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Harley-Davidson FLS/FXS Softail Big Twin Evolution 1984 - 1999Clymer Owners Service & Repair Manual

FL try a model designation applied to motorcycles produced by Harley-Davidson from 1941 to present. Mainly applied to Harley's large-framed bicycles, including the existing Touring show, the FL designation normally used with their particular Softail series, specially on Softails with traditional styling, 16-inch forward wheels, and either Springer forks or large-diameter telescopic front forks.

Early FL versions

The FL is introduced towards the Harley-Davidson model range in 1941. They utilized a 74 cu in (1,210 cc) form of the "Knucklehead" OHV motor that powered the EL in 61 cu in (1,000 cc) form. The FL shared its framework using the EL along with the U and UL, that used a 74 cubic inch flathead motor. The FL replaced the UH and ULH, that used similar framework with 80 cu in (1,300 cc) flathead engines.

The FL carried on relatively unchanged until 1948, when it therefore the EL got redesigned "Panhead" engines of the identical capabilities as prior to. These engines had a number of progress within the prior "Knuckleheads", like self-adjusting hydraulic lifters and aluminum cylinder minds to cut back pounds and enhance cooling. The U and UL flathead twins had been stopped in 1948, making the OHV EL and FL brands as Harley-Davidson's large-frame motorbikes.
Hydra-Glide

In 1949, a year after getting the "Panhead" motor, the FL was handed a fresh front suspension system featuring hydraulically damped telescopic forks, changing the key connect spring suspension system of times. These forks were standard on all huge twin products for 1949, such as the E, EL, F, and FL. Harley-Davidson provided the spring suspension models on these designs and advised their particular utilize on sidecar combinations, considering that the hydraulic forks did not have sufficient path to permit the blend become steady sufficient for safe operation.

During their first design season of 1949, Harley labeled their brand new suspension methods since the "hydraulic front side concludes". Harley's advertisements division promoted the latest suspension techniques by renaming the top twin systems "Hydra Glide" when it comes to 1950 design seasons. This is Harley-Davidson's earliest deviation from the rules of employing alphabetic lettering to spot its versions. This name would alter two times within the reputation for the fundamental large-framed age and F series versions, everytime signaling a noticable difference in the bike's technology. Additionally, the Glide closing could be applied to various other designs, according to both and FL and FX formats.

In 1952, the Hydra-Glide's transmission standard hand-shift/foot-clutch ended up being supplemented by the recommended foot-shift/hand-clutch. The original structure always been offered as an option until 1978. 1952 has also been the last 12 months of this 61 cu in (1,000 cc) EL, making the FL the past remaining large-frame model.

Even though 1903 founding happens to be the basis for "Anniversary versions", Harley-Davidson's 50th Golden Anniversary was celebrated in 1954 with special shows and badges regarding front side fender. 1st seasons of production ended up being 1904.

A more extremely tuned engine with high-compression heads, higher-lift cams, and polished ports, is provided using the FLH type of 1955. The FLH designation features continuing around today's.
Duo-Glide
1961 FLH Duo-Glide

The FL design was presented with an innovative new frame in 1958. This framework included a back swingarm suspended by a couple of coil-over-shock suspension system units. Honoring this totally suspended framework, the FL's model name ended up being altered from Hydra-Glide to Duo-Glide.

Unlike OHV setup, aluminum heads, and telescopic-fork forward suspension system, but this improvement in technology was applied to the small-frame bicycles first, the K-series having received back suspension in 1952.

The next and last changes fond of the name of fundamental FL model would take place in 1965, the final seasons of the "Panhead" motors. These last "Panheads" were the initial "big-twin" Harley-Davidson motors to be designed with electric beginners, the Servi-Car having gotten electric start the year before. This development for Harley-Davidson had been welcomed aided by the new-model name of Electra Glide.

In 1966, the "Panhead" provided solution to the "Shovelhead", gaining a 10 percent increase in power along the way.

A fork-mounted fairing became available on Electra Glides in 1969. This became unofficially known as the "batwing" fairing. Even though the batwing fairing ended up being a quickly removable choice on very early Electra Glides, it was perhaps not detachable on subsequent machines, given that instruments are moved from gas container to the fairing.
Electra Glide

The FL frame ended up being the cornerstone the 1971 FX Super Glide. The FX mated the FL framework because of the forks for the XL Sportster, with buckhorn handlebars and a large fibreglass tailpiece finishing the Super Glide requirements.

