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Harley-Davidson FXD Evolution 1991 - 1998 Clymer Owners Service & Repair Manual

FL is a design designation utilized on motorcycles manufactured by Harley-Davidson from 1941 presenting. Mostly placed on Harley's large-framed bikes, such as the present Touring series, the FL designation can be used in combination with their Softail show, specially on Softails with conventional styling, 16-inch forward wheels, and either Springer forks or large-diameter telescopic front forks.

Early FL versions

The FL had been launched towards the Harley-Davidson model range in 1941. They used a 74 cu in (1,210 cc) version of the "Knucklehead" OHV engine that driven the EL in 61 cu in (1,000 cc) form. The FL provided its frame aided by the EL along with the U and UL, which used a 74 cubic inches flathead system. The FL replaced the UH and ULH, which used the same frame with 80 cu in (1,300 cc) flathead machines.

The FL continued fairly unchanged until 1948, with regards to while the EL received redesigned "Panhead" engines of the same capabilities as before. These machines have a few improvements throughout the earlier in the day "Knuckleheads", including self-adjusting hydraulic lifters and aluminum cylinder minds to cut back weight and improve cooling. The U and UL flathead twins are discontinued in 1948, leaving the OHV EL and FL models as Harley-Davidson's large-frame motorbikes.
Hydra-Glide

In 1949, annually after receiving the "Panhead" engine, the FL was given a new forward suspension featuring hydraulically damped telescopic forks, changing the leading connect spring suspension system of that time period. These forks were standard on all big twin versions for 1949, like the age, EL, F, and FL. Harley-Davidson offered the springtime suspension system models on these designs and ideal their usage on sidecar combinations, due to the fact hydraulic forks did not have adequate trail allowing the mixture becoming steady sufficient for safe operation.

In their first model 12 months of 1949, Harley referred to their brand new suspension techniques whilst the "hydraulic front ends up". Harley's marketing division presented this new suspension system methods by renaming the major twin systems "Hydra Glide" the 1950 design season. It was Harley-Davidson's very first departure from its rules of utilizing alphabetic lettering to determine its designs. This name would transform twice when you look at the reputation for the essential large-framed E and F show systems, every time signaling a marked improvement in bike's technology. In addition, the Glide closing could be applied to various other systems, based on both and FL and FX platforms.

In 1952, the Hydra-Glide's transmission standard hand-shift/foot-clutch had been supplemented by the optional foot-shift/hand-clutch. The first structure always been supplied as a choice until 1978. 1952 was also the final season associated with the 61 cu in (1,000 cc) EL, making the FL the final continuing to be large-frame model.

Although the 1903 founding is now the basis for "Anniversary Models", Harley-Davidson's 50th Golden Anniversary was celebrated in 1954 with unique paints and badges regarding the front fender. The first 12 months of production is 1904.

A far more extremely tuned motor with high-compression minds, higher-lift webcams, and polished harbors, had been supplied aided by the FLH form of 1955. The FLH designation has carried on around today's.
Duo-Glide
1961 FLH Duo-Glide

The FL model was handed an innovative new frame in 1958. This framework included a back swingarm suspended by a pair of coil-over-shock suspension system products. Honoring this fully suspended framework, the FL's design name had been altered from Hydra-Glide to Duo-Glide.

Unlike OHV configuration, aluminum minds, and telescopic-fork forward suspension system, however, this improvement in tech had been applied to the small-frame bicycles very first, the K-series creating got rear suspension system in 1952.

The third and final change given to title of this basic FL model would occur in 1965, the final season of "Panhead" machines. These final "Panheads" had been initial "big-twin" Harley-Davidson engines becoming built with electric starters, the Servi-Car creating obtained electric start the season before. This innovation for Harley-Davidson is greeted with the new-model name of Electra Glide.

In 1966, the "Panhead" offered way to the "Shovelhead", gaining a 10 % escalation in energy in the act.

A fork-mounted fairing became available on Electra Glides in 1969. This became unofficially referred to as "batwing" fairing. Even though batwing fairing was an easily detachable alternative on early Electra Glides, it had been not detachable on subsequent machines, because the instruments were moved through the gas tank into the fairing.
Electra Glide

The FL framework was the basis for the 1971 FX Super Glide. The FX mated the FL frame utilizing the forks of XL Sportster, with buckhorn handlebars and a big fibreglass tailpiece completing the Super Glide requirements.

