION
XLH models transmission and primary chaincase share common lubricant supply.
Replace O-ring if damaged or not sealing properly to
avoid lubricant leakage.
PRIMARY CHAINCASE
LUBRICATION - GENERAL
5.
Replace clutch inspection cover and secure with screws
and new washers. Tighten to 50-70 in-lbs (6-8 Nm). Do
not overtighten.
Lubrication is a major factor in the performance and service
life of the clutch components. Use appropriate Harley-Davidson chaincase lubricant for all operating temperatures. (See
1340cc Models, XLH Models.)
Chaincase lubricant should be changed initially at 500 miles
and every 5000 miles thereafter. Chaincase capacity is 32
ounces (946 ml.) on all FLT and XLH models and 26ounces
(769 ml.) on Dyna and Softail models.
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OMF34a
Diaphragm Spring
883cc and 1200cc
1340cc (typical)
Clutch
inspection
cover
O-ring
Lubricant Level
With Motorcycle Upright and Level
Primary
chain
inspection
cover
Primary
chain
adjuster
Gasket
Drain
plug
Primary chain
inspection
cover
Drain
plug
Clutch
inspection
cover
Figure 36. Primary Chaincase
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1WARNING
When draining or refilling with lubricant, do not allow dirt
or debris to enter chaincase. Do not allow draining lubricant to get on rear wheel, tire, or brake components.
Traction could be adversely affected, possibly resulting
in personal injury.
NOTE
1.
Stand motorcycle straight up. Motorcycle must remain in
this position during entire procedure.
NOTE
An opening between the transmission and the front chain
compartments allows the same lubricant supply to lubricate
the parts in both compartments.
2.
Remove primary chaincase clutch inspection cover
screws, cover and drain plug.
Whenever draining chaincase lubricant, inspect and clean
chaincase magnetic drain plug.
NOTE
Check clutch adjustment every 5000 miles. We recommend
your Harley-Davidson dealer perform these services for you.
If the lubricant is to be changed, remove drain plug and allow
lubricant to drain. Remove foreign material from magnet on
end of plug.
XLH Models
Use only Harley-Davidson SPORT-TRANS FLUID Part No.
99896-88 for all operating temperatures. Primary chaincase
and transmission capacity is 32 U.S. ounces. Drain while
lubricant is hot.
See Figure 36. The drain plug is located under the clutch, on
the underside of the chaincase. The filler access is the clutch
inspection cover. To determine correct lubricant level in the
transmission and chaincase compartments, proceed as
follows:
3.
Install drain plug and tighten to 14-21 ft-lbs torque.
1CAUTION
Do not over-tighten drain plug. Overtightening could
cause a lubricant leak.
4.
Add approximately 32 ounces of lubricant, until it
reaches bottom of clutch diaphragm spring.
5.
Place clutch inspection cover in position on the primary
cover and install and tighten cover screws.
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PRIMARY CHAIN
OMF36
Top strand
Primary (front) chain adjustment should be checked initially
at 500 miles, every 5000 miles thereafter and serviced as
necessary. If the chain is allowed to run loose, it will cause
the motorcycle to jerk when running at low speed, and chain
and sprockets will wear excessively. If this happens, see your
dealer or Service Manual for adjustment procedure.
REAR DRIVE BELT
Bottom
strand
The rear drive (secondary) belt inner tooth surface has a thin
coating of polyethylene. During initial operation, this coating
will wear as it is burnished into the belt fabric. This is a normal condition and not an indication of belt wear.
Figure 37. Belt Deflection
Belt tension should be checked after the first 500 miles and
every 2500 miles thereafter.
Table 8. Belt Deflection
NOTE
Perform belt tension check BEFORE operating vehicle.
Vehicle should be at room temperature and dry, or you may
not get a correct measurement.
See Table 8 and Figure 37. Apply 10 lbs of force at the midpoint of the belt’s appropriate strand. The deflection should
be upward as shown. On 1340cc models, rear wheel must be
on the ground and one rider sitting on the motorcycle. On
XLH models, rear wheel must be on the ground with NO ONE
on the motorcycle.
MODEL
DEFLECTION
(Measured With 10 lbs Force)
FLST/C/F/S,
3/8 in - 1/2 in. (@TOP STRAND)
FXST/C/S
Dyna Glide,
5/16 in - 3/8 in.(@ BOTTOM STRAND)
FLT
XLH
9/16 in - 11/16 in.(@ BOTTOM STRAND)
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Use BELT TENSION GAUGE, Part No. HD-35381 to check
belt tension. If belt requires adjustment, see your HarleyDavidson dealer, or follow instructions given in the applicable
Service Manual.
Check rear brake caliper position on rear brake disc. Disc
should run true within brake caliper.
3.
Remove and lubricate handlebar throttle control grip
sleeve with fresh graphite every 5000 miles, once each
year, or when operation indicates lubrication is
necessary.
4.
Every 5000 miles lubricate throttle control cables, speedometer drive cable and clutch control cable. Lubricate
front brake hand lever and clutch control hand lever only
if necessary.
5.
On FLT and Softail models, grease the rear brake pedal
and shifter shaft pivots every 5000 miles at the fitting.
6.
On XLH and Dyna models, pack rear swing arm pivot
bearings with fresh grease at 10,000 mile intervals.
Inspect rear swing arm pivot bushings.
7.
Pack the steering head bearings with fresh grease at
10,000 mile intervals or 2 years, whichever occurs first.
8.
Lubricate the jiffy stand mechanism with LOCTITE
LUBRIPLATE® every 5000 miles.
1WARNING
A misaligned rear wheel and/or brake caliper could cause
rear brake disc to bind, resulting in personal injury.
CHASSIS LUBRICATION
Greasing
1.
Use recommended special purpose grease for steering
head bearings, wheel bearings and rear fork bushings.
Use a multi-purpose chassis grease for other
applications.
1CAUTION
Do not switch brands/greases indiscriminately because
some greases interact chemically when mixed. This can
significantly decrease the life of the bearing/bushing.
2.
Repack front and rear wheel bearings every 10,000
miles (more often in adverse conditions), or yearly if
operated under winter conditions or prior to storage.
Replace seals and axle spacers if they show any wear or
distortion.
Oil Applications
All control connections and parts as indicated in the REGULAR MAINTENANCE INTERVALS CHART should be oiled
regularly, particularly after washing motorcycle or driving in
wet weather.
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1CAUTION
Front Fork Oil
Drain front fork oil and refill every 10,000 miles or annually. If
fork does not appear to be working properly or an appreciable amount of oil leakage should develop, see your HarleyDavidson dealer. If there is insufficient oil in either side of
fork, the rebound action will be incorrect.
Operation at higher altitudes (approximately 4000 ft. elevation) may require carburetor modifications for best
engine performance. See your Harley-Davidson dealer
for these adjustments.
We recommend that any carburetor service be performed by
your Harley-Davidson dealer.
The Springer fork does not require fork oil.
FUEL STRAINER (Carburetor only)
See Figure 15. A screen type fuel strainer is located on top of
the supply valve inside the fuel tank. Screen should be
inspected/cleaned every 5000 miles. Check the fuel valve,
lines and fittings for leakage as part of the pre-ride
inspection.
AIR CLEANER (Figure 38)
The engine air cleaner is a paper/wire mesh air filter element.
Remove air cleaner cover and inspect filter element at least
every 5000 miles, or more often under dusty conditions.
CARBURETOR
The carburetor has been specifically designed for emissions
control operation. All jets are fixed at the factory.
Carburetor controls include throttle, enrichener and idle
speed adjusting screw. Operation should be checked and
adjusted after the first 500 miles and every 5000 miles
thereafter.
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1WARNING
OMF37
883cc, 1200cc
Low pressure air can blow debris into your face and
eyes, causing personal injury. Always wear eye protection or a face shield when using pressurized air.
The paper/wire mesh air filter element should be washed in
luke warm water with a mild detergent. Allow filter to either air
dry or blow it dry, from the inside, with low pressure air. Do
not use an air cleaner filter oil on the Harley-Davidson paper/
wire mesh air filter element.
Backplate
1CAUTION
Filter
element
Do not run engine without filter element in place. Debris
could be drawn into engine, causing damage.
Cover
Screw
HYDRAULIC LIFTERS
Lifters are self-adjusting, hydraulic type. They automatically
adjust length to compensate for engine expansion and valve
mechanism wear, keeping the valve mechanism free of lash
when the engine is running.
1340cc
Figure 38. Air Cleaner
When starting an engine which has been turned off even for a
few minutes, the valve mechanism may be slightly noisy until
the hydraulic units completely refill with oil.
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If at any time, other than for a short period immediately after
engine is started, valve mechanism becomes abnormally
noisy, it is an indication that one or more of the hydraulic units
may not be functioning properly.
OMF38
Always check the oil supply in the oil tank first, since normal
circulation of oil through the engine is necessary for proper
operation of the hydraulic units.
If there is oil in the tank, the units may not be functioning
properly because of dirt in the oil supply passages leading to
the lifter units. Inspect and clean tappet oil supply filter screen
(1340cc engines, Figure 34). See your Harley-Davidson
dealer for service.
Clutch cable
CLUTCH (Figure 39)
The clutch control cable must be oiled and adjusted every
5000 miles to compensate for lining wear. The need for attention to clutch and controls will be indicated by the clutch
slipping under load, or dragging when released. In this situation, the control cable adjustment should be the first thing to
be checked. See your Harley-Davidson dealer for proper
service.
BRAKES
Figure 39. Clutch Control Cable (Typical)
Every 2500 miles, check brake pads and brake discs for
wear. Every 5000 miles, check the fluid level in the master
cylinder reservoirs. Use only D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID (P/N 99902-77) approved for brake
system use and that is available from your Harley-Davidson
dealer.
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1WARNING
●
●
Because brake performance is a critical safety item,
brake system servicing requires special tools, correct replacement parts and procedures. We
recommend that you see your Harley-Davidson
dealer for these services. Failure to properly maintain brake system may result in personal injury.
brake disc. If it measures less than 1/4 in., replace both brake
pads immediately.
NOTE
This 1/4 in. dimension includes the thickness of the backing
plate plus minimum 1/16 in. for friction material.
OMF39
Brake pads must be inspected for wear every 2500
miles. However, if you ride under adverse conditions, steep hills, heavy traffic, etc., or if you tend to
use one brake only, more frequent inspection, 1000
miles or less, will be necessary. We do not recommend using only one brake.
Backing plate
Friction material
See Figure 40. Visual inspection of brake pads can be made
without removing the caliper by viewing the lower area of each
caliper with the aid of a flashlight. If the brake pad friction material is 1/16 in. thick or less (the thickness of a nickel), the pads
must be replaced immediately. Always replace brake pads in
pairs. If this routine maintenance is ignored, loss in braking performance and brake system component damage could occur.
See Figures 41, 42. The rear brake outer pad on all models can
be measured from the caliper bracket side using a thin plastic 6
in. rule. Place the rule against the brake disc through the space
alongside the caliper. The outer surface of the brake pad
backing plate should measure 1/4 in. or more away from the
1/16 in. minimum
Figure 40. Brake Pad - Side View
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OMF40
OMF41
Disc
Disc
Caliper
Figure 41. Measuring Rear Brake Outer Pad - 1340cc
Models
Caliper
Figure 42. Measuring Rear Brake Outer Pad - 883cc,
1200cc Models
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TIRES
for these services.
Be sure to keep tires properly inflated. See TIRE DATA, for
correct cold tire inflation pressures. Check before riding when
tires are cold. Do not over-inflate tires.
1WARNING
Improper tire inflation will cause abnormal tread wear
and could adversely affect handling leading to personal
injury. Under-inflation could result in the tire slipping on
the rim, or sudden tire failure.
Check inflation pressure and inspect tread for punctures, cuts
breaks, etc., at least weekly if in daily use; or before each trip,
if used occasionally.
1WARNING
●
●
●
Riding with excessively worn, unbalanced or
improperly inflated tires is hazardous and will
adversely affect traction, steering and handling, possibly leading to personal injury.
Same as original equipment tires should be used.
Other tires may not fit correctly, could adversely
affect handling, and may be hazardous to use.
Because tires, tubes and wheels are critical safety
items, and servicing these items requires special
tools and skills, we recommend you see your dealer
●
Do not attempt to use damaged or punctured and
repaired tire(s). Once a motorcycle tire has been
damaged or punctured, it is unsafe to use.
●
A tire can be severely damaged and not show the
damage externally. If you strike an object, such as a
curb, at speed, internal damage may result which is
not visible from the outside. Always remove and
carefully inspect the inside as well as the outside of
the tire for damage. A damaged tire can fail, causing
personal injury.
SHOCK ABSORBERS
Shock absorbers and rubber bushings should be inspected at
500 miles and every 5000 miles thereafter for leaks and
bushing deterioration.
NOTE
Softail and XL Sport model shock absorbers are not repairable. See your dealer if leakage or malfunction occurs.
VEHICLE ALIGNMENT
Isolation Mounted Engine Models
The stabilizer links and engine mounts should be checked for
wear according to Service Manual procedures after the first
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500 miles and every 5000 miles thereafter. See your HarleyDavidson dealer for this service.
1WARNING
Vehicle alignment is important. Vehicle stability is
adversely affected if wheels are out of alignment, possibly leading to personal injury. Major alignment of the
front and rear wheel is partially controlled by one or two
stabilizer links. One at the top of the engine and, on some
models, one at the front of the engine. Do not change the
adjustment of the link(s). Changing the adjustment as little as 1/3 turn could adversely affect motorcycle stability.