The FL was given a front side disc brake in 1972.

The three-speed plus reverse solution ended up being discontinued in 1977.

A 1977 Harley-Davidson Confederate Edition for the FLH Electra Glide that highlighted commemorative paint and tank and fender decals had been produced. The machine production was in these types of reasonable amount numbers - best 44 - concerning succeed among rarest regarding the organization's motorbikes.

An 80 cu in (1,300 cc) engine was made recommended in the Electra Glide in 1978. But the FL designation wasn't changed consequently. By 1981, the 80 cubic inches engine ended up being the standard engine; the 74 cu in (1,210 cc) engine becoming discontinued.

The low-compression FL engine was stopped in 1979, as was the choice for hand-shift/foot-clutch transmission controls.

Journey Glide

The FLT trip Glide was introduced in 1979 as a 1980 model. Sold alongside the prevailing FLH Electra Glide, the FLT had a larger framework with plastic motor supports, a five-speed transmission, the 80 cu in (1,300 cc) engine, and a frame-mounted fairing. So that the FLT frame, that was larger and more substantial compared to big and heavy FLH frame, would manage adequately, the front forks were given radical steering geometry which had all of them attached behind the steering head, because of the framework behind the steering head becoming recessed allowing sufficient steering lock.

The FLHT had been introduced in 1983. This was an Electra Glide on the basis of the FLT journey Glide frame, but making use of the Electra Glide "batwing" fairing rather than the journey Glide frame-mounted fairing. The police type of the FLHT could be the FLHTP.

Except for the bottom FLH, all 1984 FLs had been built with this new rubber-mounted development engine and a five-speed transmission.

All "Shovelhead" motors are discontinued by the 1985 model 12 months. For the reason that year, the four-speed solid-engine-mount FLH ended up being changed to just accept rubberized installation therefore the Evolution engine. The FLH was stopped in 1986; all Touring versions after that used the FLT/FLHT framework. Ironically, the FLT Tour Glide, which launched the current Touring framework, had been fallen through the lineup in 1996. An inferior form of the frame-mounted journey fairing would get back aided by the FLTR Road Glide in 1998.

The Evolution engine is changed by the Twin Cam 88 engine on all large-framed Harley-Davidson motorbikes in 1999. The Twin Cam motor was enlarged from 88 cu.in. to 96 cu.in. in 2007.
Unfaired Glides
2006 Path Master Custom

An unfaired form of the FLH Electra Glide, known as the FLHS Electra Glide athletics, was available from 1979 to 1982. An unfaired FLHT Electra Glide reintroduced the FLHS Electra Glide athletics name in 1987. In 1994, the FLHS Electra Glide Sport had been replaced because of the FLHR path master, which will continue to todays.
2009 Touring framework

The 2009 design season, Harley-Davidson redesigned the entire touring range. The changes included an innovative new frame, brand new swingarm, a completely modified engine-mounting system, 17-inch front wheels for several products except the trail King Timeless, a 6 US gallons (23 l; 5.0 imp gal) gasoline container, and a 2-1-2 exhaust. The changes lead to greater burden holding capability, better maneuvering, a smoother engine, longer number much less exhaust heat sent toward driver and traveler.
Tri-Glide Super Classic

Furthermore introduced in the FL Touring range when it comes to 2009 design season ended up being the FLHTCUTG Tri Glide super Classic, the first three-wheeled Harley-Davidson considering that the Servi-Car ended up being stopped in 1973. This model features a unique frame and a 103 cid engine unique to your trike.

The term softail refers to motorcycles and bicycles that feature a concealed back suspension system program with springs or shock absorbers to soak up bumps. Softail motorcycles give the appearance of having a hard-tail or rigid frame, ordinarily aided by the surprise absorbers or springs under the bike and regarding view.

The word "softail" try a registered trademark of Harley-Davidson motorbikes, coined using launch of the FXST Softail in 1984. Ever since then, the phrase have extended to incorporate more motorbikes with concealed rear suspensions as well as bicycles including a rear suspension.

