1985-1990 Harley Davidson FX Softail Motorcycle Service Manual

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Description

This Official 1985-1990 Harley Davidson FX Softail Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1985-1990 Harley Davidson FX Softail motorcycles including:

1990 Harley-Davidson FXST Softail
1989 Harley-Davidson FXST Softail
1988 Harley-Davidson FXST Softail
1987 Harley-Davidson FXST Softail
1986 Harley-Davidson FXST Softail
1985 Harley-Davidson FXST Softail

1985-1990 Harley Davidson FX Softail Service Manual Index of Topics

SECTION 1 – PRODUCT
General
Servicing a New Motorcycle
Check at First 500 Miles
Safe Operating Maintenance
Regular Maintenance Intervals
Storage
Removal from Storage
Metric Conversion Table
Torque Requirements
Troubleshooting
Engine
Lubrication System
Electrical System
Carburetor
Transmission
Clutch
Brakes
Handling
Tools

SECTION 2 – CHASSIS
Specifications
Dimensions
Vehicle Weight
Capacities
Adjustments
Torques
Brake Disc Size
Tire Data
Vehicle Identification Number (VIN)
Adjustments – Front Fork (All Models)
Adjustment – (All Models Except Springer)
Springer Fork Adjustment
Rocker Bearings Adjustment
Front Wheel – Laced
Removal
Disassembly
Cleaning, Inspection and Repair
Assembly
Installation
Front Wheel -Springer Fork
Removal
Disassembly
Assembly
Installation
Front Wheel – Cast
Removal
Disassembly
Cleaning, Inspection and Repair
Assembly
Installation
Rear Wheel – Laced
Removal
Disassembly
Cleaning, Inspection and Repair
Assembly
Installation
Rear Wheel – Cast or Disc
Removal
Disassembly
Cleaning, Inspection and Repair
Assembly
Installation
Lacing Wheels – 16 in
Lacing Wheels – 19 in
Lacing Wheels – 21 in
Truing Laced Wheel
Cast or Disc Rim Runout
Tires
General
Removal
Cleaning, Inspection and Repair
Installation
Check Tire Radial Runout
Vehicle Alignment
Brakes
General
Adjustment
Front Brake Master Cylinder
Removal/Disassembly
Cleaning, Inspection and Repair
Assembly/Installation
Rear Brake Master Cylinder-1987 1/2 & Earlier FXST/C, FXWG, FXSB, FXEF
Removal/Disassembly
Cleaning, Inspection and Repair
Assembly/Installation
Rear Brake Master Cylinder -FLST/C
Removal/Disassembly
Cleaning, Inspection and Repair
Assembly/Installation
Rear Brake Master Cylinder/Reservoir -FLST/C/F 1987 1/2 & Later
Removal
Disassembly
Cleaning, Inspection and Repair
Assembly
Installation
Rear Brake Master Cylinder -FXST/C/S1987 1/2 & Later
Removal
Disassembly
Cleaning, Inspection and Repair
Assembly
Installation
Front Brake Caliper
Removal
Disassembly
Cleaning, Inspection and Repair
Assembly
Installation
Front Brake – Springer Fork
Removal
Installation
Rear Brake Caliper
1987 1/2 & Earlier
Removal/Disassembly
Cleaning, Inspection and Repair
Assembly/Installation
Rear Brake Caliper –
1987 1/2 & Later
Removal/Disassembly
Cleaning, Inspection and Repair
Assembly/Installation
Bleeding the Hydraulic Brake System
Stoplight switch
Front Forks – FXSB, FXEF
General
Removal
Disassembly
Cleaning, Inspection and Repair
Assembly
Installation
Front Forks – FXST/C, FXWG, FLST/C/F
General
Removal
Disassembly
Cleaning, Inspection and Repair
Assembly
Installation
Springer Fork – Disassembly
Handlebar and Handlebar Riser Removal
Shock Absorber Removal
Fork Removal
Spring Fork Disassembly
Rockers Removal
Fork Stem Bearing Removal
Springer Fork – Assembly
Fork Stem Bearing Installation
Install Rockers In Rigid Fork
Spring Fork Assembly
Fork Installation
Shock Absorber Installation
Handlebar and Handlebar Riser Installation
Fork Stem and Bracket Assembly -FXEF, FXSB
Disassembly
Cleaning, Inspection and Repair
Assembly
Fork Stem and Bracket Assembly -FXWG, FXST/C 1988 & Earlier
Disassembly
Cleaning, Inspection and Repair
Assembly
Fork Stem and Bracket Assembly -FLST/C 1988 & Earlier
Removal/Disassembly
Cleaning, Inspection and Repair
Assembly
Softail Fork Stem and Bracket Assembly 1988
Removal/Disassembly
FLST/C
FXST/C
FXSTS
Cleaning, Inspection and Repair – All Models
Assembly – All Models
Installation
FLST/C
FXST/C
FXSTS
Rear Swing Arm – FXEF, FXSB, FXWG
Disassembly
Cleaning, Inspection and Repair
Assembly
Rear Swing Arm – FXST/C/S, FLST/C7F
Disassembly
Cleaning, Inspection and Repair
Assembly
Rear Shock Absorber – FXEF, FXSB, FXWG
Adjustment
Removal
Disassembly
Cleaning, Inspection and Repair
Assembly
Installation
Rear Shock Absorber – Softail Models
Adjustment
Disassembly
Removal
Installation
Throttle Control
General
Disassembly
Cleaning, Inspection and Repair
Assembly
Adjustment
Clutch Hand Control-1985 to 1986
Removal
Installation
Clutch Hand Control – 1987 & Later
Removal
Installation
Speedometer/Tachometer
General
Replacement
Handlebar Switches
General
Removal
Installation
Front Fender – FXEF, FXSB
Removal
Installation
Front Fender – FXWG, FXST/C
Removal
Installation
Front Fender – FLST/C/F
Removal
Installation
Front Fender – FXSTS
Removal
Installation
Rear Fender – FXEF, FXSB
Removal
Installation
Rear Fender – FXWG, FXST/C, FLST/C/F
Removal
Installation