All Models
Vehicle alignment should be checked every 5000 miles and
whenever the rear wheel is removed and installed or when
the rear drive belt is adjusted.
1WARNING
Major alignment should be performed only by your Harley-Davidson dealer using Service Manual procedures.
Improper alignment will adversely affect motorcycle handling and stability, possibly leading to personal injury.
WHEEL BEARINGS
Bearings should be repacked at 10,000 mile intervals, once a
year, or prior to storage. Use proper wheel bearing grease
and new seals. Excessive play or roughness indicates worn
bearings that will require replacement. Check each time
wheel is removed.
FRONT FORK BEARINGS
1WARNING
Adjustment of front fork bearings is critical. Improperly
adjusted bearings will adversely affect motorcycle handling and stability, possibly leading to personal injury.
We recommend that fork bearing adjustments be performed by your Harley-Davidson dealer.
Check front fork for proper bearing adjustment at 500 miles
and every 5000 miles thereafter. Bearings should be lubricated at 10,000 mile intervals. With motorcycle front end
raised off the floor, be sure front fork turns freely without any
binding or interference and that there is no appreciable front
to rear fork shake indicating excessive bearing looseness.
Steering head bearings should be adjusted according to Service Manual procedure, if necessary.
REAR FORK PIVOT SHAFT
On all models except Softails, the tightness of the rear fork
pivot shaft fastener should be checked after the first 500
miles and every 5000 miles thereafter. On XLH and Dyna
Glide models, bearings should be repacked at 10,000 mile
intervals.
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SPARK PLUGS
MODEL
Check the spark plugs every 5000 miles and replace if necessary. Replace the spark plugs every 10,000 miles on all
models.
Disconnect spark plug cables from plugs by pulling on the
molded connector caps. Connection is the simple snap-on
type.
1CAUTION
Do not pull on wires because this may damage the internal conductor causing high resistance and reduction in
firing voltage.
Before installing spark plugs, the gap should be checked and
adjusted if necessary to 0.038 - 0.043 in. (.97 - 1.09 mm).
IGNITION TIMING
Ignition timing is preset at the factory. Spark timing is
advanced electronically, as engine speed increases or
decreases, to suit starting, low speed and high speed
requirements.
Ignition timing on carburetted models should be checked
every 5000 miles. If ignition timing is not correct, see your
Harley-Davidson dealer.
The engines in these motorcycles have been designed specifically to achieve optimum fuel economy within exhaust
emission controls. Ignition characteristics have been developed to provide maximum engine performance and
driveability.
Be sure that your motorcycle has the correct spark plug:
MODEL
SPARK PLUG
NOTE
●
The ignition control unit on carburetted models uses a
two-stage curve. In certain transient load conditions, as
the throttle is opened, the timing changes from normal to
fully advanced. At this point, the operator can sometimes
hear a noise that is similar to pre-ignition detonation.
●
This noise should not be confused with detonation, which
can be stopped by the use of a higher grade fuel. It is
caused by the instant pressure rise in the combustion
1340cc Models ........................ Harley-Davidson 5R6A
883, 1200cc Models ................ Harley-Davidson 6R12
Spark plugs must be tightened to the torque specified for
proper heat transfer. See following chart. If a torque wrench
is not available, tighten plugs finger tight; then tighten an
additional one quarter turn with a spark plug wrench.
SPARK PLUG TORQUE
1340cc Models..........................18 - 22 ft-lbs (24.4 - 30 Nm)
883, 1200cc Models..................11 - 18 ft-lbs (15 - 24.4 Nm)
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chambers as the spark advances rapidly. This noise
doesn’t affect engine performance.
OMF42a
HEADLAMP (Figure 43)
The headlamps are either sealed beam or replaceable quartz
halogen bulb type.
Bulb
NOTE
When replacement is required, use only the specified sealed
beam unit or bulb, available from your Harley-Davidson
dealer. Improper wattage sealed beam or bulb may cause
charging system problems.
1CAUTION
Never touch the quartz bulb with your fingers. Fingerprints will etch the glass and cause the bulb to fail.
Always wrap the bulb in paper or a clean dry cloth during
handling.
1WARNING
The bulb contains Halogen gas under pressure. Handle
bulb carefully and wear eye protection to avoid possible
personal injury.
Figure 43. Headlamp
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ALTERNATOR CHARGING RATE
AND VOLTAGE REGULATOR
See Figure 44. The alternator output is controlled and
changed to direct current by the voltage regulator located at
the front of the engine. The voltage regulator increases
charging rate when battery is low or lamps are lit, decreases
charging rate when no lamps are lighted and when battery
charge is up. This unit requires no interval attention. If any
electrical system trouble is experienced that might be traceable to the alternator or voltage regulator, the motorcycle
should be taken to your Harley-Davidson dealer who has the
necessary electrical testing equipment to give the required
attention.
BATTERY (Figure 45)
See Table 9 for battery location. See SEAT REMOVAL and
INSTALLATION in the following section to remove seat for
battery inspection.
Table 9. Battery Location
MODEL
LOCATION ON
MOTORCYCLE
FLT Models
Under seat
Softail Models
Dyna Models
XLH Models
Under seat
Right side
Left side
Sportster, Dyna, and Softail Models
The battery installed in 1998 motorcycles is a permanently
sealed, maintenance-free, lead/calcium and sulfuric acid battery. Do not remove the cover to add water, or when charging
the battery.
FLT Models
Figure 44. Voltage Regulator (FLT shown)
Inspect the battery electrolyte level at least once a month,
adding pure distilled water as often as necessary to keep the
solution above the plates. If the motorcycle is not used for an
extended period of time, check battery solution level before
placing in service.
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Remove the battery filler plugs. With a hydrometer or syringe,
add distilled water to each cell to raise level of solution
between upper and lower level limits shown on battery.
Motorcycle should be in an upright position to check the solution level.
OMF44
Maintenance Free
Battery
Sportster,
Dyna
and Softail models
Clean connections and check tightness on all models every
2500 miles or monthly.
1WARNING
Batteries contain sulfuric acid which can cause severe
burns. Avoid contact with skin, eyes or clothing.
ANTIDOTE
FLT models
External - Flush with water.
Internal
- Drink large quantities of water followed by
milk of magnesia, vegetable oil, or beaten
eggs. Call doctor immediately.
1WARNING
Batteries produce explosive hydrogen gas at all times especially when being charged. Keep cigarettes, open
flame, and sparks away from battery at all times. Ventilate area when charging battery. Always protect hands.
Protect eyes with shield or goggles when working near a
Figure 45. Battery
battery or acid. KEEP BATTERIES AND ACID OUT OF
THE REACH OF CHILDREN! Failure to follow this warning could result in personal injury.
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1CAUTION
On FLT models if battery is filled to a higher level than
specified, some of the solution will be forced out through
the vent tube when battery is charging. This will not only
weaken the solution, but also may damage parts near the
battery. Keep battery clean and lightly coat terminals
with petroleum jelly to prevent corrosion. Do not overtighten terminal connections. To prevent battery case
damage caused by pressure build-up, be sure vent tube
is properly routed and not kinked or obstructed.
1.
Self Discharge: This is normal and occurs because the
battery discharges internally. See Table 10. Batteries
discharge continuously at a rate depending on the ambient temperature and the battery’s state of charge.
2.
Current Drain: This occurs through electrical accessories
that require continuous electricity, such as radio memories, clocks, etc. The current drain of each motorcycle is
different depending on the model, model year and what
electrical accessories it has.
Table 10. Battery Self Discharge Rate
at 77° F
Battery Sulfation
Battery sulfation is the usual reason batteries stop holding an
electrical charge.
Sulfation occurs when a battery stands in a discharged condition (low specific gravity of electrolyte) over a period of time
or when the battery plates are exposed to the air because of
low electrolyte level.
This causes the active lead materials to crystallize, permanently damaging the affected area. When this happens the
battery will not hold a charge, and it cannot be restored to full
capacity.
C
a
p
a
c
i
t
y
It is not true that the battery is no longer discharging when
the motorcycle is parked and the ignition is turned off. There
are two possible ways for the battery to discharge itself.
Maintenance Free
(FX, FXD, XL)
FLT
MONTHS
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To reduce battery self discharge, remove and store the battery in a cool, (not freezing) dry place when the motorcycle is
being stored.
1CAUTION
●
The more discharged a battery is, the more easily it
can freeze.
●
You should use ONLY a trickle charger to charge a
battery. Do not trickle charge battery more than 24
hours at a time. Charging more than 24 hours at a
time will damage the battery. Before charging, be
sure the electrolyte level is above the plates.
Use a 1 Amp 12 Volt trickle charger (P/N 96800-77C or equivalent), and trickle charge stored battery once a month. On
FLT models keep the electrolyte level above the plates.
H-D Battery Tender Automatic Battery Charger (P/N 9986393T) may also be used to maintain a battery for extended
periods of time with no risk of overcharging or boiling.
JUMP - STARTING PROCEDURE
Harley-Davidson does not recommend jump-starting a motorcycle; however we realize that there may be circumstances
when it is done. Therefore, we suggest jump-starting be done
as follows:
1WARNING
When making connections, be sure the jumper cable
clamps do not accidentally touch each other or anything
else except battery terminals or appropriate ground.
Inadequate precautions when working with batteries can
lead to personal injury.
1WARNING
Do not smoke or allow sparks while performing this procedure. Smoking or sparks could cause an explosion,
leading to personal injury.
NOTE
This procedure presumes the BOOSTER battery is in another
vehicle.
1CAUTION
Be sure radio (if equipped) is turned off. A voltage surge
will erase or damage the radio memory circuits.
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1CAUTION
b0140box
Discharged
battery
All Harley-Davidson motorcycles have a 12 Volt battery and
a 12 Volt electrical system. Be sure the booster vehicle has
a 12 Volt system or electrical components may be
damaged.
1.
Negative
jumper cable
Turn off all unnecessary lights and accessories.
POSITIVE CABLE
2.
See Figure 46. Connect one end of a jumper cable to the
DISCHARGED battery positive (+) terminal.
3.
Connect the other end of the same cable to the BOOSTER
battery positive (+) terminal.
Positive
jumper cable
NEGATIVE CABLE
4.
Booster
battery
Connect one end of a jumper cable to the BOOSTER battery
negative (-) terminal.
1WARNING
●
Suggested spot for ground cable connection is the engine
case bolts.
●
Do not connect negative cable to or near the discharged
battery negative terminal. If you do, a spark could cause an
explosion.
●
Be sure you do not connect the negative cable near the
Figure 46. Jump Start Cable Connections
battery vent tube. A spark could cause an explosion leading to personal injury.
●
Do not connect the negative cable to painted or
chrome parts. They will become discolored at the
attachment point.
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5.
Connect other end of the same cable to a safe ground,
(away from the DISCHARGED battery).
6.
Start motorcycle.
7.
Disconnect cables in reverse order of steps 2, 3, 4, 5.
That is: steps 5, 4, 3, 2.
remove the seat. See DYNA GLIDE BATTERY COVER
REMOVAL, following.
1.
See Figure 47. Remove screw from rear seat bracket.
o0025aox
SEAT
To check the battery on all motorcycles except the XLH models, you will have to remove the seat. See BATTERY, in the
preceding section.
REMOVAL
NOTE
Screw
The seat nut is inserted from the under side of the fender and
retained by a clip located on the top side of the fender. The
seat nut and clip stay attached to the fender when removing
the seat.
●
This is a general procedure. It applies to all motorcycles
with batteries under the seat; but with differences
according to the particular motorcycle. For example:
●
If you have a Sissy bar installed on your bike, you will
have to remove the Sissy bar.
●
On FLSTC/F/N models, there is an additional fastener at
each side of the operator’s seat.
●
On Dyna models, you will have to remove the battery
side cover and top cover. To do this, you will have to
Bracket
Seat nut
Retaining
clip
Figure 47. Seat and Mounting Hardware (Typical)
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2.
Slide seat to the rear of the motorcycle, under grab strap,
and lift.
NOTE
There is a U-shaped bracket at the front of the seat that slips
under a frame bracket.
1.
2.
3.
4.
5.
Mounting bolt
Mounting bolt
Battery tray
Battery side cover
Battery top cover
o0014ax
5
INSTALLATION
1.
Slide U-shaped bracket under frame bracket.
2.
Install screw at rear of seat.
There is no need to remove the seat bracket and its fasteners
from the seat pan.
1
2
4
Dyna Glide Battery and Cover Removal
(Figure 48)
1.
Remove seat. See SEAT.
2.
3.
Remove negative connection at frame, then positive
connection at battery terminal.
Remove lower rear bolt (2).
4.
Remove upper rear bolt (1).
5.
Remove top cover (5).
3
Figure 48. Dyna Glide Battery Tray and Mounting
Hardware
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6.
CIRCUIT BREAKERS
Remove side cover (4).
Battery and Cover Installation (Figure 48)
1CAUTION
Connecting cables to wrong battery terminals can cause
serious damage to motorcycle electrical system.
1.
Clean cable connectors with wire brush or sandpaper to
remove oxidation. Coat with Vaseline®.
2.
Install battery with negative cable connected to negative
post.
3.
Install battery side cover (4) making sure that bottom of
its outboard side is properly seated inboard of the retaining lip on the base of the battery tray.
Softail and Dyna models have several circuit breakers to protect the motorcycle wiring. They are: main, lighting,
accessory, instruments and ignition. Each of these breakers
is self-resetting and automatically returns steady power to the
circuit when an electrical fault that causes it to trip is found
and corrected. If the electrical fault is not found and corrected, the breaker cycles on and off causing the motorcycle
to operate erratically and eventually the battery will lose its
charge.
