Harley Davidson Softail 1999 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: Softail Year: 1999 Generation Platform Generation: Fourth Generation Softail Codes Vin Decoder First Character: 1 Vin Decoder Eighth Character: Engine Type Identifier 👋 Introduction Market Position Target Audience: Harley-Davidson owners, independent repair shops, technicians Value Proposition: Provides OEM-level diagnostic and repair information for maintaining and restoring the 1999 Softail models. Competitive Analysis Competitor Manuals: Haynes, Clymer (often less detailed than factory manuals) Key Features Completeness: Official, factory-issued content ensuring accuracy and detail. Detail Level: Hundreds of pages offering in-depth coverage. 📋 Manual Details Coverage Areas Coverage Scope: Complete factory service and repair Specific Models Covered: All 1999 Harley-Davidson Softail models (e.g., Heritage Softail Classic, Fat Boy, Night Train, Springer Softail, Bad Boy, Custom) Page Count Estimated Pages: Hundreds (exact count not specified but implies a comprehensive volume) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanics: Detailed engine overhaul, assembly, disassembly, tuning, performance adjustments Fuel System: Carburetor (CV carburetor) service and adjustment, fuel tank, fuel lines, fuel pump (if applicable) Ignition System: Ignition timing, module service, spark plugs, wiring Transmission Drivetrain: 5-speed transmission service, clutch operation and adjustment, primary drive, final drive belt maintenance Electrical System: Wiring diagrams, charging system (stator, regulator/rectifier), lighting, starter, battery maintenance Suspension Steering: Front fork service and overhaul, rear shock absorber replacement, steering head bearing adjustment Braking System: Front and rear brake caliper service, master cylinder overhaul, brake fluid bleeding, pad replacement Wheel Tire Hub: Wheel bearing inspection and replacement, tire changing procedures, spoke tensioning (spoked wheels) Frame Chassis: Frame inspection, component mounting, jiffy stand service Bodywork Fenders: Fender removal/installation, fuel tank mounting, seat removal/installation, fairing (if applicable) Diagnostics Troubleshooting: Step-by-step troubleshooting guides for common and complex issues Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug inspection/replacement, air cleaner service, chain/belt adjustment, lubrication points Engine Rebuild: Complete engine disassembly, inspection, measurement, component replacement, and reassembly Transmission Service: Clutch adjustment, primary chain tensioning, transmission oil change, seal replacement Electrical Diagnostics: Troubleshooting electrical faults using wiring diagrams, testing components Brake System Repair: Brake pad replacement, caliper rebuild, master cylinder service, bleeding procedure Suspension Overhaul: Fork seal replacement, oil level adjustments, shock absorber installation Carburetor Tuning: Idle speed adjustment, mixture screw settings, jetting recommendations Component Installation: Detailed instructions for replacing major components and accessories Technical Depth Diagnostic Capabilities: Advanced diagnostics with specific fault codes and troubleshooting trees Rebuild Procedures: Comprehensive procedures for complete engine and transmission rebuilds Specifications Tolerances: Precise torque specifications, clearances, and dimensional tolerances for all components Wiring Diagrams: Detailed, color-coded electrical schematics for accurate diagnosis and repair Special Tools: Identification and usage instructions for specialized Harley-Davidson tools required for specific tasks 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable (typical for official factory PDFs) Print Quality Printability: High-resolution, suitable for printing specific sections or the entire manual Binding Type Binding Type For Printed: N/A (Digital PDF) Paper Type Paper Type For Printed: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Family: Evolution (Evo) Engine Type: Air-cooled, pushrod V-twin Displacement Cc: 1340cc (82 cubic inches) Bore X Stroke: 3.496 in x 4.25 in (88.8 mm x 108 mm) Compression Ratio: 8.8:1 (typical for Evolution Big Twin) Performance Horsepower Est: Approx. 65-70 HP (at crankshaft, varies by model and tuning) Torque Ft Lbs Est: Approx. 78-85 ft-lbs (at crankshaft, varies by model and tuning) Fuel System Carburetor Type: Keihin CV (Constant Velocity) 40mm Fuel Requirement: 87-91 Octane Unleaded Gasoline 🔧 Transmission Standard Transmission Type: 5-speed Manual Constant Mesh Optional Optional Transmission: N/A (5-speed was standard for Softail) Features Clutch Type: Wet, multi-plate, diaphragm spring Primary Drive: Multi-plate clutch in oil bath, chain drive Final Drive: Belt drive Gear Ratios 4Th To 5Th: Key for highway cruising performance (details in manual) 📐 Dimensions Exterior Wheelbase Inches: Approx. 64.5 - 65.5 inches (varies by specific Softail model) Seat Height Inches Laden: Approx. 25.5 - 26.5 inches (varies by specific Softail model) Weights Dry Weight Lbs: Approx. 600 - 650 lbs (varies by specific Softail model) Gross Vehicle Weight Rating Lbs: Typically around 1000 lbs Cargo Cargo Capacity: N/A (motorcycle) 🛡️ Safety Features Ratings Safety Certifications: Meets DOT and EPA standards for motorcycles Active Features Braking System Type: Hydraulic disc brakes, front and rear ABS: N/A (Anti-lock Braking System not available on 1999 Softail models) Passive Features Lighting: Halogen headlight, LED tail light, turn signals 💡 Technology Features Infotainment Infotainment System: N/A (Base model, no integrated infotainment systems) Driver Assistance Driver Assistance Features: N/A (No electronic driver assistance features) Connectivity Connectivity Options: N/A (No Bluetooth, USB, or smartphone integration) 🔧 Maintenance Service Intervals Oil Change Interval: Every 2,500-5,000 miles or annually (consult manual for exact recommendations based on usage). Primary Chain Tension Check: Inspect every 2,500 miles Spark Plug Replacement Interval: Every 10,000-20,000 miles (depending...