The FL was presented with a front side disc braking system in 1972.

The three-speed plus reverse choice was discontinued in 1977.

A 1977 Harley-Davidson Confederate Edition of the FLH Electra Glide that presented commemorative paint and container and fender decals had been created. The unit production was at such lower volume numbers - just 44 - regarding succeed one of several rarest of this organization's motorcycles.

An 80 cu in (1,300 cc) engine is made recommended regarding Electra Glide in 1978. But the FL designation wasn't changed as a result. By 1981, the 80 cubic inch system was the conventional engine; the 74 cu in (1,210 cc) engine being discontinued.

The low-compression FL motor had been discontinued in 1979, because is the choice for hand-shift/foot-clutch transmission settings.

Journey Glide

The FLT Tour Glide had been launched in 1979 as a 1980 model. Sold alongside the prevailing FLH Electra Glide, the FLT have a more substantial framework with plastic system supports, a five-speed transmission, the 80 cu in (1,300 cc) engine, and a frame-mounted fairing. In order that the FLT framework, that has been larger and heavy than the large and heavier FLH framework, would manage acceptably, the front forks received radical steering geometry which have them attached behind the steering head, aided by the frame behind the steering head being recessed to allow sufficient steering lock.

The FLHT was launched in 1983. This was an Electra Glide in line with the FLT trip Glide frame, but utilizing the Electra Glide "batwing" fairing instead of the Tour Glide frame-mounted fairing. The police form of the FLHT may be the FLHTP.

With the exception of the bottom FLH, all 1984 FLs are equipped with this new rubber-mounted development system and a five-speed transmission.

All "Shovelhead" machines are stopped because of the 1985 design season. In that seasons, the four-speed solid-engine-mount FLH had been changed to simply accept plastic mounting in addition to development system. The FLH is discontinued in 1986; all Touring designs after that put the FLT/FLHT frame. Ironically, the FLT trip Glide, which launched current Touring frame, had been fallen from the lineup in 1996. A smaller version of the frame-mounted trip fairing would come back aided by the FLTR Road Glide in 1998.

The advancement motor had been replaced because of the Twin Cam 88 engine on all large-framed Harley-Davidson motorcycles in 1999. The Twin Cam system had been increased from 88 cu.in. to 96 cu.in. in 2007.
Unfaired Glides
2006 Path Master Customized

An unfaired version of the FLH Electra Glide, referred to as FLHS Electra Glide Sport, is available from 1979 to 1982. An unfaired FLHT Electra Glide reintroduced the FLHS Electra Glide recreation name in 1987. In 1994, the FLHS Electra Glide recreation was changed by the FLHR path King, which consistently todays.
2009 Touring chassis

For the 2009 design year, Harley-Davidson redesigned the complete touring number. The modifications included a frame, latest swingarm, an entirely modified engine-mounting program, 17-inch front rims for several brands except the street King Timeless, a 6 United States gallons (23 l; 5.0 imp girl) gas tank, and a 2-1-2 fatigue. The changes bring about better burden holding ability, better maneuvering, a smoother motor, longer number much less exhaust temperatures transmitted towards the driver and traveler.
Tri-Glide Ultra Classic

In addition released when you look at the FL Touring range the 2009 model seasons is the FLHTCUTG Tri Glide super Classic, 1st three-wheeled Harley-Davidson since the Servi-Car had been stopped in 1973. This design features an original framework and a 103 cid system unique into trike.

The definition of softail describes motorcycles and bicycles that feature a concealed rear suspension system with springs or surprise absorbers to absorb bumps. Softail motorcycles supply the look of having a hard-tail or rigid-frame, ordinarily with the surprise absorbers or springs in bike and out-of see.

The word "softail" is a registered trademark of Harley-Davidson motorbikes, coined utilizing the release of the FXST Softail in 1984. Subsequently, the phrase possess broadened to add more motorbikes with hidden back suspensions including bikes including a rear suspension.