All other models have a main circuit breaker.
4.
Install battery top cover (5) over side cover and battery.
5.
Install upper rear bolt (1).
6.
Install lower rear mounting bolt (2).
7.
Connect positive cable first, then connect negative cable
to frame.
8.
Install seat. See SEAT.
For electrical problems, it is best to see your Harley-Davidson
dealer who has necessary parts and equipment to perform
electrical services.
FUSES
FLT and XL models have fuses located under left side cover,
FX models have fuses located under the seat.
FLT MODELS FUSE REPLACEMENT
99466-98
If it is necessary to replace the radio or the CB/Intercom
fuses, carefully follow the procedures below or see your
Harley-Davidson dealer for service. Do not skip any steps or
damage to the sound system and/or other motorcycle
systems may result.
169
Raise lid of left side saddle bag. Grasp bail wire inside
saddlebag and rotate each stud a full 1/4 turn in a
counter-clockwise direction. Remove bail head studs
with flat washers. Remove saddlebag.
3.
Gently pull side cover from frame downtubes (no tools
required). Radio fuses are located in the fuse block, CB/
Intercom fuses are in the fuse box. See Figure 49.
®
2.
CONTROL ASSEMBLY
Place the Ignition/Light Key Switch in the OFF position.
70955-98
1.
f1415c8x
ELECTRO-MOTOR CRUISE
PRELIMINARY INSTRUCTIONS
Fuse Blocks
RADIO FUSE REPLACEMENT
FLHTC/FLHTC-I/FLHTC-U/FLHTCU-I
1.
See Preliminary Instructions on this page.
2.
Pull fuse blocks from tabs on mounting panel. Tabs on
panel fit into slots on each side of fuse block cover. To
remove cover, raise latches slightly to disengage tabs on
fuse blocks
3.
See Figure 50. Locate the two radio fuses in the front
Figure 49. Left Side Cover Removed - FLHTCU
fuse block. The 10 amp fuse allows power to the radio
through activation of an internal relay. The 15 amp fuse
provides direct and continuous power to the radio
memory and clock and when the internal relay is
activated, feeds the main circuits of the radio as well.
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4.
f1411a8x
Slot
Cover
Slot
Using the puller tool in the fuse block cover, remove the
fuse and inspect the element. See Figure 51. Replace
the fuse if the element is burned or broken. Automotive
type ATO fuses are used.
NOTE
Two spare fuses (one each) can be found in the fuse block
cover.
GAUGES
LIGHTS
ACCY.
LOCKED
10A
IGNITION
15A
RADIO
MEMORY
10A
(ITEMS IN PARENTHESES POLICE ONLY)
BRAKES/
CRUISE
(PURSUIT
LAMPS)
RADIO
POWER
(SIREN)
Radio
Memory
FUSE PULLER
15A
15A
15A
15A
15A
SPARE
Cover Label
f1411f8x
SPARE
Radio
Power
Latch
P&A
Latch
SPARE FUSES AND FUSE PULLER INSIDE CAP. TO SERVICE, PULL FUSE BLOCK
ASSY. OFF BIKE, GENTLY LIFT TAB AND REMOVE FUSE BLOCK FROM CAP.
Inside Cover
Front
Fuse Block
Rear
Fuse Block
Spare
10 Amp Fuse
Fuse
Puller
Spare
15 Amp Fuse
Figure 50. Fuse Blocks
Figure 51. Fuse Block Cover
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1CAUTION
Always use replacement fuses that are of the correct
type and value. Use of incorrect fuses can result in
damage to electrical systems.
5.
Slide cover over fuse blocks until latches fully engage
tabs on blocks. Slide fuse blocks into position on
mounting panel. Tabs on panel fit into slots on each side
of fuse block cover.
6.
See Final Instructions.
FINAL INSTRUCTIONS
1.
Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place (no tools required).
2.
Position left side saddlebag on vehicle. Place flat
washers on bail head studs. Insert stud through holes in
saddlebag and front mounting bracket. When groove on
stud engages wire form of spring plate on inboard side of
bracket, turn stud clockwise a full 1/4 turn until it snaps in
place. Install rear bail head stud in the same manner.
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XL MODELS FUSE REPLACEMENT
NOTE
1.
Place the Ignition in the OFF position.
Two spare fuses and a puller tool can be found in the fuse
block cover.
2.
See Figure 52 and 53. Gently pull left side cover from
frame (no tools required). Lift latch on fuse block holder
to remove fuse block.
3.
x0103x7x
Using the puller tool, remove the fuse and inspect the
element. Replace the fuse if the element is burned or
broken. Automotive type ATO fuses are used.
1CAUTION
Always use replacement fuses that are of the correct
type and value. Use of incorrect fuses can result in
damage to electrical systems.
Data link
XL-Sport only
4.
Slide fuse block into holder until latche fully engages tab
on holder.
5.
Align barbed studs in side cover with grommets in frame
and push firmly into place (no tools required).
Latch
Figure 52. XL Side cover (1200S shown)
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GENERAL MAINTENANCE
x0104x7x
Chrome and aluminum parts must be maintained regularly to
ensure that they retain their original shine and luster. Care
should be taken to keep your new Harley-Davidson motorcycle cleaned and waxed as often as possible to inhibit rust and
corrosion.
CLEANING YOUR MOTORCYCLE
To aid you in keeping your motorcycle clean, see your Harley-Davidson dealer for cleaning, polishing and waxing
products.
1WARNING
Observe warnings and cautions given on labels of cleaning compounds to prevent personal injury or damage to
your motorcycle.
Figure 53. XL Fuse block
1WARNING
Do not wash your brake discs with any cleaners that contain either chlorine or silicon. Chlorine will cause rust
and silicon will make the brake discs slick, impairing
brake function which may result in personal injury.
1CAUTION
When washing your motorcycle, be careful not to get the
brakes, engine, mufflers or air cleaner too wet. Wet brake
pads or a wet disc may affect braking, and a wet engine
could start and run poorly until it dries. Start engine
immediately after washing and be sure brakes and
engine are operating properly before riding in traffic.
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ACCESSORIES MAINTENANCE
LEATHER
Leather must be periodically cleaned and treated to maintain
its appearance and extend its life. Clean and treat leather
once a season or more frequently under adverse conditions.
NOTE
●
●
Many Harley-Davison accessories and seats are
either made of leather or have leather inserts.
Natural materials age differently and require
different care than man-made materials. Seat
covers and panels made of leather will gain
“character”, such as wrinkles, with age. Leather is
porous and organic and each leather product will
settle into its own distinct form with use. Your
leather product will mature into its own custom
shape and style from the sun, rain and the miles.
This maturing is natural and will enhance the
custom
quality
of
your
Harley-Davidson
motorcycle.
Road King Classic Models (FLHRC-I) have leather
covered saddlebags. The leather covering may
appear to loosen or grow slightly in damp or wet
weather. This condition will disappear as the
natural leather covering dries.
1CAUTION
●
Do not use bleach or detergents containing bleach
on saddlebags, seats or tank panels.
●
Do not use ordinary soap to clean leather or fur. It
could dry or remove the oils from the leather.
●
Use ONLY a good quality saddle soap to clean
leather. Be sure you rinse saddle soap off thoroughly before treating leather.
●
Never try to dry leather quickly, using artificial
means. Always let leather dry naturally, at room
temperature.
1.
Vacuum or blow dust off.
2.
Thoroughly clean leather with a good quality saddle
soap, following manufacturer’s directions. Rinse thoroughly with clean sponge or cloth and water. Allow
leather to dry.
3.
Once leather is dry, treat with a good quality leather
treatment, such as Harley-Davidson Leathercare®.
4.
Always allow leather to dry completely before using.
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CLOTH
windshield surface.
1.
Vacuum or blow dust off.
2.
Use mild soap and warm water for more difficult stains
on the cloth. Rinse thoroughly. Always allow cloth to dry
completely before using.
●
To remove minor surface scratches use NOVUS® No.
2 Scratch Remover, P/N 99836-94T.
NOTE
VINYL
Covering the windshield with a clean, wet cloth for approximately 15-20 minutes before washing will make dried bug
removal easier.
Wash with a good quality detergent or S100®. Treat with
Mothers Preserves® or a quality vinyl treatment.
Use mild soap and warm water to wash the windshield. Wipe
dry with a soft, clean towel.
WHITEWALL TIRES
WINDSHIELDS
1CAUTION
Harley-Davidson windshields are made of Lexan®. Lexan
is a more durable and distortion-resistant material than
other types of motorcycle windshield material, but still
requires attention and care to maintain.
●
DO NOT use harsh chemicals including rain sheeting
products on Harley-Davidson windshields. They may
cause dulling or hazing. If you want to use a windshield protectant on your windshield, try Harley
Glaze Polish and Sealant®.
●
DO NOT use benzine, paint thinner, gasoline or any
other types of harsh cleaner. They will damage the
1WARNING
If you get a cleaner on brake components, wipe it off
immediately. Foreign substances of any kind on brake
calipers or disc(s) may cause reduced braking efficiency,
possibly leading to personal injury.
Use a good quality, commercial whitewall cleaner and follow
the manufacturer's directions.
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HINGES, LATCHES - FUEL DOOR, TOURPAK, SADDLEBAGS - FLT MODELS
OMF46
Lubricate the rub points of latches and hinges using either
Teflon Precision Lubricator® or Tri-flow® every 5000 miles.
These lubricants resist attracting dust.
See Figures 25 and 54. Lubricate the “fingers” on the saddlebag latches, where they engage the hinge.
Saddlebag
latch
“fingers”
Figure 54. FLT Models Saddlebag Latch
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STORAGE
NOTE
1CAUTION
Proper long-term storage is important for the safe, trouble-free operation of your Harley-Davidson motorcycle. If
you do not do these tasks yourself, contact your HarleyDavidson dealer. Your dealer has the trained technicians
who can complete the work according to Service Manual
procedures using proper tools and equipment.
Make a list of everything you do and fasten it to a handgrip.
When you take the motorcycle out of storage, this list will be
your reference/check-list to get your motorcycle in operating
condition.
1.
Warm motorcycle to operating temperature; change oil
and turn engine over to circulate the new oil.
2.
On both carbureted and fuel injected vehicles, fill fuel
tank and add a gasoline stabilizer. Use one of the
commercially available gasoline stabilizers, following the
manufacturer's instructions. Run the engine until the
gasoline stabilizer has had a chance to reach the
carburetor float bowl/fuel injectors. On carbureted
vehicles, turn fuel supply valve OFF.
3.
Adjust the belt.
1WARNING
4.
Check tire inflation. Adjust to proper inflation pressure.
Wash and wax painted and chrome surfaces.
Fuel is flammable. Do not store motorcycle having gasoline in tank within the home or garage where open
flames, pilot lights, sparks or electric motors are present.
Failure to heed this warning may lead to an explosion or
fire resulting in personal injury.
5.
See BATTERY for proper battery care. Remove battery
from the motorcycle and charge. Store the battery above
freezing temperatures, trickle charge once a month and
on FLT models keep the electrolyte level above the
plates.
Placing Motorcycle In Storage
If the motorcycle will not be operated for several months,
such as during the winter season, there are several things
which should be done to protect parts against corrosion, to
preserve the battery and to prevent the build-up of gum and
varnish in the fuel system.
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NOTE
On FLT models disconnect the battery vent tube from battery
before removing battery; or take note of vent tube routing so it
is installed in the proper place when you remove vehicle from
storage.
1WARNING
Keep battery away from areas that may have sparks or
flames. A spark could cause an explosion resulting in
personal injury.
6.
If motorcycle is to be covered, use a material such as
light canvas, that will breathe. Plastic materials that do
not breathe promote the formation of condensation.
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Removal From Storage
1WARNING
After extended periods of storage and prior to starting
vehicle, place transmission in gear, disengage clutch
and push vehicle back and forth a few times to ensure
proper clutch disengagement. Failure to observe this
warning may result in personal injury.
1.
See BATTERY for proper battery care. On FLT models
be sure plates are covered by electrolyte before
charging. Install vent tube and route according to FLT
Service Manual. Fill the battery with distilled water to the
proper level. Charge and install it.
2.
Remove and inspect the spark plugs. Replace if
necessary.
3.
Clean the air cleaner element.
4.
Start the engine and run until it reaches normal operating
temperature. Turn off engine.
5.
Check amount of oil in the oil tank. Check the
transmission lubricant level.
6.
Check controls to be sure they are operating properly.
Operate the front and rear brakes, throttle, clutch and
shifter.
7.
Check steering for smoothness by turning
handlebars through the full operating range.
the
8.
Check tire pressure. Incorrect pressure will result in poor
riding characteristics and can affect handling and
stability.
9.
Check all electrical equipment and switches including the
stoplamp, turn signals and horn for proper operation.
10. Check for any fuel, oil or brake fluid leaks.
1CAUTION
Turn engine over a few times to be sure there is no oil in
the crankcase; and that all oil has been pumped back
into the oil tank. Stop engine and re-check oil level.
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Engine Turns Over But Does Not Start
The following checklist of possible operating troubles and
their probable causes will be helpful in keeping your motorcycle in good operating condition. More than one of these
conditions may be causing the trouble and all should be carefully checked.
1.
2.
3.
4.
5.
1WARNING
The troubleshooting section of this Owner’s Manual is
intended solely as a guide to diagnosing problems. Carefully read the appropriate sections of this manual before
performing any work. Repair and maintenance operations not listed in this Owner’s Manual are in the Service
Manual and should be performed by your Harley-Davidson dealer. Improper repair and/or maintenance may
result in personal injury.