Harley-Davidson Softail

In Harley-Davidson motorbikes, the softail framework is made to appear to be the rigid frame bicycles of the past, while still providing the comfort of rear suspension system. The shock absorbers are put along the axis associated with motorcycle, saved underneath the transmission.
2011 Harley-Davidson FLSTFB Softail Fat Boy Lo
2008 Harley Davidson FXSTC Softail Personalized

There are several Harley-Davidson designs using the Softail frame, like the Softail Standard, Customized, Springer Softail, Heritage Softail, Heritage Springer, evening Train, Deluxe, Deuce, Fat child, Softail Slim, the black Personalized Cross Bones, the deep Personalized Blackline and Breakout. Except for the Deuce, that has a 2 ins (51 mm) backbone stretch, these motorbikes have the same motor, transmission and frame and vary mainly in choice of hand, tires and add-ons.
Front side forks

The Softail design line has included several options ahead hand designs. Historically, they will have furthermore supplied the Springer trusted link forks that are similar to the sprung front-ends that have been made use of ahead of the introduction for the Hydra-Glide in 1949. The FXST designation can be used for 21" Front Wheel Bikes or if the Springer hand is employed with a 21 inches wheel, as the FLST designation is employed for 16" front-wheel Bikes or when the Springer hand is used with a 16 inches wheel.
Motors

The Softail models would not have rubber-mounted motors. This led to even more vibration in Evolution-engined Softails compared to rubber-mounted Touring or Dyna versions with Evolution motors. To compensate because of this, latest Softail systems incorporate a counterbalanced version of the Twin Cam engine rather than the regular Twin Cam motor used in the Touring and Dyna versions.
Records

Costs Davis, an enthusiastic Harley driver and engineer from St. Louis, Mo. designed the softail when you look at the mid-1970s. His first build, which he done in 1974 and 1975, had a cantilever swingarm pivoted at the end and sprung towards the top aided by the springs and shock absorber concealed beneath the chair. Upon working-out his build, Davis built a prototype based on their 1972 Super Glide. Davis patented his design and called Willie G. Davidson, arranging a gathering in August 1976. Davidson was impressed, but made no commitments. Davidson replied half a year later, saying your providers would not be able to use the design during the time but is still thinking about they.

Davis continuing to develop the style, changing the pivot together with springing guidelines around so the springs and surprise absorber had been in framework therefore the pivot point was at the top the triangular swingarm. This permitted the traditional Harley-Davidson oil tank to be placed under the seat. Davis attempted to emit the newest build individually given that path Worx Sub-Shock, nevertheless the partnership he had come up with for this function collapsed. Harley-Davidson executive Jeffrey Bleustein called Davis soon later and began negotiations purchasing Davis's build. Davis marketed their patents, model, and tooling to Harley-Davidson in January 1982. After further assessment and development, Davis's design had been launched in Summer 1983 as 1984 Harley-Davidson FXST Softail.
Harley-Davidson, Inc. (H-D), or Harley, is an US motorcycle producer, founded in Milwaukee, Wisconsin in 1903.

As one of two major United states bike providers to survive the fantastic anxiety (along with Indian), the organization has actually survived many ownership plans, subsidiary plans (age.g., Aermacchi 1974-1978 and Buell 1987-2009), periods of poor economic health and goods quality, along with intense global competitors --- to be the world's 5th largest motorcycle maker and an iconic brand name well regarded for its dedicated following --- with owner groups and events globally also an organization sponsored brand-focused museum.

Noted for a mode of customization that provided rise towards chopper bike design, Harley-Davidson traditionally advertised heavyweight, air-cooled cruiser motorbikes with engine displacements greater than 700 cc --- and has broadened their choices to add their more contemporary VRSC (2001) and middle-weight road (2014) platforms.

Harley-Davidson manufactures its motorcycles at production facilities in York, Pennsylvania; Milwaukee, Wisconsin; Kansas town, Missouri; Manaus, Brazil; and Bawal, India --- and markets their merchandise worldwide.

The classic Harley-Davidson motors tend to be V-twin motors, with a 45 angle involving the cylinders. The crankshaft has one pin, and both pistons were attached to this pin through their particular connecting rods.

This 45 direction is covered under a few united states of america patents and it is a manufacturing tradeoff that allows a sizable, high-torque engine in a comparatively smaller room. They produces the cylinders to fire at irregular intervals and creates the choppy "potato-potato" noise so strongly for this Harley-Davidson brand.