Harley-Davidson Softail

In Harley-Davidson motorcycles, the softail frame is designed to appear to be the rigid frame bicycles of history, while nonetheless providing the comfort of back suspension system. The shock absorbers are placed over the axis for the bike, saved under the transmission.
2011 Harley-Davidson FLSTFB Softail Fat Man Lo
2008 Harley Davidson FXSTC Softail Custom

There are several Harley-Davidson products aided by the Softail frame, like the Softail Standard, Personalized, Springer Softail, traditions Softail, Heritage Springer, evening Train, Deluxe, Deuce, Fat Boy, Softail Slim, the deep Customized Cross Bones, the Dark Customized Blackline and Breakout. Apart from the Deuce, with a 2 inches (51 mm) anchor stretch, these motorcycles have the same engine, transmission and framework and differ mainly into the chosen fork, wheels and add-ons.
Front side forks

The Softail design range have included many choices ahead fork designs. Typically, they will have furthermore provided the Springer trusted connect forks that are similar to the sprung front-ends that were utilized ahead of the introduction associated with the Hydra-Glide in 1949. The FXST designation is used for 21" front-wheel Bikes or when the Springer fork can be used with a 21 inch wheel, although the FLST designation is used for 16" front-wheel Bikes or if the Springer hand can be used with a 16 inches wheel.
Motors

The Softail products don't have rubber-mounted engines. This resulted in more vibration in Evolution-engined Softails than in rubber-mounted Touring or Dyna designs with development machines. To pay for this, latest Softail models need a counterbalanced type of the Twin Cam system instead of the regular Twin Cam engine utilized in the Touring and Dyna brands.
Records

Bill Davis, an avid Harley driver and professional from St. Louis, Mo. created the softail in mid-1970s. His very first build, that he worked on in 1974 and 1975, had a cantilever swingarm pivoted at the end and sprung at the very top utilizing the springs and shock absorber hidden underneath the chair. Upon working-out their design, Davis built a prototype centered on his 1972 Super Glide. Davis patented their design and contacted Willie G. Davidson, organizing a meeting in August 1976. Davidson had been impressed, but made no commitments. Davidson answered 6 months later, stating that organization wouldn't be able to utilize the look at the time but is nevertheless interested in they.

Davis carried on to build up the style, changing the pivot in addition to springing guidelines around so your springs and shock absorber were in framework plus the pivot aim is at the top of the triangular swingarm. This let the original Harley-Davidson oils tank to-be placed directly under the chair. Davis attempted to create the newest design separately as the path Worx Sub-Shock, nevertheless the relationship he previously put together for this specific purpose collapsed. Harley-Davidson manager Jeffrey Bleustein contacted Davis immediately later and started negotiations to get Davis's build. Davis offered his patents, model, and tooling to Harley-Davidson in January 1982. After further evaluating and developing, Davis's design is introduced in June 1983 as 1984 Harley-Davidson FXST Softail.
Harley-Davidson, Inc. (H-D), or Harley, is an United states bike manufacturer, founded in Milwaukee, Wisconsin in 1903.

As one of two biggest United states bike providers to endure the truly amazing despair (and Indian), the organization features survived many ownership arrangements, subsidiary arrangements (e.g., Aermacchi 1974-1978 and Buell 1987-2009), durations of bad economic health and product quality, along with intense global competitors --- in order to become the entire world's fifth largest motorcycle producer and an iconic brand well regarded because of its faithful next --- with holder groups and occasions globally in addition to an organization sponsored brand-focused museum.

Noted for a mode of modification that provided increase into chopper motorcycle style, Harley-Davidson usually promoted heavyweight, air-cooled cruiser motorbikes with system displacements greater than 700 cc --- and it has broadened their choices to incorporate its more sophisticated VRSC (2001) and middle-weight Street (2014) systems.

Harley-Davidson manufactures its motorcycles at factories in York, Pennsylvania; Milwaukee, Wisconsin; Kansas town, Missouri; Manaus, Brazil; and Bawal, Asia --- and markets its items globally.

The classic Harley-Davidson motors become V-twin motors, with a 45 direction between your cylinders. The crankshaft features one pin, and both pistons tend to be connected to this pin through their connecting rods.