Fuel tank empty.
Fuel valve turned “OFF.” *
Fuel valve vacuum line disconnected.*
Fuel valve or filter clogged.*
Discharged battery or loose or broken battery terminal
connections.
6. Fouled spark plugs.
7. Spark plug cables connections loose or in bad condition
and shorting.
8. Loose or corroded wire or cable connection(s) at coil or
battery.
9. Engine flooded with fuel as a result of over-enrichening.*
10. Engine oil too heavy (winter operation).
11. Throttle held open when enrichener is used.*
12. Fuel pump inoperative.
ENGINE
Starts Hard
Starter Does Not Operate or Does Not Turn
Engine Over
1.
1.
Engine run switch in “OFF” position.
2.
Ignition switch not “ON.”
3.
Discharged battery or loose or corroded connections
(solenoid chatters).
* carbureted models only
2.
3.
4.
5.
6.
Spark plugs in bad condition, have improper gap, or are
partially fouled.
Spark plug cables in bad condition and leaking.
Battery nearly discharged.
Loose wire or cable connection(s) at one of the battery
terminals or at coil.
Carburetor not adjusted correctly.*
Engine oil too heavy (winter operation).
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RIDER TROUBLESHOOTING
GENERAL
Ignition not timed properly. See Dealer.*
Fuel tank vent plugged or fuel line closed off, restricting
fuel flow.
9. Water or dirt in fuel system.
10. On fuel injected models - not allowing fuel pump time to
pressurize fuel lines.
Overheats
Starts But Runs Irregularly or Misses
Excessive Vibration
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
7.
8.
6.
7.
8.
Spark plugs in bad condition or partially fouled.
Spark plug cables in bad condition and leaking.
Spark plug gap too close or too wide.
Battery nearly discharged.
Damaged wire or loose connection at battery terminals
or coils.
Intermittent short circuit due to damaged wire insulation.
Water or dirt in fuel system.
Fuel vent system plugged. See Dealer.
9.
One or both injectors fouled.
A Spark Plug Fouls Repeatedly
1.
2.
3.
Excessive enrichener use.*
Fuel mixture too rich.
Incorrect spark plug.
Pre-ignition or Detonation (Knocks or
Pings)
1.
2.
Incorrect fuel.
Incorrect spark plug for the kind of service.
1.
2.
3.
Insufficient oil supply or oil not circulating.
Heavy carbon deposit from “lugging” engine. See dealer.
Ignition timing retarded. See Dealer.*
Stabilizer links worn or loose.* See Dealer.
Engine isolation mounts loose.* See Dealer.
Rear fork pivot shaft nuts loose.* See Dealer.
Front engine mounting bolts loose.* See Dealer.
Engine to transmission mounting bolts loose.* See
Dealer.
6. Broken frame. See Dealer.
7. Belt badly worn.
8. Wheels and/or tires damaged. See Dealer.
9. Vehicle not properly aligned. See Dealer.
*If applicable.
LUBRICATION SYSTEM
Oil Does Not Return to Oil Tank
1.
2.
3.
Oil tank empty.
Restricted oil lines or fittings. See Dealer.
Restricted oil filter. See Dealer.
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Engine Leaks Oil From Cases, Push Rods,
Hoses
TRANSMISSION
1.
2.
1.
2.
3.
Loose parts. See Dealer.
Imperfect seal at gaskets, push rod cover, washers, etc.
See Dealer.
Restricted oil return line to tank. See Dealer.
ELECTRICAL SYSTEM
1. Module not grounded. See Dealer.
2. Engine ground wire loose or broken.* See Dealer.
3. Loose or broken wires in charging circuit. See Dealer.
*If applicable.
Alternator Charge Rate is Below Normal
Weak battery.
Excessive use of add-on accessories.
Loose or corroded connections.
4.
Extensive periods of idling or low speed riding.
Bent shifter rod. See Dealer.
Transmission shifting mechanism needs adjustment.
See Dealer.
Transmission Jumps Out of Gear
1.
2.
Alternator Does Not Charge
1.
2.
3.
Transmission Shifts Hard
3.
Shifter rod improperly adjusted. See Dealer.
Shifter forks (inside transmission) improperly adjusted.
See Dealer.
Worn shifter dogs in transmission. See Dealer.
Clutch Slips
1.
2.
3.
Clutch controls improperly adjusted. See Dealer.
Worn friction discs. See Dealer.
Insufficient clutch spring tension. See Dealer.
Clutch Drags or Does Not Release
CARBURETOR
1.
2.
3.
4.
Carburetor Floods
Clutch Chatters
1.
1.
Excessive “pumping” of hand throttle grip.
Clutch controls improperly adjusted. See Dealer.
Insufficient clutch spring tension. See Dealer.
Transmission case over-filled.
Clutch discs warped. See Dealer.
Friction discs or steel discs worn or warped. See Dealer.
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BRAKES
Brakes Do Not Hold Normally
1.
2.
3.
4.
Master cylinder low on fluid. See Dealer.
Brake line contains air bubbles. See Dealer.
Master or wheel cylinder piston worn. See Dealer.
Brake pads contaminated with grease or oil. See Dealer.
5.
Brake pads badly worn (1/16 in. minimum lining thickness). See Dealer.
6.
Brake disc badly worn or warped. See Dealer.
7.
Brake fades because of heat build up. Excessive braking
or brake pads dragging. See Dealer.
8.
Brake drags. Insufficient hand lever free play. See
Dealer.
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See Figure 55. A permanent Owner's Identification Card is
issued to each Harley-Davidson new motorcycle owner when
the completed warranty registration form is received at Harley-Davidson Motor Company.
o0026aox
Keep this card in your possession, since it is required by your
Harley-Davidson dealer for any warranty service performed
on your motorcycle.
If you have any questions regarding service or warranty, we
recommend that you contact your Harley-Davidson dealer for
service.
WARRANTY AND MAINTENANCE
This Owner’s Manual contains your new motorcycle warranty
and a number of tear-out service coupons.
The approved service and maintenance procedures on each
coupon and the mileage intervals cover items which are the
owner’s responsibility to have performed. All of the specified
maintenance services must be performed to keep your warranty in force.
Figure 55. Owner’s Warranty Identification Card
The Owner’s Identification Card is a permanent record showing proof of your ownership and gives all of the information
necessary for you and your dealer to simplify and expedite
service and obtain parts and accessories.
Bring this Owner’s Manual with you when you visit your
dealer at the specified mileages to have your motorcycle
inspected and serviced. Have the owner record stubs dated
and signed for required proof of service during the warranty
period. The dealer records should be retained by the dealer,
or owner, as a record of proper maintenance. Also keep other
receipts covering any service or maintenance performed.
These records should be transferred to each subsequent
owner.
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WARRANTY & RESPONSIBILITIES
OWNER’S IDENTIFICATION CARD
1WARNING
We caution you against the use of certain non-standard
parts such as after-market and custom made extended
front forks which may adversely affect performance and
handling, with possible injury to yourself or others.
Removing or altering factory installed standard parts
may also affect performance and cause injury. The use of
any non-standard parts including mufflers may void your
warranty according to terms of the warranty.
Harley-Davidson dealerships are independently owned and
operated and may sell parts and accessories that are not
manufactured or approved by Harley-Davidson. Therefore,
you should understand that we are not and cannot be responsible for the quality, suitability, or safety of any non-HarleyDavidson part, accessory or design modification, including
labor, which may be sold and/or installed by our dealers.
KEEPING IT ALL HARLEY
To keep your Harley-Davidson motorcycle and its warranty
intact, insist that your dealer uses only Genuine® replacement parts. Keep your Harley-Davidson completely HarleyDavidson. Exacting design and stringent testing ensure performance and warranty coverage. Insist on Genuine parts for
your genuine Harley-Davidson motorcycle.
Installing off-road or competition parts to enhance performance may void your new motorcycle warranty. See your
dealer for details.
1CAUTION
It is possible to overload your motorcycle’s charging
system by adding too many electrical accessories. If your
combined electrical accessories consume more
electrical current than your vehicle’s charging system
can produce, the electrical consumption can discharge
the battery and cause vehicle electrical system damage.
Ask your dealer for advice about the amount of current
consumed by additional electrical accessories.
IMPORTANT
If you move from your present address, or sell your motorcycle, please fill out and mail the post card at the back of this
manual. This is necessary in the event that the Company
needs to contact the owner concerning information that could
affect the safe operation of this motorcycle.
186
99466-98
CALIFORNIA EVAPORATIVE
EMISSION CONTROL
AMONG THOSE ACTS PRESUMED TO CONSTITUTE
TAMPERING ARE THE ACTS LISTED BELOW.
All new 1998 Harley-Davidson motorcycles sold in the state
of California are equipped with an evaporative emission control system. This system is designed to meet the CARB
regulations in effect at the time of manufacture.
1.
Replacing the muffler(s) and/or the entire exhaust system with parts not certified to be noise legal for street
use.
2.
Removing or modifying the muffler internal baffles in any
way.
3.
Replacing the air intake/cleaner assembly with one not
certified to be noise legal for street use.
4.
Modifying the air intake/cleaner assembly in such a way
as to make the vehicle no longer noise legal for street
use.
The system requires a small amount of maintenance. Periodic inspection is required to make sure hoses are properly
routed, not kinked or blocked, and that all fittings are secure.
Mounting hardware should also be checked periodically for
tightness.
EPA NOISE REGULATIONS
EPA noise regulations require that the following statements
be included in the Owner’s Manual.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing
thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or
replacement of any device or element of design incorporated
into any new vehicle for the purpose of noise control prior to
its sale or delivery to the ultimate purchaser or while it is in
use, or (2) the use of the vehicle after such device or element
of design has been removed or rendered inoperative by any
person.
Harley-Davidson recommends that any and all noise related
maintenance be done by an authorized Harley-Davidson
dealer using genuine Harley-Davidson parts.
WARRANTY/SERVICE INFORMATION
Your selling dealer is responsible for providing the warranty
repair work on your motorcycle.
For normal service work or warranty work under the above
conditions, you may obtain the name and location of your
nearest U.S. Harley-Davidson dealer by calling 1-800-4432153 (toll free), in any state except Alaska and Hawaii.
187
99466-98
NOTE
The number shown above is accessible only with a touchtone phone.
REPORTING SAFETY DEFECTS
Required by the National Highway Traffic Safety Administration (NHTSA).
NHTSA STATEMENT:
If you believe that your vehicle has a defect which
could cause a crash or could cause injury or death, you
should immediately inform the National Highway Traffic
Safety Administration (NHTSA) in addition to notifying
Harley-Davidson.
If NHTSA receives similar complaints, it may open an
investigation, and if it finds that a safety defect exists in
a group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved
in individual problems between you, your dealer, or
Harley-Davidson.
To contact NHTSA, you may either call the Auto Safety
Hotline toll-free at 1-800/424-9393 (or 366-0123 in
Washington D.C. area) or write to: NHTSA, U.S.
Department of Transportation, Washington, D.C.
20590. You can also obtain other information about
motor vehicle safety from the Hotline.
188
99466-98
HARLEY-DAVIDSON LIMITED WARRANTY
(12 MONTHS/UNLIMITED MILEAGE)
Harley-Davidson Warrants to the first retail purchaser and authorized transferees of our new 1998 model motorcycles/sidecars
that any authorized Harley-Davidson Dealer will repair or replace without charge any parts (except tires, maintenance items and
battery under certain conditions) found under normal use in the U.S.A. or Canada to be defective in factory materials or workmanship, and upon the following terms and conditions:
DURATION AND TRANSFER
1.
The duration of this limited warranty is twelve months,
measured from the date of initial retail purchase from
an authorized Harley-Davidson Dealer.
2.
Any unexpired portion of this limited warranty may be
transferred, with written authorization, upon the resale
of the motorcycle/sidecar during the warranty period.
To obtain authorization, a transfer application must be
filed with Harley-Davidson and the motorcycle/sidecar
must pass inspection by one of our authorized Dealers. The customer is responsible for any charge
incurred for work performed by the Dealer beyond the
inspection procedure itself. (See your Owner’s Manual
for complete details.)
OWNER OBLIGATIONS
1.
2.
EXCLUSIONS
IMPORTANT/READ CAREFULLY
This warranty will not apply to any motorcycle/sidecar as
follows:
1.
Which has not been operated or maintained as specified in the Owner’s Manual.
2.
Which has been abused, altered outside of original
factory specifications, improperly stored or used “off
the highway”, for racing or competition of any kind.
3.
Which has had the odometer removed or tampered
with.
OTHER LIMITATIONS
To qualify for warranty protection, you and the selling
Dealer must complete the Warranty Registration Form
and return it to us within 10 days after delivery. We will
then send you an Owner-Warranty Identification Card.
To obtain warranty service, return your motorcycle/
sidecar at your expense within the warranty period to
any authorized Dealer. You must be able to present
your Owner-Warranty Identification Card and/or
Owner's Manual upon our Dealer's request. Our
Dealer should be able to provide warranty service during normal business hours and as soon as possible,
depending upon the workload of the Dealer’s service
department and the availability of necessary parts.
This warranty does not cover:
1.
Parts and labor for normal maintenance as recommended in the Owner’s Manual, including such items
as the following: lubrication, oil and filter change, fuel
system cleaning, battery maintenance, engine tuneup, spark plugs, light bulbs, brake, clutch and chain/
belt adjustment (including chain replacement).
2.
