Harley-Davidson Softail 1991–1992 Service & Repair Manual (P/N 99482-92)

Harley-Davidson factory service and repair manual for the 1991–1992 Softail FLSTC, FLSTF, FXSTC, and FXSTS, P/N 99482-92.

Printable PDF and Wiring Diagram Detail

Search, navigation and small labels: PDF text search and embedded bookmarks are not available. Small wire codes and connector labels in the wiring diagrams require zooming; the 1992 diagrams have lighter linework.

The ZIP download contains one printable 348-page PDF. This total includes 12 opening pages with the cover, publication information, foreword, contents and notes; nine section/index divider pages; six further notes pages; and the back cover.

Evolution Engine, Softail Chassis and Electrical Service

The following selected coverage highlights outline the repair and diagnostic content rather than reproduce the complete contents list. Other topics include storage preparation and jiffy-stand service.

• Wheels and brakes: Laced and disc wheel/hub service, bearing inspection, spoke lacing and truing, rim runout, tire work, vehicle alignment, master-cylinder and caliper repair, and bleeding.

• Forks and suspension: Telescopic-fork service for FXSTC/FLSTC/FLSTF, FXSTS Springer disassembly and assembly, rocker-bearing adjustment, steering-head repair, rear-fork removal, and rear-shock adjustment and replacement.

• V² Evolution engine: Troubleshooting and step-by-step top-end and bottom-end repair, extending from cylinder-head removal to crankcase, bearing and flywheel work.

• Carburetor and fuel system: Constant-velocity carburetor troubleshooting, vacuum-piston checks, adjustment and overhaul, plus fuel-tank, supply-valve, air-cleaner, California emissions and exhaust service.

• Electric starter: Current-draw and relay testing, assembled-starter checks, solenoid service, armature and field-winding tests, jackshaft work, and starter overhaul.

• Primary drive and transmission: Chain, belt and sprocket service, clutch repair, shifter-cam and fork inspection, shaft disassembly, side-door bearing replacement, and transmission-case procedures.

• Electrical diagnosis: Ignition and VOES testing, charging-system and stator checks, battery and lighting service, turn-signal microprocessor troubleshooting, and model/year wiring diagrams.

The manual introduces basic maintenance and repair alongside major repair methods for professional Harley-Davidson technicians; the brake chapter specifically recommends a qualified technician.

Maintenance Reference and Repair Planning

Section 1 provides initial-service and regular-maintenance schedules, shop practices, fluid requirements, fastener-torque guidance, labeled left- and right-side model views, VIN decoding, and an illustrated specialty-tool catalog.

Within the repair sections, specifications and troubleshooting lead into adjustment, testing and component procedures. This layout helps identify the appropriate assembly and test path before parts are removed.

Engine Inspection and Internal Repair

Compression and cylinder-leakage tests support diagnosis of valve, ring and head-gasket problems before teardown. Engine-removal instructions distinguish upper-end access from the removal needed for crankcase work.

Internal coverage includes push-rod installation, rocker-arm bushings, valve guides, valve-face and seat repair, cylinder boring and honing, piston inspection, rod-bushing and connecting-rod repair, and oil-pump troubleshooting.

The manual also documents the 1992 oil-filter mount, tappet-guide alignment, timing gears, flywheel end-play adjustment, crankcase-bearing repair, flywheel rebuilding and truing, and oil-tank removal and installation.

Year-specific engine parts: The instructions distinguish 1991 and 1992 cylinder-head bolts, rocker boxes and gaskets, which are not interchangeable between those years. Reference tables provide component torques, service-wear limits, ignition-timing data, oil-pressure specifications, capacities, running clearances and electrical test values.

Chassis Differences and Rear-Shock Limits

Separate wheel/hub procedures address the 1991 and 1992 builds. Model-specific material covers rear master cylinders, calipers, fenders, headlamps and cable routing, while the telescopic and Springer front ends receive separate treatment.

Rear brakes: Early- and late-1991 pads require their matching abutment shims. The manual warns that mixing these combinations impairs brake operation; using 1992 pads on 1991 discs substantially reduces pad life.

Rear-shock coverage is limited to preload adjustment, removal and replacement. The shock absorbers themselves are nonrepairable.

Carburetor and California Emissions Differences

Carburetor instructions distinguish the float-setting procedures and replacement inlet-valve requirements. Fuel-system coverage also explains why the vented 1991 fuel cap and the 1992 continuous-venting arrangement use different caps.

The California emissions sections separate the 1991 vacuum-operated valve and reed valves from the solenoid-operated backplate butterfly valve that replaces them for 1992. System schematics, canister and vapor-valve information, hose routing, and backplate-solenoid resistance and operating tests support identification of the correct configuration.

These distinctions matter when a general procedure or replacement part does not match the emissions-equipped machine being serviced.

Clutch, Gearbox and Belt Repair Details

Transmission-sprocket locking hardware differs by model year. Shifter-cam instructions also distinguish the inner positioning spacer used on early-1991 assemblies from the later arrangement.

The belt-handling cautions explain how tight bending can weaken the belt and cause premature failure. Transmission instructions warn that hammering the shafts out damages the side-door bearings.

Diagnostic Illustrations and Workshop Tools

Illustrations include “Adjusting ‘Fall-away,’” the two-part “Springer Fork,” “Timing Gears with Marks Aligned,” the 1992 California evaporative-emissions schematic, “Starting Circuit,” and “Mainshaft, Countershaft Assembly.”

Four wiring diagrams cover 1991 FLSTC (S-1), 1991 FXSTC/FXSTS/FLSTF (S-2), 1992 FLSTC (S-3), and 1992 FXSTC/FXSTS/FLSTF (S-4). Battery load tests and turn-signal fault tables complement the ignition, starter and charging-system checks.

The tool catalog identifies equipment such as the HD-35381 belt tension gauge, H-D 38515 clutch spring compressor, HD-35316 main-drive-gear remover/installer, HD-39301 and HD-39302 steering-head race tools, and HD-96650-80 flywheel truing stand.

Secure motorcycle support and the specified spring-compressor, puller, press and brake-fluid practices are required for the covered chassis, engine and driveline work. The foreword also directs technicians to separate Service Bulletins for interim engineering changes; those bulletins are not included.

Examples of Oil-Pressure and VOES Test Data

The engine specifications give an oil-pressure range of 12–35 psi at 2000 rpm with the oil at normal operating temperature, providing the reference conditions for the documented pressure check.

For ignition diagnosis, the VOES inspection specifies switch closure at 3.5–4.5 in. of mercury, linking the vacuum test to the ignition system’s advance control.