This 45 angle are covered under a few united states of america patents and is an engineering tradeoff that allows a big, high-torque motor in a somewhat smaller room. It causes the cylinders to fire at irregular periods and creates the choppy "potato-potato" sound so strongly from the Harley-Davidson brand name.

To streamline the system and lower expenses, the V-twin ignition ended up being built to function with an individual group of guidelines with no distributor. This can be referred to as a double fire ignition program, causing both spark plugs to fire no matter which cylinder was on its compression swing, utilizing the more spark-plug shooting on their cylinder's exhaust swing, effortlessly "wasting a spark". The fatigue note is simply a throaty growling sound with some popping. The 45 build associated with motor hence creates a plug shooting sequencing therefore: The first cylinder fires, the second (back) cylinder fires 315 later, then there's a 405 space through to the very first cylinder fires once again, giving the engine their special noise.

Harley-Davidson has put different ignition techniques throughout its records -- become they the early guidelines and condenser program, (Big Twin to 1978 and Sportsters around 1978), magneto ignition system applied to some 1958 to 1969 Sportsters, very early electronic with centrifugal mechanical advance loads, (all models 1978 and a half to 1979), or perhaps the belated electronic with transistorized ignition controls component, additional familiarly known as the black colored package or the brain, (all brands 1980 presenting).

Beginning in 1995, the business launched Electronic Fuel injections (EFI) as a choice for 30th anniversary edition Electra Glide. EFI became standard on all Harley-Davidson motorbikes, including Sportsters, upon the development of the 2007 brand.

In 1991, Harley-Davidson begun to participate in the quality of sound doing work team, created by Orfield Labs, Bruel and Kjaer, TEAC, Yamaha, Sennheiser, SMS and Cortex. This is the nation's first group to generally share research on psychological acoustics. Later that 12 months, Harley-Davidson participated in a number of audio quality researches at Orfield laboratories, centered on recordings taken during the Talladega Superspeedway, with the objective to lower the sound level for EU standards while analytically acquiring the "Harley noise". This studies led to the bicycles that have been launched in compliance with EU specifications for 1998.

On February 1, 1994, the business recorded an audio trademark application for the distinctive noise associated with Harley-Davidson bike system: "The level comes with the exhaust sound of applicant's motorbikes, created by V-twin, typical crankpin bike engines when the merchandise are in use". Nine of Harley-Davidson's rivals recorded reviews opposing the application, arguing that cruiser-style motorcycles of various companies use a single-crankpin V-twin engine which build the same noise. These objections are accompanied by litigation. In June 2000, the business dropped attempts to federally sign up their trademark.

The Evolution motor (popularly generally Evo) are an air-cooled, 45-degree, V-twin engine manufactured from 1984 by Harley-Davidson for the organization's motorbikes. It absolutely was built in the 1,340 cc (82 cu in) displacement for Harley-Davidson gigantic V-twins bikes, replacing the Shovelhead system until 2000 whenever final EVO ended up being positioned in a production factory customized FXR4 (FXR2 and FXR3 are initial CVO's). In 1999, it had been replaced because of the Harley-Davidson Twin Cam 88 into the Touring and Dyna design plus in 2000 in Softail brands. In addition available in the Sportster design from 1986, it was produced in the 1,100 cc (67 cu in) displacement until 1988 and is nonetheless built 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 analysts think about the advancement becoming the system your stored the reorganized Harley-Davidson team from specific personal bankruptcy. Harley-Davidson's official title the system ended up being most likely linked to the business's attempt to reform its picture following 1981 administration buyout from earlier holder United states device and Foundry (AMF).

Though a significant design advance for Harley-Davidson in lots of ways, the Evolution are most distinct from prior Harley-Davidson engine design by virtue of its reliability, oil tightness, and capability to become operate hard under a myriad of situations for tens and thousands of kilometers further than just about any of its predecessors. Both the minds and cylinders of this development motor are made of aluminum to cut back fat when compared with a cast iron build. Air cooling effectiveness are enhanced as aluminum are an excellent thermal conductor to cast-iron. The blocky rocker bins (thus becoming nicknamed "block mind" which never caught on), aluminum heads and cylinders (generally known as "jugs") are the only part of the advancement system that can be considered essential; the major Twin and Sportster incarnations associated with advancement are notably different.
Touring versions need Big-Twin engines and large-diameter telescopic forks. All Touring designations begin with the letters FL, e.g., FLHR (roadway King) and FLTR (path Glide).