Seats, saddlebags, paint, chrome, or trim deterioration
caused by ordinary wear and tear, exposure or
improper maintenance.
Harley-Davidson Motor Company
.
P.O. Box 653
99466-98
.
1.
Our Dealers are independently owned and operated
and may sell other products. Because of this, HARLEY-DAVIDSON IS NOT RESPONSIBLE FOR THE
SAFETY, QUALITY, OR SUITABILITY OF ANY NONHARLEY-DAVIDSON PART, ACCESSORY OR
DESIGN MODIFICATION INCLUDING LABOR
WHICH MAY BE SOLD AND/OR INSTALLED BY
OUR DEALERS.
2.
THERE IS NO OTHER EXPRESS WARRANTY
(OTHER THAN EMISSIONS AND NOISE WARRANTIES) ON THE MOTORCYCLE. ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS
IS LIMITED TO THE DURATION OF THIS
WARRANTY.
3.
TO THE FULLEST EXTENT ALLOWED BY LAW,
HARLEY-DAVIDSON AND ITS DEALERS SHALL
NOT BE LIABLE FOR LOSS OF USE, INCONVENIENCE, LOST TIME, COMMERCIAL LOSS OR
OTHER INCIDENTAL OR CONSEQUENTIAL
DAMAGES.
Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long
an implied warranty lasts, so the above limitations and exclusions may not apply to you. This warranty gives you specific
legal rights, and you may have other rights which vary from
state to state.
Milwaukee, Wisconsin 53201, U.S.A.
189
SA
M
PL
E
o0022aox
190
99466-98
Warranty Transfer Applications
are available from your HarleyDavison Dealer
HARLEY-DAVIDSON EMISSION CONTROL SYSTEM WARRANTY
The following warranty applies to the emission control system and is in addition to the LIMITED WARRANTY, and NOISE CONTROL SYSTEM WARRANTY.
Harley-Davidson Motor Company warrants to the first owner and each subsequent owner that his vehicle is designed and built
so as to conform at the time of sale with applicable regulations of the U.S. Federal Environmental Protection Agency at the time
of manufacture and that it is free from defects in materials and workmanship which cause his motorcycle not to meet U.S. Environmental Protection Agency Standards within 5 years or 18,641 miles (30,000 kilometers) whichever occurs first.
The warranty period shall begin on the date the motorcycle is delivered to the first retail purchaser or, if the motorcycle is placed
in service as a demonstrator or company vehicle prior to sale at retail, on the date it is first placed in service.
THE FOLLOWING ITEMS ARE NOT COVERED BY THE EMISSION CONTROL SYSTEM WARRANTY
1.
Failures which arise as a result of misuse, alterations, accident or non-performance of maintenance as specified in the
Owner's Manual.
2.
The replacement of parts (such as spark plugs, fuel and oil filters, etc.) used in required maintenance.
3.
Loss of time, inconvenience, loss of motorcycle use or other consequential damages.
4.
Any motorcycle on which the odometer mileage has been changed so that the mileage cannot be determined.
RECOMMENDATIONS FOR REQUIRED MAINTENANCE
IT IS RECOMMENDED THAT ANY EMISSION SYSTEM MAINTENANCE BE PERFORMED BY AN AUTHORIZED HARLEYDAVIDSON DEALER USING GENUINE HARLEY-DAVIDSON REPLACEMENT PARTS. THE MAINTENANCE, REPLACEMENT OR REPAIR OF THE EMISSION CONTROL SYSTEM MAY BE PERFORMED BY ANY OTHER QUALIFIED SERVICE
OUTLET OR INDIVIDUAL. NON-GENUINE PARTS MAY BE USED ONLY IF SUCH PARTS ARE CERTIFIED TO COMPLY
WITH U.S. ENVIRONMENTAL PROTECTION AGENCY STANDARDS.
Harley-Davidson Motor Company, P.O. Box 653 Milwaukee, Wisconsin 53201, U.S.A.
191
99466-98
HARLEY-DAVIDSON NOISE CONTROL SYSTEM WARRANTY
The following warranty applies to the noise control system and is in addition to the LIMITED WARRANTY, and EMISSION CONTROL SYSTEM WARRANTY.
Harley-Davidson Motor Company warrants to the first owner and each subsequent owner that his vehicle is designed and built
so as to conform at the time of sale with applicable regulations of the U.S. Environmental Protection Agency (as tested following
F-76 Drive-By test procedure) at the time of manufacture and that it is free from defects in materials and workmanship which
cause his motorcycle not to meet U.S. Environmental Protection Agency Standards within 1 year or 3,730 miles (6,000 kilometers) whichever occurs first.
The warranty period shall begin on the date the motorcycle is delivered to the first retail purchaser or, if the motorcycle is placed
in service as a demonstrator or company vehicle prior to sale at retail, on the date it is first placed in service.
THE FOLLOWING ITEMS ARE NOT COVERED BY THE NOISE CONTROL SYSTEM WARRANTY
1.
Failures which arise as a result of misuse, alterations, or accident as specified in the Owner's Manual.
2.
Replacing, removing, or modifying any portion of the NOISE CONTROL SYSTEM (consisting of the exhaust system and air
intake/cleaner assembly) with parts not certified to be noise legal for street use.
3.
Loss of time, inconvenience, loss of motorcycle use or other consequential damages.
4.
Any motorcycle on which the odometer mileage has been changed so that the mileage cannot be determined.
RECOMMENDATIONS FOR REQUIRED MAINTENANCE
IT IS RECOMMENDED THAT ANY NOISE SYSTEM MAINTENANCE BE PERFORMED BY AN AUTHORIZED HARLEYDAVIDSON DEALER USING GENUINE HARLEY-DAVIDSON REPLACEMENT PARTS. THE MAINTENANCE, REPLACEMENT OR REPAIR OF THE NOISE CONTROL SYSTEM MAY BE PERFORMED BY ANY OTHER QUALIFIED SERVICE
OUTLET OR INDIVIDUAL. NON-GENUINE PARTS MAY BE USED ONLY IF SUCH PARTS ARE CERTIFIED TO COMPLY
WITH U.S. ENVIRONMENTAL PROTECTION AGENCY STANDARDS.
Harley-Davidson Motor Company, P.O. Box 653 Milwaukee, Wisconsin 53201, U.S.A.
192
99466-98
500 MILE
500 MILE
(800 km)
(800 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Dealer (or other) Signature
Date
Mileage
DEALER RECORD
OWNER RECORD
193
99466-98
500 MILE MAINTENANCE
500 MILE MAINTENANCE
❏1.
❏2.
❑3.
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑13.
❑14.
❑15.
❑16.
❑17.
❑18.
❑19.
❑20.
❑21.
❑22.
❑23.
❑24.
❑25.
❑26.
❑27.
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Change primary chaincase lubricant and clean magnetic drain plug.
Check/adjust primary chain.
Check clutch adjustment.
Change transmission lubricant and clean magnetic drain plug.
Check and adjust drive belt.
Lube the foot shift/brake lever bearings.*
Check rear brake pedal adjustment.
Inspect brake pads and discs for wear.
Check brake fluid reservoir levels and condition.
Inspect oil lines and brake system for leaks.
Lubricate the following: front brake hand lever, throttle control
cables, throttle, clutch control cable and hand lever, jiffy stand.
Lubricate and adjust all Springer steering head bearings.
Check, adjust operation of enrichener.*
Inspect fuel valve*, lines and fittings for leaks.
Check tire pressure and inspect tread.
Check wheel spoke tightness.*
Check battery electrolyte level* and clean battery connections.
Check operation of all electrical equipment and switches.
Check cruise control disengage switch & other components.*
Check shock absorbers.
Check rear fork pivot nut.*
Check air suspension - pressure, operation and leakage.*
Check stabilizer links* and engine mounts.
Check tightness of all fasteners except engine head bolts.
Check engine idle speed adjustment.
Road test.
*If applicable.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑13.
❑14.
❑15.
❑16.
❑17.
❑18.
❑19.
❑20.
❑21.
❑22.
❑23.
❑24.
❑25.
❑26.
❑27.
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Change primary chaincase lubricant and clean magnetic drain plug.
Check/adjust primary chain.
Check clutch adjustment.
Change transmission lubricant and clean magnetic drain plug.
Check and adjust drive belt.
Lube the foot shift/brake lever bearings.*
Check rear brake pedal adjustment.
Inspect brake pads and discs for wear.
Check brake fluid reservoir levels and condition.
Inspect oil lines and brake system for leaks.
Lubricate the following: front brake hand lever, throttle control
cables, throttle, clutch control cable and hand lever, jiffy stand.
Lubricate and adjust all Springer steering head bearings.
Check, adjust operation of enrichener.*
Inspect fuel valve*, lines and fittings for leaks.
Check tire pressure and inspect tread.
Check wheel spoke tightness.*
Check battery electrolyte level* and clean battery connections.
Check operation of all electrical equipment and switches.
Check cruise control disengage switch & other components.*
Check shock absorbers.
Check rear fork pivot nut.*
Check air suspension - pressure, operation and leakage.*
Check stabilizer links* and engine mounts.
Check tightness of all fasteners except engine head bolts.
Check engine idle speed adjustment.
Road test.
*If applicable.
194
99466-98
2500 MILE
2500 MILE
(4000 km)
(4000 km)
MAINTENANCE
MAINTENANCE
Date
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Mileage
Owner’s Signature
VIN
Dealer (or other) Signature
Date
Mileage
DEALER RECORD
OWNER RECORD
195
99466-98
2500 MILE MAINTENANCE
2500 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inspect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inspect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
196
99466-98
5000 MILE
5000 MILE
(8000 km)
(8000 km)
MAINTENANCE
MAINTENANCE
Date
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Mileage
Owner’s Signature
VIN
Dealer (or other) Signature
Date
Mileage
DEALER RECORD
OWNER RECORD
197
99466-98
5000 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑13.
❑14.
❑15.
❑16.
❑17.
❑18.
❑19.
❑20.
❑21.
❑22.
❑23.
❑24.
❑25.
❑26.
❑27.
❑28.
❑29.
❑30.
❑31.
❑32.
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean magnetic drain plug.
Check/adjust primary chain.
Check clutch adjustment.
Change transmission lubricant and clean the magnetic drain plug.
Check and adjust belt.
Lube the foot shift/brake lever bearings* and speedometer cable.*
Lubricate all Springer steering head bearings.
Check rear brake pedal adjustment.
Inspect brake pads and discs for wear.
Check brake fluid reservoir levels and condition.
Inspect oil lines and brake system for leaks.
Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
Check, adjust operation of enrichener.
Inspect fuel valve*, lines and fittings for leaks.
Clean fuel tank filter screen.
Check tire pressure and inspect tread.
Check wheel spoke tightness.*
Check front fork bearing adjustment.
Check operation of all electrical equipment and switches.
Check cruise control disengage switch & other components.*
Check battery electrolyte level* and clean battery connections.
Inspect spark plugs.
Check condition of rear shock absorbers.
Check air suspension - pressure, operation and leakage.*
Check engine mounts.
Check tightness of all fasteners except engine head bolts.
Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
Check ignition timing and vacuum hose.*
Check engine idle speed adjustment.
Road test.
*If applicable.
5000 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑13.
❑14.
❑15.
❑16.
❑17.
❑18.
❑19.
❑20.
❑21.
❑22.
❑23.
❑24.
❑25.
❑26.
❑27.
❑28.
❑29.
❑30.
❑31.
❑32.
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean magnetic drain plug.
Check/adjust primary chain.
Check clutch adjustment.
Change transmission lubricant and clean the magnetic drain plug.
Check and adjust belt.
Lube the foot shift/brake lever bearings* and speedometer cable.*
Lubricate all Springer steering head bearings.
Check rear brake pedal adjustment.
Inspect brake pads and discs for wear.
Check brake fluid reservoir levels and condition.
Inspect oil lines and brake system for leaks.
Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
Check, adjust operation of enrichener.
Inspect fuel valve*, lines and fittings for leaks.
Clean fuel tank filter screen.
Check tire pressure and inspect tread.
Check wheel spoke tightness.*
Check front fork bearing adjustment.
Check operation of all electrical equipment and switches.
Check cruise control disengage switch & other components.*
Check battery electrolyte level* and clean battery connections.
Inspect spark plugs.
Check condition of rear shock absorbers.
Check air suspension - pressure, operation and leakage.*
Check engine mounts.
Check tightness of all fasteners except engine head bolts.
Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
Check ignition timing and vacuum hose.*
Check engine idle speed adjustment.
Road test.
*If applicable.
198
99466-98
7500 MILE
7500 MILE
(12000 km)
(12000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
199
99466-98
7500 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inspect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
7500 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inspect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
200
99466-98
10,000 MILE
10,000 MILE
(16000 km)
(16000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
201
99466-98
10,000 MILE MAINTENANCE
10,000 MILE MAINTENANCE
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean
magnetic drain plug. Check/adjust primary chain.
❑5. Check clutch adjustment.
❑6. Change transmission lubricant and clean the magnetic drain plug.
❑7. Check and adjust belt.
❑8. Lube the foot shift/brake lever bearings* and speedometer cable.*
❑9. Check rear brake pedal adjustment.
❑10. Inspect brake pads and discs for wear.
❑11. Check brake fluid reservoir levels and condition.
❑12. Inspect oil lines and brake system for leaks.
❑13. Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
❑14. Lubricate and adjust steering head bearings (all models).
❑15. Check, adjust operation of enrichener.*
❑16. Inspect fuel valve*, lines and fittings for leaks.
❑17. Clean fuel tank filter screen (Carb. only).
❑18. Check operation of all electrical equipment and switches.