To simplify the system and lower prices, the V-twin ignition is made to work with an individual group of points and no supplier. That is known as a double fire ignition system, causing both spark plugs to fire regardless of which cylinder was on its compression stroke, because of the various other spark-plug firing on their cylinder's exhaust swing, effectively "wasting a spark". The fatigue note is simply a throaty growling noise with some popping. The 45 build for the system thus brings a plug shooting sequencing as a result: The first cylinder fires, the 2nd (back) cylinder fires 315 later on, then there is a 405 space before first cylinder fires once again, providing the system its special sound.

Harley-Davidson has actually made use of different ignition methods throughout its background -- feel it the first points and condenser program, (gigantic Twin to 1978 and Sportsters as much as 1978), magneto ignition system utilized on some 1958 to 1969 Sportsters, very early electric with centrifugal mechanical advance loads, (all models 1978 . 5 to 1979), or even the belated electronic with transistorized ignition control component, even more familiarly known as the black colored field and/or mind, (all models 1980 to present).

Beginning in 1995, the organization launched Electronic gasoline shot (EFI) as a choice when it comes to 30th anniversary edition Electra Glide. EFI became standard on all Harley-Davidson motorbikes, like Sportsters, upon the development of the 2007 brand.

In 1991, Harley-Davidson started to be involved in the Sound Quality doing work Group, launched by Orfield Labs, Bruel and Kjaer, TEAC, Yamaha, Sennheiser, SMS and Cortex. This was the nation's very first team to share with you research on mental acoustics. Later that 12 months, Harley-Davidson took part in a number of sound quality scientific studies at Orfield laboratories, according to tracks taken during the Talladega Superspeedway, with the objective to lessen the sound level for EU standards while analytically taking the "Harley Sound". This analysis lead to the bikes that were introduced in conformity with EU guidelines for 1998.

On February 1, 1994, the company submitted an audio trademark application when it comes to distinctive noise of the Harley-Davidson motorcycle system: "The level is composed of the exhaust sound of candidate's motorcycles, from V-twin, typical crankpin motorcycle engines when the items have been in utilize". Nine of Harley-Davidson's competitors submitted opinions opposing the program, arguing that cruiser-style motorbikes of varied brands utilize a single-crankpin V-twin system which produce an identical sound. These objections had been followed closely by litigation. In June 2000, the organization fallen efforts to federally subscribe its trademark.

The development engine (popularly called Evo) are an air-cooled, 45-degree, V-twin system constructed from 1984 by Harley-Davidson the company's motorcycles. It was produced in the 1,340 cc (82 cu in) displacement for Harley-Davidson Big V-twins bikes, replacing the Shovelhead motor until 2000 once the final EVO ended up being placed in a production factory customized FXR4 (FXR2 and FXR3 were the initial CVO's). In 1999, it absolutely was changed by the Harley-Davidson Twin Cam 88 within the Touring and Dyna design as well as in 2000 inside Softail products. Additionally for sale in the Sportster model beginning in 1986, it had been built in the 1,100 cc (67 cu in) displacement until 1988 and is however made in the 883 cc (53.9 cu in) and 1,200 cc (73 cu in) displacements when it comes to Harley-Davidson Sportster, replacing the ironhead Sportster system.

Most experts think about the Evolution to-be the engine it saved the reorganized Harley-Davidson team from particular bankruptcy. Harley-Davidson's official name for engine is most likely linked to their attempt to reform their picture following 1981 control buyout from previous owner United states device and Foundry (AMF).

Though an important build advance for Harley-Davidson in many ways, the Evolution is most distinct from early in the day Harley-Davidson motor design by virtue of its reliability, oils tightness, and capability to feel operate hard under all sorts of situations for tens and thousands of kilometers farther than just about any of their predecessors. The heads and cylinders regarding the development system are made of aluminum to cut back pounds versus a cast metal design. Air cooling effectiveness try improved as aluminum was an exceptional thermal conductor to cast-iron. The blocky rocker bins (thus becoming nicknamed "block mind" which never ever caught on), aluminum minds and cylinders (generally known as "jugs") are the just the main advancement system that may be reported to be crucial; the Big Twin and Sportster incarnations of development are notably different.
Touring models utilize Big-Twin engines and large-diameter telescopic forks. All Touring designations begin with the letters FL, e.g., FLHR (Road master) and FLTR (roadway Glide).