The touring families, also called "dressers" or "baggers", includes Road master, Road Glide, Street Glide and Electra Glide systems available in different trims. The Road Kings have actually a "retro cruiser" look as they are designed with a sizable clear windshield. Path leaders are similar to big-twin designs through the 1940s and 1950s. Electra Glides is identified by their full front fairings. Most Electra Glides sport a fork-mounted fairing known as the "Batwing" because of its unmistakable form. The Road Glide and path Glide super Timeless have actually a frame-mounted fairing, referred to as the "Sharknose". The Sharknose include a distinctive, double front side headlight.

Touring systems is distinguishable by their particular huge saddlebags, rear coil-over environment suspension system and tend to be the only models to provide full fairings with radios and CBs. All touring systems make use of the exact same framework, initially launched with a Shovelhead motor in 1980, and transported ahead with only moderate updates until 2009, when it ended up being thoroughly redesigned. The framework is distinguished because of the precise location of the steering mind at the forks and had been initial H-D frame to rubber mount the drivetrain to separate the rider from vibration of huge V-twin.

The frame had been customized the 1994 model year when the oil tank gone in transmission plus the power is moved inboard from underneath the right saddlebag to in chair. In 1997, the frame was once again changed to accommodate a more substantial power beneath the chair also to reduced chair level. In 2007, Harley-Davidson introduced the 96 cubic ins (1,570 cubic centimetres) Twin Cam 96 motor, aswell the six-speed transmission to provide the driver better rates on the road.

In 2006, Harley launched the FLHX Street Glide, a bicycle designed by Willie G. Davidson to-be their private ride, to their touring range.

In 2008, Harley included anti-lock braking techniques and cruise control as a factory set up solution on all touring models (standard on CVO and Anniversary versions). Additionally brand new for 2008 may be the 6-US-gallon (23 l; 5.0 imp gal) fuel container for several touring brands. 2008 also brought throttle-by-wire to all touring systems.

For the 2009 model season, Harley-Davidson redesigned the whole touring range with a few changes, like a framework, brand new swingarm, an entirely modified engine-mounting program, 17-inch (430 mm) forward wheels for several but the FLHRC path master Classic, and a 2--1--2 exhaust. The modifications end in higher burden carrying capability, better control, a smoother motor, much longer number much less exhaust temperatures sent to the rider and traveler. Additionally released when it comes to 2009 design year is the FLHTCUTG Tri-Glide Ultra Timeless, the very first three-wheeled Harley because the Servi-Car was stopped in 1973. The model features a distinctive framework and a 103-cubic-inch (1,690 cc) engine unique toward trike.

In 2014, Harley-Davidson circulated a redesign for certain touring bikes and called they "venture Rushmore". Adjustment include a new 103CI tall Output system, one handed simple available saddlebags and compartments, a increase! Package Infotainment system with either 4.3" or 6.5" displays featuring touchscreen efficiency , Bluetooth (media and mobile with accepted suitable equipment), offered GPS and SiriusXM, Text-to-Speech functionality (with approved appropriate products) and USB connectivity with asking. Other functions add ABS with Reflex connected brakes, enhanced styling, Halogen or LED lighting and upgraded traveler convenience.
The development motor (popularly known as Evo) was an air-cooled, 45-degree, V-twin engine manufactured from 1984 by Harley-Davidson the organization's motorcycles. It absolutely was made in the 1,340 cc (82 cu in) displacement for Harley-Davidson gigantic V-twins bicycles, changing the Shovelhead engine until 2000 whenever final EVO ended up being placed in a production factory personalized FXR4 (FXR2 and FXR3 are initial CVO's). In 1999, it was changed because of the Harley-Davidson Twin Cam 88 into the Touring and Dyna design plus in 2000 when you look at the Softail brands. In addition available in the Sportster design starting in 1986, it had been built in the 1,100 cc (67 cu in) displacement until 1988 and is still manufactured in the 883 cc (53.9 cu in) and 1,200 cc (73 cu in) displacements the Harley-Davidson Sportster, replacing the ironhead Sportster engine.