❑19. Check cruise control disengage switch & other components.*
❑20. Check battery electrolyte level* and clean battery connections.
❑21. Change spark plugs.
❑22. Check tire pressure and inspect tread.
❑23. Check wheel spoke tightness.*
❑24. Repack wheel bearings with grease.
❑25. Change front fork oil.*
❑26. Repack rear fork bearings.*
❑27. Adjust Springer rocker bearings.*
❑28. Check condition of rear shock absorbers.
❑29. Check air suspension - pressure, operation and leakage.*
❑30. Check stabilizer links* and engine mounts.
❑31. Check tightness of all fasteners except engine head bolts.
❑32. Inspect Road King windshield bushings.
❑33. Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
❑34. Check ignition timing and vacuum hose.*
❑35. Check engine idle speed adjustment.
❑36. Road test.
*If applicable
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean magnetic drain plug.
Check/adjust primary chain.
❑5. Check clutch adjustment.
❑6. Change transmission lubricant and clean the magnetic drain plug.
❑7. Check and adjust belt
❑8. Lube the foot shift/brake lever bearings* and speedometer cable.*
❑9. Check rear brake pedal adjustment.
❑10. Inspect brake pads and discs for wear.
❑11. Check brake fluid reservoir levels and condition.
❑12. Inspect oil lines and brake system for leaks.
❑13. Lubricate the following: front brake hand lever, throttle control
cables, throttle, clutch control cable and hand lever, jiffy stand.
❑14. Lubricate and adjust steering head bearings (all models).
❑15. Check, adjust operation of enrichener.*
❑16. Inspect fuel valve*, lines and fittings for leaks.
❑17. Clean fuel tank filter screen (Carb. only).
❑18. Check operation of all electrical equipment and switches.
❑19. Check cruise control disengage switch & other components.*
❑20. Check battery electrolyte level* and clean battery connections.
❑21. Change spark plugs.
❑22. Check tire pressure and inspect tread.
❑23. Check wheel spoke tightness.*
❑24. Repack wheel bearings with grease.
❑25. Change front fork oil.*
❑26. Repack rear fork bearings.*
❑27. Adjust Springer rocker bearings.*
❑28. Check condition of rear shock absorbers.
❑29. Check air suspension - pressure, operation and leakage.*
❑30. Check stabilizer links* and engine mounts.
❑31. Check tightness of all fasteners except engine head bolts.
❑32. Inspect Road King windshield bushings.
❑33. Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
❑34. Check ignition timing and vacuum hose.*
❑35. Check engine idle speed adjustment.
❑36. Road test.
*If applicable
❑1.
❑2.
❑3.
❑4.
❑1.
❑2.
❑3.
❑4.
202
99466-98
12,500 MILE
12,500 MILE
(20000 km)
(20 000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
203
99466-98
12,500 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inpect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
12,500 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inspect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
204
99466-98
15,000 MILE
15,000 MILE
(24000 km)
(24000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
205
99466-98
15,000 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑13.
❑14.
❑15.
❑16.
❑17.
❑18.
❑19.
❑20.
❑21.
❑22.
❑23.
❑24.
❑25.
❑26.
❑27.
❑28.
❑29.
❑30.
❑31.
❑32.
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean magnetic drain plug.
Check/adjust primary chain.
Check clutch adjustment.
Change transmission lubricant and clean the magnetic drain plug.
Check and adjust belt.
Lube the foot shift/brake lever bearings* and speedometer cable.*
Lubricate all Springer steering head bearings.
Check rear brake pedal adjustment.
Inspect brake pads and discs for wear.
Check brake fluid reservoir levels and condition.
Inspect oil lines and brake system for leaks.
Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
Check, adjust operation of enrichener.
Inspect fuel valve*, lines and fittings for leaks.
Clean fuel tank filter screen.
Check tire pressure and inspect tread.
Check wheel spoke tightness.*
Check front fork bearing adjustment.
Check operation of all electrical equipment and switches.
Check cruise control disengage switch & other components.*
Check battery electrolyte level* and clean battery connections.
Inspect spark plugs.
Check condition of rear shock absorbers.
Check air suspension - pressure, operation and leakage.*
Check engine mounts.
Check tightness of all fasteners except engine head bolts.
Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
Check ignition timing and vacuum hose.*
Check engine idle speed adjustment.
Road test.
*If applicable.
15,000 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑13.
❑14.
❑15.
❑16.
❑17.
❑18.
❑19.
❑20.
❑21.
❑22.
❑23.
❑24.
❑25.
❑26.
❑27.
❑28.
❑29.
❑30.
❑31.
❑32.
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean magnetic drain plug.
Check/adjust primary chain.
Check clutch adjustment.
Change transmission lubricant and clean the magnetic drain plug.
Check and adjust belt.
Lube the foot shift/brake lever bearings* and speedometer cable.*
Lubricate all Springer steering head bearings.
Check rear brake pedal adjustment.
Inspect brake pads and discs for wear.
Check brake fluid reservoir levels and condition.
Inspect oil lines and brake system for leaks.
Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
Check, adjust operation of enrichener.
Inspect fuel valve*, lines and fittings for leaks.
Clean fuel tank filter screen.
Check tire pressure and inspect tread.
Check wheel spoke tightness.*
Check front fork bearing adjustment.
Check operation of all electrical equipment and switches.
Check cruise control disengage switch & other components.*
Check battery electrolyte level* and clean battery connections.
Inspect spark plugs.
Check condition of rear shock absorbers.
Check air suspension - pressure, operation and leakage.*
Check engine mounts.
Check tightness of all fasteners except engine head bolts.
Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
Check ignition timing and vacuum hose.*
Check engine idle speed adjustment.
Road test.
*If applicable.
206
99466-98
17,500 MILE
17,500 MILE
(28000 km)
(28000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
207
99466-98
17,500 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inspect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
17,500 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inspect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
208
99466-98
20,000 MILE
20,000 MILE
(32000 km)
(32000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
209
99466-98
20,000 MILE MAINTENANCE
20,000 MILE MAINTENANCE
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean
magnetic drain plug. Check/adjust primary chain.
❑5. Check clutch adjustment.
❑6. Change transmission lubricant and clean the magnetic drain plug.
❑7. Check and adjust belt.
❑8. Lube the foot shift/brake lever bearings* and speedometer cable.*
❑9. Check rear brake pedal adjustment.
❑10. Inspect brake pads and discs for wear.
❑11. Check brake fluid reservoir levels and condition.
❑12. Inspect oil lines and brake system for leaks.
❑13. Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
❑14. Check, adjust operation of enrichener.*
❑15. Inspect fuel valve*, lines and fittings for leaks.
❑16. Clean fuel tank filter screen (Carb. only).
❑17. Check operation of all electrical equipment and switches.
❑18. Check cruise control disengage switch & other components.*
❑19. Check battery electrolyte level* and clean battery connections.
❑20. Change spark plugs.
❑21. Check tire pressure and inspect tread.
❑22. Check wheel spoke tightness.*
❑23. Repack wheel bearings with grease.
❑24. Visually inspect, adjust, and repack steering head bearings (all models).
❑25. Change front fork oil.*
❑26. Repack rear fork bearings.*
❑27. Adjust Springer rocker bearings.*
❑28. Check condition of rear shock absorbers.
❑29. Check air suspension - pressure, operation and leakage.*
❑30. Check stabilizer links* and engine mounts.
❑31. Check tightness of all fasteners except engine head bolts.
❑32. Inspect Road King windshield bushings.
❑33. Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
❑34. Check ignition timing and vacuum hose.*
❑35. Check engine idle speed adjustment.
❑36. Road test.
*If applicable
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean magnetic drain plug.
Check/adjust primary chain.
❑5. Check clutch adjustment.
❑6. Change transmission lubricant and clean the magnetic drain plug.
❑7. Check and adjust belt
❑8. Lube the foot shift/brake lever bearings* and speedometer cable.*
❑9. Check rear brake pedal adjustment.
❑10. Inspect brake pads and discs for wear.
❑11. Check brake fluid reservoir levels and condition.
❑12. Inspect oil lines and brake system for leaks.
❑13. Lubricate the following: front brake hand lever, throttle control
cables, throttle, clutch control cable and hand lever, jiffy stand.
❑14. Check, adjust operation of enrichener.*
❑15. Inspect fuel valve*, lines and fittings for leaks.
❑16. Clean fuel tank filter screen (Carb. only).
❑17. Check operation of all electrical equipment and switches.
❑18. Check cruise control disengage switch & other components.*
❑19. Check battery electrolyte level* and clean battery connections.
❑20. Change spark plugs.
❑21. Check tire pressure and inspect tread.
❑22. Check wheel spoke tightness.*
❑23. Repack wheel bearings with grease.
❑24. Visually inspect, adjust, and repack steering head bearings (all models).
❑25. Change front fork oil.*
❑26. Repack rear fork bearings.*
❑27. Adjust Springer rocker bearings.*
❑28. Check condition of rear shock absorbers.
❑29. Check air suspension - pressure, operation and leakage.*
❑30. Check stabilizer links* and engine mounts.
❑31. Check tightness of all fasteners except engine head bolts.
❑32. Inspect Road King windshield bushings.
❑33. Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
❑34. Check ignition timing and vacuum hose.*
❑35. Check engine idle speed adjustment.
❑36. Road test.
*If applicable
❑1.
❑2.
❑3.
❑4.
❑1.
❑2.
❑3.
❑4.
210
99466-98
22,500 MILE
22,500 MILE
(36000 km)
(36000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
211
99466-98
22,500 MILE MAINTENANCE
22,500 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inpect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inspect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
212
99466-98
25,000 MILE
25,000 MILE
(40000 km)
(40000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
213
99466-98
25,000 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑13.
❑14.
❑15.
❑16.
❑17.
❑18.
❑19.
❑20.
❑21.
❑22.
❑23.
❑24.
❑25.
❑26.
❑27.
❑28.
❑29.
❑30.
❑31.
❑32.
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean magnetic drain plug.
Check/adjust primary chain.
Check clutch adjustment.
Change transmission lubricant and clean the magnetic drain plug.
Check and adjust belt.
Lube the foot shift/brake lever bearings* and speedometer cable.*
Lubricate all Springer steering head bearings.
Check rear brake pedal adjustment.
Inspect brake pads and discs for wear.
Check brake fluid reservoir levels and condition.
Inspect oil lines and brake system for leaks.
Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
Check, adjust operation of enrichener.
Inspect fuel valve*, lines and fittings for leaks.
Clean fuel tank filter screen.
Check tire pressure and inspect tread.
Check wheel spoke tightness.*
Check front fork bearing adjustment.
Check operation of all electrical equipment and switches.
Check cruise control disengage switch & other components.*
Check battery electrolyte level* and clean battery connections.
Inspect spark plugs.
Check condition of rear shock absorbers.
Check air suspension - pressure, operation and leakage.*
Check engine mounts.
Check tightness of all fasteners except engine head bolts.
Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
Check ignition timing and vacuum hose.*
Check engine idle speed adjustment.
Road test.
*If applicable.
25,000 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑13.
❑14.
❑15.
❑16.
❑17.
❑18.
❑19.
❑20.
❑21.
❑22.
❑23.
❑24.
❑25.
❑26.
❑27.
❑28.
❑29.
❑30.
❑31.
❑32.
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean magnetic drain plug.
Check/adjust primary chain.
Check clutch adjustment.
Change transmission lubricant and clean the magnetic drain plug.
Check and adjust belt.
Lube the foot shift/brake lever bearings* and speedometer cable.*
Lubricate all Springer steering head bearings.
Check rear brake pedal adjustment.
Inspect brake pads and discs for wear.
Check brake fluid reservoir levels and condition.
Inspect oil lines and brake system for leaks.
Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
Check, adjust operation of enrichener.
Inspect fuel valve*, lines and fittings for leaks.
Clean fuel tank filter screen.
Check tire pressure and inspect tread.
Check wheel spoke tightness.*
Check front fork bearing adjustment.
Check operation of all electrical equipment and switches.
Check cruise control disengage switch & other components.*
Check battery electrolyte level* and clean battery connections.
Inspect spark plugs.
Check condition of rear shock absorbers.
Check air suspension - pressure, operation and leakage.*
Check engine mounts.
Check tightness of all fasteners except engine head bolts.
Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
Check ignition timing and vacuum hose.*
Check engine idle speed adjustment.
Road test.
*If applicable.
214
99466-98
27,500 MILE
27,500 MILE
(44000 km)
(44000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
215
99466-98
27,500 MILE MAINTENANCE
27,500 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inpect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inspect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
216
99466-98
30,000 MILE
30,000 MILE
(48000 km)
(48000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
217
99466-98
30,000 MILE MAINTENANCE
30,000 MILE MAINTENANCE
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean
magnetic drain plug. Check/adjust primary chain.
❑5. Check clutch adjustment.
❑6. Change transmission lubricant and clean the magnetic drain plug.
❑7. Check and adjust belt.
❑8. Lube the foot shift/brake lever bearings* and speedometer cable.*
❑9. Check rear brake pedal adjustment.
❑10. Inspect brake pads and discs for wear.
❑11. Check brake fluid reservoir levels and condition.
❑12. Inspect oil lines and brake system for leaks.
❑13. Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
❑14. Lubricate and adjust steering head bearings (all models).
❑15. Check, adjust operation of enrichener.*
❑16. Inspect fuel valve*, lines and fittings for leaks.
❑17. Clean fuel tank filter screen (Carb. only).
❑18. Check operation of all electrical equipment and switches.