The touring family members, also known as "dressers" or "baggers", include roadway master, path Glide, Street Glide and Electra Glide brands available in numerous trims. The Road leaders has a "retro cruiser" look and are also designed with a big obvious windshield. Path Kings were similar to big-twin designs from 1940s and 1950s. Electra Glides are identified by their complete front fairings. Many Electra Glides recreation a fork-mounted fairing known as the "Batwing" because of its unmistakable shape. The Road Glide and roadway Glide Ultra Timeless have a frame-mounted fairing, described as the "Sharknose". The Sharknose include a distinctive, double front headlight.

Touring brands are distinguishable by their huge saddlebags, back coil-over atmosphere suspension system and generally are the only real products to supply full fairings with radios and CBs. All touring designs make use of the exact same framework, very first launched with a Shovelhead engine in 1980, and transported ahead with best moderate updates until 2009, with regards to is extensively redesigned. The framework try recognized because of the located area of the steering head while watching forks and ended up being the initial H-D frame to rubber attach the drivetrain to isolate the driver from the vibration of the huge V-twin.

The framework had been modified for the 1994 design seasons when the oils tank went under the transmission and battery pack was relocated inboard from under the best saddlebag to underneath the seat. In 1997, the framework had been once more modified to allow for a bigger battery underneath the chair and reduced chair height. In 2007, Harley-Davidson launched the 96 cubic inches (1,570 cubic centimetres) Twin Cam 96 engine, aswell the six-speed transmission to provide the driver better speeds traveling.

In 2006, Harley introduced the FLHX road Glide, a bicycle designed by Willie G. Davidson to be their private ride, to its touring line.

In 2008, Harley included anti-lock braking techniques and cruise control as a factory setup solution on all touring versions (traditional on CVO and Anniversary designs). Furthermore newer for 2008 may be the 6-US-gallon (23 l; 5.0 imp gal) gas tank for several touring versions. 2008 additionally brought throttle-by-wire to all touring versions.

When it comes to 2009 model 12 months, Harley-Davidson redesigned the whole touring number with a number of adjustment, including a frame, latest swingarm, a completely revised engine-mounting system, 17-inch (430 mm) front tires for many nevertheless the FLHRC Road King Timeless, and a 2--1--2 exhaust. The modifications lead to higher burden carrying ability, better managing, a smoother motor, much longer range and less exhaust temperatures sent to your driver and traveler. Also introduced for 2009 design 12 months may be the FLHTCUTG Tri-Glide super Classic, the initial three-wheeled Harley because the Servi-Car is discontinued in 1973. The design features a distinctive framework and a 103-cubic-inch (1,690 cc) system unique on trike.

In 2014, Harley-Davidson revealed a redesign for specific touring bicycles and labeled as it "Project Rushmore". Adjustment feature a unique 103CI extreme Output motor, one-handed easy available saddlebags and compartments, a fresh growth! Field Infotainment program with either 4.3" or 6.5" displays featuring touchscreen usability , Bluetooth (media and phone with accepted compatible equipment), readily available GPS and SiriusXM, Text-to-Speech usability (with authorized appropriate products) and USB connectivity with asking. More services consist of ABS with Reflex linked brakes, improved styling, Halogen or LED lights and upgraded passenger comfort.
The advancement system (popularly called Evo) try an air-cooled, 45-degree, V-twin engine constructed from 1984 by Harley-Davidson when it comes to organization's motorcycles. It had been manufactured in the 1,340 cc (82 cu in) displacement for Harley-Davidson gigantic V-twins bicycles, changing the Shovelhead engine until 2000 as soon as the last EVO was put in a production factory customized FXR4 (FXR2 and FXR3 were the initial CVO's). In 1999, it absolutely was changed by the Harley-Davidson Twin Cam 88 inside Touring and Dyna design as well as in 2000 into the Softail brands. Furthermore obtainable in the Sportster model starting in 1986, it absolutely was made in the 1,100 cc (67 cu in) displacement until 1988 and is however manufactured in the 883 cc (53.9 cu in) and 1,200 cc (73 cu in) displacements the Harley-Davidson Sportster, changing the ironhead Sportster engine.