Many experts consider the advancement to be the system your saved the reorganized Harley-Davidson company from specific bankruptcy. Harley-Davidson's official title the motor ended up being most likely regarding the company's try to reform its image following 1981 control buyout from earlier holder American Machine and Foundry (AMF).

Though an important build advance for Harley-Davidson in several ways, the advancement are more distinct from earlier Harley-Davidson motor designs by virtue of its dependability, oils rigidity, and capacity to be run difficult under all sorts of circumstances for tens of thousands of kilometers further than any of its predecessors. Both the minds and cylinders for the advancement system are produced from aluminum to cut back weight when compared with a cast metal design. Air cooling performance try improved as aluminum is an exceptional thermal conductor to cast iron. The blocky rocker cardboard boxes (hence becoming nicknamed "block mind" which never caught on), aluminum minds and cylinders (also called "jugs") will be the only area of the Evolution system that can be reported to be important; the top Twin and Sportster incarnations of the Evolution were dramatically various.

The system construction for the Harley-Davidson Sportster, which has been component and parcel with the highly effective model range since their creation due to the fact sidevalve 750cc "K" Model in 1952, ended up being retained using the Evolution system update in 1986, resulting in a distinctive device train setup. Unlike just about any more engine in production nowadays, the Sportster advancement uses one cam per engine overhead-valve, leading to four individual, single-lobe, gear-driven camshafts. The cam lobes tend to be therefore all located one behind another, and pushrods tend to be arrayed in sets (front side and rear) parallel to your cylinder axis as a result. This permits each lifter and pushrod to deflect through the cam lobes perpendicular towards the lobe airplane. This configuration is friendly to radical, high-output webcams, making the Sportster Evolution an all-natural option for the once Harley-Davidson possessed distinct Buell bike business sportbikes from 1986 up to belated 2009 (2010 design season).

The Sportster advancement system has stayed largely unchanged from 1986 to 2006, though changes towards the transmission, best drive and engine mounts have necessitated adjustment into Sportster development circumstances. Construction is almost totally the same between 883 cc and 1,200 cc versions; the chief difference between the 2 is an inferior bore in the 883 cc (inherited from the prior "ironhead" moms and dad), along side slightly various minds. Conversions from 883 cc to 1,200 cc become relatively affordable and commonplace, and cheaper than the price premiums to go from an 883 to 1,200 engine on a fresh cycle. Carburetors had been standard on Sportster motors until 2007, when they were replaced by the Delphi Electronic Sequential-Port gas Injection (ESPFI) program.
Advancement regarding larger bicycles

The advancement gigantic Twin saw a fifteen-year run in Harley-Davidson's Dyna, Softail, FXR, and Touring structures, although a limited number of Evolutions were utilized in the 2000 model seasons CVO FXR4. Although the main case was just slightly modified from earlier Shovelhead motor, the most effective and is somewhat improved.

The 1340cc Evolution makes use of one, four-lobe, gear-driven camshaft found right above the crankshaft axis. Although this simplifies camshaft replacement, it complicates the top Twin valve train with tappet/lifters and pushrods that all deflect from camshaft at extremely various perspectives. The major Twin pushrods posses a definite helical appearance because the vertical plane formed by each cylinder's rockers (front-to-back) is exactly perpendicular to the vertical airplane formed because of the cam lobes (left-to-right). The need for one lifter and pushrod set to reach entirely off to the most outboard cam lobe provides increase into Big Twin's tell-tale offset lifter assemblies, where the forward lifter assembly is based somewhat further aside and turned to enable the device gear to really make the reach.

The major Twin is followed closely by a variety of biggest drives and transmissions, both on production Harley-Davidson motorcycles as well as in customized programs. The aftermarket selection of accessories for these closely related methods is large, as it's for the engine it self.

The development Big Twin motor is, for the present time, the past of line of single cam, overhead-valve engines tracing their lineage back into the ground breaking Knucklehead build penned by president costs Harley. In its 1994 to 2000 (FXR4) final setup, with rockerbox and base gasket leaks set, they became a robust, durable, and functional power-plant for many of the gigantic Twin platforms. It is also the largest aftermarket supported Harley-Davidson build, to date

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