SECTION 3 – ENGINE
Specifications
General
Valves
Rocker Arm
Rocker Arm Shaft
Piston
Cylinder Head
Connecting Rod
Tappets
Oil Pump Pressure
Gearcase
Flywheels
Sprocket Shaft Bearing
Pinion Shaft Bearing
Ignition Timing
Torques
Service Wear Limits
General
Valves
Rocker Arm
Rocker Arm Shaft
Piston
Cylinder Head
Cylinder
Connecting Rod
Tappets
Gearcase
Flywheels
Pinion Shaft Bearings
Genera! Information
Description
Fuel
Lubrication
Troubleshooting
Stripping Motorcycle for Engine Repair
Cylinder Head
Removal
Disassembly
Cleaning and Inspection
Repair – Rocker Arms and Bushings
– Valve Guides
– Valve Faces and Seats
Assembly
Installation
Push Rod Meaurement and Gauging
Push Rod Installation
Cylinder and Piston
Removal
Cleaning and Inspection
Repair – Cylinder
– Piston
– Rod Bushings
– Connecting Rods
Oil Pump
General
Troubleshooting
Disassembly
Cleaning, Inspection and Repair
Assembly
Valve Tappets and Guides
General
Removal/Disassembly
Cleaning and Inspection
Assembly
Gearcase Cover and Timing Gears
General
Disassembly
Cleaning, Inspection and Repair
Assembly
Crankcase
General
Adjustment – Flywheel End Play
Disassembly
Installation – Cylinder Studs
Flywheels
Disassembly
Cleaning and Inspection
Repair
Assembly
Assembly (into Crankcase)

SECTION 4 – FUEL SYSTEM
Specifications – 1989 & Earlier
Jet Sizes
Capacity
Torques- 1985 – 1986 and Later
Carburetor
General
Operation
Adjustment
Troubleshooting
Removal
Disassembly
Cleaning, Inspection and Repair
Assembly
Installation
Air Cleaner – 1985
General
Removal
Cleaning, Inspection and Repair
Installation
Air Cleaner – 1986 pnd Later
Removal
Cleaning, Inspection and Repair
Installation
Fuel Supply Valve
General
Removal
Cleaning, Inspection and Repair
Installation
Fuel Tank
General
Removal
Cleaning, Inspection and Repair
Installation
Evaporative Emissions Control -T985
General
Canister Mounting
Vapor Valve Mounting
Evaporative Emissions Control -T986
General
Removal
Installation
Evaporative Emissions Control –
1987
General
Removal
Installation
Evaporative Emissions Control -1988 & 1989
General
Troubleshooting
Removal
Installation
Specifications – 1990
Jet Sizes
Capacity
Torques
Carburetor
General
Troubleshooting
Vacuum Piston Troubleshooting
Operation
Adjustment
Operation Check – Vacuum Piston
Removal
Disassembly
Cleaning, Inspection and Repair
Assembly
Installation
Air Cleaner
Removal
Cleaning, Inspection and Repair
Installation
Evaporative Emissions Control -T990
General
Troubleshooting
Removal
Installation
Hose Routing/Replacement