❑19. Check cruise control disengage switch & other components.*
❑20. Check battery electrolyte level* and clean battery connections.
❑21. Change spark plugs.
❑22. Check tire pressure and inspect tread.
❑23. Check wheel spoke tightness.*
❑24. Repack wheel bearings with grease.
❑25. Change front fork oil.*
❑26. Repack rear fork bearings.*
❑27. Adjust Springer rocker bearings.*
❑28. Check condition of rear shock absorbers.
❑29. Check air suspension - pressure, operation and leakage.*
❑30. Check stabilizer links* and engine mounts.
❑31. Check tightness of all fasteners except engine head bolts.
❑32. Inspect Road King windshield bushings.
❑33. Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
❑34. Check ignition timing and vacuum hose.*
❑35. Check engine idle speed adjustment.
❑36. Road test.
*If applicable
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean
magnetic drain plug. Check/adjust primary chain.
❑5. Check clutch adjustment.
❑6. Change transmission lubricant and clean the magnetic drain plug.
❑7. Check and adjust belt.
❑8. Lube the foot shift/brake lever bearings* and speedometer cable.*
❑9. Check rear brake pedal adjustment.
❑10. Inspect brake pads and discs for wear.
❑11. Check brake fluid reservoir levels and condition.
❑12. Inspect oil lines and brake system for leaks.
❑13. Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
❑14. Lubricate and adjust steering head bearings (all models).
❑15. Check, adjust operation of enrichener.*
❑16. Inspect fuel valve*, lines and fittings for leaks.
❑17. Clean fuel tank filter screen (Carb. only).
❑18. Check operation of all electrical equipment and switches.
❑19. Check cruise control disengage switch & other components.*
❑20. Check battery electrolyte level* and clean battery connections.
❑21. Change spark plugs.
❑22. Check tire pressure and inspect tread.
❑23. Check wheel spoke tightness.*
❑24. Repack wheel bearings with grease.
❑25. Change front fork oil.*
❑26. Repack rear fork bearings.*
❑27. Adjust Springer rocker bearings.*
❑28. Check condition of rear shock absorbers.
❑29. Check air suspension - pressure, operation and leakage.*
❑30. Check stabilizer links* and engine mounts.
❑31. Check tightness of all fasteners except engine head bolts.
❑32. Inspect Road King windshield bushings.
❑33. Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
❑34. Check ignition timing and vacuum hose.*
❑35. Check engine idle speed adjustment.
❑36. Road test.
*If applicable
❑1.
❑2.
❑3.
❑4.
❑1.
❑2.
❑3.
❑4.
218
99466-98
32,500 MILE
32,500 MILE
(52000 km)
(52000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
zzzzz
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORDzzz
219
99466-98
32,500 MILE MAINTENANCE
32,500 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inpect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inpect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
220
99466-98
35,000 MILE
35,000 MILE
(56000 km)
(56000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
221
99466-98
35,000 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑13.
❑14.
❑15.
❑16.
❑17.
❑18.
❑19.
❑20.
❑21.
❑22.
❑23.
❑24.
❑25.
❑26.
❑27.
❑28.
❑29.
❑30.
❑31.
❑32.
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean magnetic drain plug.
Check/adjust primary chain.
Check clutch adjustment.
Change transmission lubricant and clean the magnetic drain plug.
Check and adjust belt.
Lube the foot shift/brake lever bearings* and speedometer cable.*
Lubricate all Springer steering head bearings.
Check rear brake pedal adjustment.
Inspect brake pads and discs for wear.
Check brake fluid reservoir levels and condition.
Inspect oil lines and brake system for leaks.
Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
Check, adjust operation of enrichener.
Inspect fuel valve*, lines and fittings for leaks.
Clean fuel tank filter screen.
Check tire pressure and inspect tread.
Check wheel spoke tightness.*
Check front fork bearing adjustment.
Check operation of all electrical equipment and switches.
Check cruise control disengage switch & other components.*
Check battery electrolyte level* and clean battery connections.
Inspect spark plugs.
Check condition of rear shock absorbers.
Check air suspension - pressure, operation and leakage.*
Check engine mounts.
Check tightness of all fasteners except engine head bolts.
Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
Check ignition timing and vacuum hose.*
Check engine idle speed adjustment.
Road test.
*If applicable.
35,000 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑13.
❑14.
❑15.
❑16.
❑17.
❑18.
❑19.
❑20.
❑21.
❑22.
❑23.
❑24.
❑25.
❑26.
❑27.
❑28.
❑29.
❑30.
❑31.
❑32.
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean magnetic drain plug.
Check/adjust primary chain.
Check clutch adjustment.
Change transmission lubricant and clean the magnetic drain plug.
Check and adjust belt.
Lube the foot shift/brake lever bearings* and speedometer cable.*
Lubricate all Springer steering head bearings.
Check rear brake pedal adjustment.
Inspect brake pads and discs for wear.
Check brake fluid reservoir levels and condition.
Inspect oil lines and brake system for leaks.
Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
Check, adjust operation of enrichener.
Inspect fuel valve*, lines and fittings for leaks.
Clean fuel tank filter screen.
Check tire pressure and inspect tread.
Check wheel spoke tightness.*
Check front fork bearing adjustment.
Check operation of all electrical equipment and switches.
Check cruise control disengage switch & other components.*
Check battery electrolyte level* and clean battery connections.
Inspect spark plugs.
Check condition of rear shock absorbers.
Check air suspension - pressure, operation and leakage.*
Check engine mounts.
Check tightness of all fasteners except engine head bolts.
Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
Check ignition timing and vacuum hose.*
Check engine idle speed adjustment.
Road test.
*If applicable.
222
99466-98
37,500 MILE
37,500 MILE
(60000 km)
(60000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
223
99466-98
37,500 MILE MAINTENANCE
37,500 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inpect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inpect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
224
99466-98
40,000 MILE
40,000 MILE
(64000 km)
(64000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
225
99466-98
40,000 MILE MAINTENANCE
40,000 MILE MAINTENANCE
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean
magnetic drain plug. Check/adjust primary chain.
❑5. Check clutch adjustment.
❑6. Change transmission lubricant and clean the magnetic drain plug.
❑7. Check and adjust belt.
❑8. Lube the foot shift/brake lever bearings* and speedometer cable.*
❑9. Check rear brake pedal adjustment.
❑10. Inspect brake pads and discs for wear.
❑11. Check brake fluid reservoir levels and condition.
❑12. Inspect oil lines and brake system for leaks.
❑13. Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
❑14. Check, adjust operation of enrichener.*
❑15. Inspect fuel valve*, lines and fittings for leaks.
❑16. Clean fuel tank filter screen (Carb. only).
❑17. Check operation of all electrical equipment and switches.
❑18. Check cruise control disengage switch & other components.*
❑19. Check battery electrolyte level* and clean battery connections.
❑20. Change spark plugs.
❑21. Check tire pressure and inspect tread.
❑22. Check wheel spoke tightness.*
❑23. Repack wheel bearings with grease.
❑24. Visually inspect, adjust, and repack steering head bearings (all models).
❑25. Change front fork oil.*
❑26. Repack rear fork bearings.*
❑27. Adjust Springer rocker bearings.*
❑28. Check condition of rear shock absorbers.
❑29. Check air suspension - pressure, operation and leakage.*
❑30. Check stabilizer links* and engine mounts.
❑31. Check tightness of all fasteners except engine head bolts.
❑32. Inspect Road King windshield bushings.
❑33. Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
❑34. Check ignition timing and vacuum hose.*
❑35. Check engine idle speed adjustment.
❑36. Road test.
*If applicable
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean magnetic drain plug.
Check/adjust primary chain.
❑5. Check clutch adjustment.
❑6. Change transmission lubricant and clean the magnetic drain plug.
❑7. Check and adjust belt
❑8. Lube the foot shift/brake lever bearings* and speedometer cable.*
❑9. Check rear brake pedal adjustment.
❑10. Inspect brake pads and discs for wear.
❑11. Check brake fluid reservoir levels and condition.
❑12. Inspect oil lines and brake system for leaks.
❑13. Lubricate the following: front brake hand lever, throttle control
cables, throttle, clutch control cable and hand lever, jiffy stand.
❑14. Check, adjust operation of enrichener.*
❑15. Inspect fuel valve*, lines and fittings for leaks.
❑16. Clean fuel tank filter screen (Carb. only).
❑17. Check operation of all electrical equipment and switches.
❑18. Check cruise control disengage switch & other components.*
❑19. Check battery electrolyte level* and clean battery connections.
❑20. Change spark plugs.
❑21. Check tire pressure and inspect tread.
❑22. Check wheel spoke tightness.*
❑23. Repack wheel bearings with grease.
❑24. Visually inspect, adjust, and repack steering head bearings (all models).
❑25. Change front fork oil.*
❑26. Repack rear fork bearings.*
❑27. Adjust Springer rocker bearings.*
❑28. Check condition of rear shock absorbers.
❑29. Check air suspension - pressure, operation and leakage.*
❑30. Check stabilizer links* and engine mounts.
❑31. Check tightness of all fasteners except engine head bolts.
❑32. Inspect Road King windshield bushings.
❑33. Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
❑34. Check ignition timing and vacuum hose.*
❑35. Check engine idle speed adjustment.
❑36. Road test.
*If applicable
❑1.
❑2.
❑3.
❑4.
❑1.
❑2.
❑3.
❑4.
226
99466-98
42,500 MILE
42,500 MILE
(68000 km)
(68000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
227
99466-98
42,500 MILE MAINTENANCE
42,500 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inpect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inspect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
228
99466-98
45,000 MILE
45,000 MILE
(72000 km)
(72000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
229
99466-98
45,000 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑13.
❑14.
❑15.
❑16.
❑17.
❑18.
❑19.
❑20.
❑21.
❑22.
❑23.
❑24.
❑25.
❑26.
❑27.
❑28.
❑29.
❑30.
❑31.
❑32.
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean magnetic drain plug.
Check/adjust primary chain.
Check clutch adjustment.
Change transmission lubricant and clean the magnetic drain plug.
Check and adjust belt.
Lube the foot shift/brake lever bearings* and speedometer cable.*
Lubricate all Springer steering head bearings.
Check rear brake pedal adjustment.
Inspect brake pads and discs for wear.
Check brake fluid reservoir levels and condition.
Inspect oil lines and brake system for leaks.
Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
Check, adjust operation of enrichener.
Inspect fuel valve*, lines and fittings for leaks.
Clean fuel tank filter screen.
Check tire pressure and inspect tread.
Check wheel spoke tightness.*
Check front fork bearing adjustment.
Check operation of all electrical equipment and switches.
Check cruise control disengage switch & other components.*
Check battery electrolyte level* and clean battery connections.
Inspect spark plugs.
Check condition of rear shock absorbers.
Check air suspension - pressure, operation and leakage.*
Check engine mounts.
Check tightness of all fasteners except engine head bolts.
Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
Check ignition timing and vacuum hose.*
Check engine idle speed adjustment.
Road test.
*If applicable.
45,000 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑13.
❑14.
❑15.
❑16.
❑17.
❑18.
❑19.
❑20.
❑21.
❑22.
❑23.
❑24.
❑25.
❑26.
❑27.
❑28.
❑29.
❑30.
❑31.
❑32.
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean magnetic drain plug.
Check/adjust primary chain.
Check clutch adjustment.
Change transmission lubricant and clean the magnetic drain plug.
Check and adjust belt.
Lube the foot shift/brake lever bearings* and speedometer cable.*
Lubricate all Springer steering head bearings.
Check rear brake pedal adjustment.
Inspect brake pads and discs for wear.
Check brake fluid reservoir levels and condition.
Inspect oil lines and brake system for leaks.
Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
Check, adjust operation of enrichener.
Inspect fuel valve*, lines and fittings for leaks.
Clean fuel tank filter screen.
Check tire pressure and inspect tread.
Check wheel spoke tightness.*
Check front fork bearing adjustment.
Check operation of all electrical equipment and switches.
Check cruise control disengage switch & other components.*
Check battery electrolyte level* and clean battery connections.
Inspect spark plugs.
Check condition of rear shock absorbers.
Check air suspension - pressure, operation and leakage.*
Check engine mounts.
Check tightness of all fasteners except engine head bolts.
Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
Check ignition timing and vacuum hose.*
Check engine idle speed adjustment.
Road test.
*If applicable.
230
99466-98
47,500 MILE
47,500 MILE
(76000 km)
(76000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
231
99466-98
47,500 MILE MAINTENANCE
47,500 MILE MAINTENANCE
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
❑1.
❑2.
❑3.
❑4.
❑5.
❑6.
❑7.
❑8.
❑9.
❑10.
❑11.
❑12.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inpect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
Inspect engine oil.
Inspect rear belt.
Inspect transmission lubricant.
Inpect brake pads and discs for wear.
Inspect fuel valve*, lines and fittings for leaks.
Inspect tire pressure and inspect tread.
Inspect operation of throttle and enrichener* controls.
Inspect operation of all electrical equipment and switches.
Inspect battery fluid level* and connections.
Check stabilizer links* and engine mounts.
Lubricate all Springer steering head bearings.
Road test.
*If applicable.
232
99466-98
50,000 MILE
50,000 MILE
(80000 km)
(80000 km)
MAINTENANCE
MAINTENANCE
You are authorized to perform the applicable maintenance
and lubrication services listed on the back of this coupon.
These services are to be performed at your regular rates and
paid for by me, the owner. I also authorize you to road test
this motorcycle for proper operation.