Detailed instructions for replacing major components and accessories
Technical Depth
Diagnostic Capabilities:
Advanced diagnostics with specific fault codes and troubleshooting trees
Rebuild Procedures:
Comprehensive procedures for complete engine and transmission rebuilds
Specifications Tolerances:
Precise torque specifications, clearances, and dimensional tolerances for all components
Wiring Diagrams:
Detailed, color-coded electrical schematics for accurate diagnosis and repair
Special Tools:
Identification and usage instructions for specialized Harley-Davidson tools required for specific tasks
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable (typical for official factory PDFs)
Print Quality
Printability:
High-resolution, suitable for printing specific sections or the entire manual
Binding Type
Binding Type For Printed:
N/A (Digital PDF)
Paper Type
Paper Type For Printed:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Family:
Evolution (Evo)
Engine Type:
Air-cooled, pushrod V-twin
Displacement Cc:
1340cc (82 cubic inches)
Bore X Stroke:
3.496 in x 4.25 in (88.8 mm x 108 mm)
Compression Ratio:
8.8:1 (typical for Evolution Big Twin)
Performance
Horsepower Est:
Approx. 65-70 HP (at crankshaft, varies by model and tuning)
Torque Ft Lbs Est:
Approx. 78-85 ft-lbs (at crankshaft, varies by model and tuning)
Fuel System
Carburetor Type:
Keihin CV (Constant Velocity) 40mm
Fuel Requirement:
87-91 Octane Unleaded Gasoline
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Constant Mesh
Optional
Optional Transmission:
N/A (5-speed was standard for Softail)
Features
Clutch Type:
Wet, multi-plate, diaphragm spring
Primary Drive:
Multi-plate clutch in oil bath, chain drive
Final Drive:
Belt drive
Gear Ratios 4Th To 5Th:
Key for highway cruising performance (details in manual)
📐 Dimensions
Exterior
Wheelbase Inches:
Approx. 64.5 - 65.5 inches (varies by specific Softail model)
Seat Height Inches Laden:
Approx. 25.5 - 26.5 inches (varies by specific Softail model)
Weights
Dry Weight Lbs:
Approx. 600 - 650 lbs (varies by specific Softail model)
Gross Vehicle Weight Rating Lbs:
Typically around 1000 lbs
Cargo
Cargo Capacity:
N/A (motorcycle)
🛡️ Safety Features
Ratings
Safety Certifications:
Meets DOT and EPA standards for motorcycles
Active Features
Braking System Type:
Hydraulic disc brakes, front and rear
ABS:
N/A (Anti-lock Braking System not available on 1999 Softail models)
Passive Features
Lighting:
Halogen headlight, LED tail light, turn signals
💡 Technology Features
Infotainment
Infotainment System:
N/A (Base model, no integrated infotainment systems)
Driver Assistance
Driver Assistance Features:
N/A (No electronic driver assistance features)
Connectivity
Connectivity Options:
N/A (No Bluetooth, USB, or smartphone integration)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 2,500-5,000 miles or annually (consult manual for exact recommendations based on usage).
Primary Chain Tension Check:
Inspect every 2,500 miles
Spark Plug Replacement Interval:
Every 10,000-20,000 miles (depending on plug type)
Belt Tension Check:
Check every 5,000 miles
Fluid Specifications
Engine Oil Type:
Harley-Davidson 20W50 SYN3 or equivalent motorcycle-specific oil
Engine Oil Capacity Quarts:
Approx. 4 quarts (including filter)
Primary Chain Case Oil Type:
Harley-Davidson primary chain case lubricant or suitable heavy-duty motorcycle transmission oil
Primary Chain Case Oil Capacity Quarts:
Approx. 1 quart (26-28 oz)
Transmission Oil Type:
Harley-Davidson Formula+ Transmission Lubricant or suitable heavy-duty motorcycle transmission oil
Transmission Oil Capacity Quarts:
Approx. 20-24 oz
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Known Issues
Cam Chain Tensioner Wear:
Known wear issue on later Evo engines, potentially leading to noise or internal damage. Manual covers inspection and replacement procedures.
Crankcase Breather System:
Can require cleaning/maintenance to prevent oil blow-by. Manual details system operation and cleaning.
Rear Wheel Alignment:
Importance of proper rear wheel alignment and belt tension for tire wear and handling. Manual covers alignment checks.
📚 Vehicle History
Brand Heritage
Brand Origin:
Milwaukee, Wisconsin, USA - Founded 1903
Brand Identity:
Iconic American motorcycle manufacturer known for V-twin engines and cruiser styling.
Model Evolution
Softail Introduction:
The Softail platform was introduced in 1983, featuring a hidden rear suspension designed to mimic the look of a hardtail frame.
1999 Updates:
The 1999 models generally represent a refined version of the Evo Softail platform, with minor updates for emissions and componentry over prior years.
Production
Engine Production Years:
Evolution engine produced from 1984 to 1999 (air-cooled versions).
Softail Production Years:
1983-Present (continuous evolution of the platform)
🏆 Awards & Recognition
Recognitions
Motorcycle Awards:
Softail models are generally recognized for their classic styling and riding experience, not typically associated with specific industry awards in the same way cars are.
Ratings
Consumer Ratings:
The Evolution engine is highly regarded for its reliability and torque, making the 1999 models a sought-after classic.
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