SECTION 5 – ELECTRIC STARTER STARTER – 1988 & Earlier
Specifications
Starter
Torques
Starting System Diagnosis
Starter System
General
Troubleshooting
Starter Relay
General
Testing
Starter-1988 & Earlier
Testing
Removal
Disassembly
Cleaning, Inspection and Repair
Assembly
Installation
Solenoid
General
Testing
Removal
Disassembly
Cleaning, Inspection and Repair
Assembly
Installation
Starter Shaft and Gear Housing -Chain Drive Models
Removal
Cleaning, Inspection and Repair
Installation
Starter Shaft and Gear Housing -Belt Drive Models
Removal
Cleaning, Inspection and Repair
Installation
STARTER – 1989 & Later Specifications
Starter
Service Wear Limits
Torques
Starter System
General
Troubleshooting
Testing
Starter-1989 & Later
Removal
Testing Assembled Starter
Disassembly, Inspection and Repair
Assembly
Installation
Starter Jackshaft – 1989
Starter Jackshaft – 1990

SECTION 6 – DRIVE
Specifications
Chains
Belts
Clutch
Lubricants
Sprockets
Torques
Primary Chain
General
Adjustment
Lubrication
Disassembly
Cleaning, Inspection and Repair
Assembly
Secondary Chain and Sprocket
General
Adjustment
Lubrication
Removal
Installation
Transmission Sprocket – Chain
Removal
Cleaning, Inspection and Repair
Installation
Secondary Belt and Sprocket
General
Adjustment
Lubrication
Removal
Installation
Transmission Sprocket -Belt
Removal
Cleaning, Inspection and Repair
Installation
Clutch – 1989 & Earlier
General
Lubrication
Adjustment
Disassembly
Cleaning, Inspection and Repair
Assembly
Primary Chaincase – 1988 & Earlier
General
Disassembly
Cleaning, Inspection and Repair
Assembly
Primary Chaincase – 1989 & 1990
General
Disassembly
Cleaning, Inspection and Repair
Assembly
Clutch – 1990 & Later
General
Lubrication
Adjustment
Disassembly
Cleaning, Inspection and Repair
Assembly

SECTION 7 – TRANSMISSION
Specifications – 4-Speed
Mainshaft Main Drive Gear
Mainshaft
Countershaft
Torques
Lubricants
Wear Limits
Transmission – 4-Speed
General
Adjustment
Shifter Assembly
Disassembly
Cleaning, Inspection and Repair
Assembly
Shifter Forks
Adjustment
Disassembly
Cleaning, Inspection and Repair
Assembly
Transmission Case
Removal
Cleaning, Inspection and Repair
Installation
Side Cover – 1985 FXEF
Disassembly
Cleaning, Inspection and Repair
Assembly
Side Cover – Kick Start
Disassembly
Cleaning, Inspection and Repair
Assembly
Starter Clutch – Kick Start
Disassembly
Cleaning, Inspection and Repair
Assembly
Countershaft
Disassembly
Cleaning, Inspection and Repair
Assembly
Mainshaft and Main Drive Gear
Disassembly
Cleaning, Inspection and Repair
Assembly
Specifications – 5 Speed
Main Drive Gear (5th)
Mainshaft
Lubrication
Shifter Dog Clearance
Side Door Bearing
Countershaft
Shifter Cam Assembly
Shifter Forks
Torques
Transmission – 5 Speed
General
Adjustments
Shifter Cam Assembly
Disassembly
Cleaning, Inspection and Repair
Assembly
Shifter Forks
Removal
Cleaning, Inspection and Repair
Installation
Transmission Side Cover –
1987 and Later
Removal
Disassembly
Cleaning, Inspection and Repair
Assembly/Installation
Mainshaft and Countershaft
Removal
Disassembly
Cleaning, Inspection and Repair
Replace the Side Door Bearing
Assembly/Installation
Transmission Case
Removal
Disassembly
Cleaning, Inspection and Repair
Assembly/Installation

SECTION 8 – ELECTRICAL
Specifications
Ignition
Battery
Alternator
Alternator
Regulator
Bulb Charts
Ignition System
General
Troubleshooting
Adjustment/Testing
Vacuum Operated Electric Switch
Testing
Removal
Installation
Ignition Module and Sensor Plate
Removal
Installation
Spark Plugs
General
Inspection
Installation
Ignition Coil
General
Troubleshooting
Installation
Ignition/Light Switch
General
Disassembly
Cleaning, Inspection and Repair
Assembly
Charging System
General
Troubleshooting
Alternator
Disassembly
Cleaning, Inspection and Repair
Assembly
Regulator
Removal
Installation
Battery
General
Adjustment/Testing
Cleaning and Inspection
Battery Charging
Headlamp
General
Adjustment
Removal and Installation
Turn Signals and Running Lights
Repair
Horn
Wiring Diagrams

Additional information

Weight 2 lbs
Dimensions 10 × 7.5 × 0.7 in