More experts look at the development becoming the motor it saved the reorganized Harley-Davidson business from particular personal bankruptcy. Harley-Davidson's formal name for the system is most likely pertaining to the company's try to reform its picture following 1981 management buyout from previous holder United states device and Foundry (AMF).

Though a significant build advance for Harley-Davidson in lots of ways, the Evolution is many distinct from earlier Harley-Davidson system design by virtue of the dependability, oil rigidity, and power to feel run difficult under a myriad of situations for tens and thousands of miles further than just about any of the predecessors. Both the minds and cylinders of the advancement system are manufactured from aluminum to reduce fat compared to a cast iron build. Atmosphere cooling effectiveness try improved as aluminum was a superior thermal conductor to cast iron. The blocky rocker cardboard boxes (hence becoming nicknamed "block mind" which never ever caught on), aluminum minds and cylinders (also called "jugs") would be the just part of the advancement system which can be said to be important; the major Twin and Sportster incarnations for the advancement tend to be somewhat different.

The system building of the Harley-Davidson Sportster, which was parts and parcel aided by the highly successful model range since its inception as sidevalve 750cc "K" design in 1952, is retained using the Evolution engine upgrade in 1986, causing a distinctive device train configuration. Unlike nearly every various other system in manufacturing nowadays, the Sportster advancement uses one cam per engine overhead-valve, resulting in four specific, single-lobe, gear-driven camshafts. The cam lobes are therefore all located one behind another, and pushrods are arrayed in sets (front side and rear) parallel into cylinder axis thus. This enables each lifter and pushrod to deflect from cam lobes perpendicular toward lobe airplane. This configuration are friendly to radical, high-output cams, making the Sportster development an all natural option for the as soon as Harley-Davidson possessed line of Buell bike providers sportbikes from 1986 up to belated 2009 (2010 design 12 months).

The Sportster Evolution motor have stayed largely unchanged from 1986 to 2006, though modifications into transmission, best drive and motor mounts posses necessitated changes to your Sportster development circumstances. Building is virtually totally the same between 883 cc and 1,200 cc models; the principle difference between both is an inferior bore regarding 883 cc (inherited from its previous "ironhead" parent), along side a little various heads. Conversions from 883 cc to 1,200 cc are relatively affordable and commonplace, and less expensive than the purchase price premium going from an 883 to 1,200 engine on a unique bicycle. Carburetors had been standard on Sportster motors until 2007, once they were replaced because of the Delphi Electronic Sequential-Port gas injections (ESPFI) program.
Advancement regarding big bikes

The Evolution Big Twin saw a fifteen-year run-in Harley-Davidson's Dyna, Softail, FXR, and Touring structures, although a small wide range of Evolutions were used when you look at the 2000 model seasons CVO FXR4. Whilst main case was only a little altered from the previous Shovelhead engine, the very best and ended up being notably enhanced.

The 1340cc Evolution utilizes one, four-lobe, gear-driven camshaft located just over the crankshaft axis. Although this simplifies camshaft replacement, it complicates the major Twin valve train with tappet/lifters and pushrods that each deflect through the camshaft at extremely various angles. The major Twin pushrods have a definite helical look considering that the straight jet created by each cylinder's rockers (front-to-back) is precisely perpendicular into the straight jet created because of the cam lobes (left-to-right). The need for one lifter and pushrod set to attain right off to more outboard cam lobe offers rise toward gigantic Twin's tell-tale offset lifter assemblies, in which the forward lifter construction is found somewhat further out and turned make it possible for the valve gear to help make the reach.

The Big Twin has-been followed closely by a number of different main drives and transmissions, both on production Harley-Davidson motorbikes plus in personalized solutions. The aftermarket variety of add-ons for those closely associated systems are large, as it is the system itself.

The Evolution Big Twin motor is, for now, the past of this line of solitary cam, overhead-valve engines tracing their lineage back once again to the bottom breaking Knucklehead design penned by president Bill Harley. With its 1994 to 2000 (FXR4) last configuration, with rockerbox and base gasket leakages set, they became a robust, durable, and functional power-plant for all associated with Big Twin systems. Additionally, it is the greatest aftermarket supported Harley-Davidson build, currently

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