Date
Mileage
Owner’s Signature
VIN
Date
Dealer (or other) Signature
Mileage
DEALER RECORD
OWNER RECORD
233
99466-98
50,000 MILE MAINTENANCE
50,000 MILE MAINTENANCE
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean
magnetic drain plug. Check/adjust primary chain.
❑5. Check clutch adjustment.
❑6. Change transmission lubricant and clean the magnetic drain plug.
❑7. Check and adjust belt.
❑8. Lube the foot shift/brake lever bearings* and speedometer cable.*
❑9. Check rear brake pedal adjustment.
❑10. Inspect brake pads and discs for wear.
❑11. Check brake fluid reservoir levels and condition.
❑12. Inspect oil lines and brake system for leaks.
❑13. Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
❑14. Lubricate and adjust steering head bearings (all models).
❑15. Check, adjust operation of enrichener.*
❑16. Inspect fuel valve*, lines and fittings for leaks.
❑17. Clean fuel tank filter screen (Carb. only).
❑18. Check operation of all electrical equipment and switches.
❑19. Check cruise control disengage switch & other components.*
❑20. Check battery electrolyte level* and clean battery connections.
❑21. Change spark plugs.
❑22. Check tire pressure and inspect tread.
❑23. Check wheel spoke tightness.*
❑24. Repack wheel bearings with grease.
❑25. Change front fork oil.*
❑26. Repack rear fork bearings.*
❑27. Adjust Springer rocker bearings.*
❑28. Check condition of rear shock absorbers.
❑29. Check air suspension - pressure, operation and leakage.*
❑30. Check stabilizer links* and engine mounts.
❑31. Check tightness of all fasteners except engine head bolts.
❑32. Inspect Road King windshield bushings.
❑33. Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
❑34. Check ignition timing and vacuum hose.*
❑35. Check engine idle speed adjustment.
❑36. Road test.
*If applicable
Change engine oil & oil filter.
Inspect air cleaner and service as required.
Clean tappet oil screen.*
Change primary chaincase lubricant and clean
magnetic drain plug. Check/adjust primary chain.
❑5. Check clutch adjustment.
❑6. Change transmission lubricant and clean the magnetic drain plug.
❑7. Check and adjust belt.
❑8. Lube the foot shift/brake lever bearings* and speedometer cable.*
❑9. Check rear brake pedal adjustment.
❑10. Inspect brake pads and discs for wear.
❑11. Check brake fluid reservoir levels and condition.
❑12. Inspect oil lines and brake system for leaks.
❑13. Lubricate the following: front brake hand lever, throttle control cables,
throttle, clutch control cable and hand lever, jiffy stand.
❑14. Lubricate and adjust steering head bearings (all models).
❑15. Check, adjust operation of enrichener.*
❑16. Inspect fuel valve*, lines and fittings for leaks.
❑17. Clean fuel tank filter screen (Carb. only).
❑18. Check operation of all electrical equipment and switches.
❑19. Check cruise control disengage switch & other components.*
❑20. Check battery electrolyte level* and clean battery connections.
❑21. Change spark plugs.
❑22. Check tire pressure and inspect tread.
❑23. Check wheel spoke tightness.*
❑24. Repack wheel bearings with grease.
❑25. Change front fork oil.*
❑26. Repack rear fork bearings.*
❑27. Adjust Springer rocker bearings.*
❑28. Check condition of rear shock absorbers.
❑29. Check air suspension - pressure, operation and leakage.*
❑30. Check stabilizer links* and engine mounts.
❑31. Check tightness of all fasteners except engine head bolts.
❑32. Inspect Road King windshield bushings.
❑33. Lubricate hinges, latches - fuel door, Tour-Pak, saddlebags.*
❑34. Check ignition timing and vacuum hose.*
❑35. Check engine idle speed adjustment.
❑36. Road test.
*If applicable
❑1.
❑2.
❑3.
❑4.
❑1.
❑2.
❑3.
❑4.
234
99466-98
SERVICE LITERATURE
For more detailed and complete technical and parts information the following publications are available (Fall of 1995) through
your Harley-Davidson dealer. Order by part numbers below.
FLT
SOFTAIL
DYNA GLIDE
XLH
Publication......................................................................... Part No.
Part No.
Part No.
Part No.
Service Manual .................................................................. 99483-98
99482-98
99481-98
99484-98
Parts Catalog ..................................................................... 99456-98
99455-98
99439-98
99451-98
Wiring Diagrams & Electrical Troubleshooting Manual 99948-98
99948-98
99948-98
99948-98
International Service Literature
Publication:
Owner’s Manual
German ................................................................ 99463-98
Contact your local Harley-Davidson dealer
regarding International Service Manuals.
French.................................................................. 99463-98
Italian ................................................................... 99463-98I
Spanish................................................................ 99463-98
Portuguese .......................................................... 99465-98P
235
99466-98
NOTES
236
99466-98
Battery........................................................................... 162
Battery Sulfation............................................................ 164
Brakes ..................................................................... 90, 155
Break-In Maintenance ................................................... 135
Break-In - The First 500 Miles....................................... 128
Bulb Chart - FLHT/C/U/I, FLHR/I, FLTR/I ....................... 22
Bulb Chart - FLSTC/F/S, FXSTC/S/B ............................. 52
Bulb Chart - Dyna ........................................................... 54
Page No.
Bulb Chart - XLH..............................................................73
California Evap. Emission Control .................................187
Capacities - FLSTC/F, FXSTC, FXSTS/B, Dyna .............47
Capacities - FLHT/C/U/I, FLHR/I, FLTR/I ........................17
Capacities - XLH..............................................................69
Carburetor......................................................................153
Chain, Primary ...............................................................151
Chassis Lubrication .......................................................152
Check at First 500 Miles ................................................136
Checking Chaincase Lubrication ...................................148
Checking Oil Level.........................................................142
Circuit Breakers .............................................................169
Cleaning Your Motorcycle..............................................174
Clock..............................................................................101
Clutch.............................................................................155
Clutch Hand Lever ...........................................................88
Controls and Indicators....................................................83
Cruise Control - Ultra Models ..........................................91
Custom ............................................................................25
Dimensions - FLSTC/F, FXSTC, FXSTS/B, Dyna ...........47
Dimensions - FLHT/C/U/I, FLHR/I, FLTR/I ......................17
Dimensions - XLH............................................................69
Drive - Belt ....................................................................151
237
99466-98
INDEX
Page No.
Accessories and Cargo ................................................... 80
Accessories Maintenance ............................................. 175
Cloth....................................................................... 176
Hinges, Latches, Fuel Door, Saddlebags .............. 177
Leather................................................................... 175
Vinyl ....................................................................... 176
Whitewall Tires....................................................... 176
Windshields............................................................ 176
Acc. Switch...................................................................... 95
Adjustable Suspension - FLT Models ........................... 106
Adjustable Suspension - Dyna, XLH ............................. 109
Adjustable Suspension - Softail Models........................ 108
Adjustable Suspension - XL Sport ................................ 110
Air Cleaner .................................................................... 153
Alternator Charging Rate and Voltage Regulator.......... 162
Page No.
Electric Starter Switch ..................................................... 86
Engine - FLSTC/F, FXSTC, FXSTS, Dyna ..................... 48
Engine - FLHT/C/U/I, FLHR/I, FLTR/I ............................. 18
Engine - XLH................................................................... 70
Engine Lubrication ........................................................ 142
Engine Stop Switch ......................................................... 86
Enrichener....................................................................... 88
EPA Noise Regulations................................................. 187
Fork Lock ...................................................................... 102
Front Fork Bearings ...................................................... 159
Fuel ..................................................................... 20, 50, 71
Fuel Filler Cap............................................................... 105
Fuel Gauge ................................................................... 101
Fuel Strainer.................................................................. 153
Fuel Supply Valve ......................................................... 104
Fuses ............................................................................ 169
Fuse Replacement ........................................................ 169
Gasoline Blends .................................................. 20, 50, 72
Gear Shifter..................................................................... 89
General Maintenance.................................................... 174
Hazard warning 4-way Flasher ....................................... 95
Headlamp...................................................................... 161
Page No.
Headlamp Dimmer Switch ...............................................90
Horn Switch......................................................................90
Hydraulic Lifters .............................................................154
Identification - FLSTC/F, FXSTC, FXSTS, Dyna .............27
Identification - FLHT/C/U/I, FLHR/I, FLTR/I .......................3
Identification - XLH...........................................................59
Ignition System - FLSTC/F, FXSTC, FXSTS, Dyna.........48
Ignition System - FLHT/C/U/I, FLHR/I, FLTR/I.................17
Ignition System - XLH ......................................................69
Ignition/Light Key Switch..................................................83
Ignition Timing................................................................160
Indicator Lights.................................................................96
Jiffy Stand ......................................................................101
Jump-Starting Procedure ...............................................165
Lubrication Summary .....................................................138
Luggage .........................................................................117
Maintenance and Lubrication.........................................135
Maintenance Intervals Chart .........................................140
Maintenance Coupons ...................................................193
Mirrors............................................................................100
238
99466-98
Page No.
No. of Sprocket Teeth - FLSTC/F, FXSTC, FXSTS,
Dyna .........................................................................48
No. of Sprocket Teeth - FLHT/C/U/I, FLHR/I, FLTR/I ......18
Number of Sprocket Teeth - XLH ....................................70
Odometer.........................................................................98
Oil Filter .........................................................................145
Oil Pressure Gauge .......................................................101
Operation .......................................................................127
Operating Recommendations ........................................127
Overall Gear Ratios - FLSTC/F, FXSTC, FXSTS,
Dyna .........................................................................48
Overall Gear Ratios - FLHT/C/U/I, FLHR, FLTR/I ...........18
Overall Gear Ratios - XLH ...............................................70
Owner's Identification Card............................................185
Passing Lamp Switch ......................................................90
Pre-riding Checklist........................................................128
Primary Chain ................................................................151
Primary Chaincase Lubrication - 1340cc .......................148
Primary Chaincase Lubrication - XLH............................150
Rear Drive Belt ..............................................................151
Rear Fork Pivot Shaft ....................................................159
Rear Shock Absorber Adjustment - FLT........................106
Page No.
Rear Shock Absorber Adjustment - XLH, Dyna............. 109
Rear Shock Absorber Adjustment - Softail Models ....... 108
Rear Shock Absorber Adjustment - XL Sport ................ 114
Regular Service Intervals .............................................. 139
Reporting Safety Defects (NHTSA Statement).............. 188
Rider Troubleshooting ................................................... 181
Rules of the Road............................................................ 79
Saddlebag(s) - FLT........................................................ 118
Saddlebag(s) - FXDS-CON ........................................... 122
Safety First ...................................................................... 75
Safe Operating Maintenance......................................... 135
Safe Operating Rules ...................................................... 75
Service Literature .......................................................... 235
Sequential Port Fuel Injected Models........................... 131
Shifting Gears................................................................ 132
Shock Absorbers ........................................................... 158
Sound System Controls................................................... 95
Spark Plugs ................................................................... 160
Specifications - FLSTC/F, FXSTC, FXSTS, Dyna .......... 47
Specifications - FLHT/C/U/I, FLHR/.I, FLTR/I.................. 17
Specifications - XLH ........................................................ 69
Speedometer ................................................................... 98
Speedometer, Electronic ............................................... 100
Sportster .......................................................................... 57
Starting the Engine ........................................................ 129
239
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Page No.
Stopping the Engine...................................................... 131
Storage.......................................................................... 178
Suspension Adjustments............................................... 106
Tachometer ..................................................................... 98
Throttle Control Grip........................................................ 86
Tire Data - FLSTC/F, FXSTC, FXSTS, Dyna.................. 48
Tire Data - FLHTC/U/I, FLHR/I, FLTR/I........................... 18
Tire Data - XLH ............................................................... 70
Tires .............................................................................. 158
Touring .............................................................................. 1
Tour-Pak - FLT.............................................................. 117
Transmission - FLSTC/F, FXSTC, FXSTS, Dyna ........... 48
Transmission - FLHT/C/U/I, FLHR/I, FLTR/I ................... 18
Transmission - XLH......................................................... 70
Transmission Lubrication - 1340cc ............................... 147
Transmission Lubrication - XLH .................................... 150
Page No.
Vehicle Alignment ..........................................................158
Vehicle Identification Number (VIN) - FLSTC/F, FXST/C,
FXSTS, Dyna............................................................27
Vehicle Identification Number (VIN) - FLHT/C/U/I,
FLHR/I, FLTR/I ...........................................................3
Vehicle Identification Number (VIN) - XLH.......................59
Voltmeter........................................................................101
Warranties:
Motorcycle Limited Warranty ..................................185
Emission Control System Warranty .......................191
Noise Control System Warranty .............................192
Warranty and Responsibilities ...............................189
Warranty and Maintenance.....................................189
Warranty/Service Information .................................192
Warranty Transfer Form (Sample)..........................190
Weights - FLSTC/F, FXSTC, FXSTS, Dyna ....................47
Weights - FLHT/C/U/I, FLHR/I, FLTR/I ............................17
Weights - XLH..................................................................69
Wheel Bearings..............................................................159
Windshield - FXDS-CON ...............................................124
Windshield - FLHR/I.......................................................121
Windshield Maintenance................................................176
Trip-Odometer............................................................... 100
Troubleshooting ............................................................ 181
Turn Signal Switches ...................................................... 94
240
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99466-98
99466-98
99466-98_cvr:RERUN_OWNRS MANUAL
8/6/08
10:03 AM
Page 1
Part No. 99466-98
Printed in U.S.A.
*99466-98*
Harley-Davidson Motor Company
Technical Communications
Milwaukee, WI 53201
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