Harley-Davidson Softail Models 1997–1998 Service Manual (P/N 99482-98)

• Covers 1997–1998 Fat Boy (FLSTF), Heritage Softail Classic (FLSTC), Heritage Springer (FLSTS), Softail Custom (FXSTC), and Springer Softail (FXSTS), plus the 1997 Bad Boy (FXSTSB).
• Engine removal, cylinder-head repair, cylinder and piston inspection, oil-pump overhaul, and flywheel rebuilding.
• Hydraulic fork and Springer fork service, wheel-bearing adjustment, wheel truing, chassis alignment, and brake bleeding.
• CVH carburetor troubleshooting, vacuum-piston checks, float and needle-valve service, and vacuum-operated fuel-valve diagnosis.
• Primary-drive and clutch repair, final-drive belt and sprocket replacement, and transmission disassembly and reassembly.
• Starter voltage-drop testing, ignition and charging-system diagnostics, plus separate 1997 and 1998 wiring diagrams.

Technical Documentation and Systems Breakdown

This 436-page PDF reproduces Harley-Davidson’s 1997–1998 Softail Service Manual, Part No. 99482-98, documenting the 1340 cc Evolution engine. It introduces motorcycle construction and basic maintenance and repair, with major repair methods written for professional Harley-Davidson technicians.

Incomplete scan: The PDF contains duplicate pages and omits printed pages, including 5-16 (starter testing) and 7-1 (transmission specifications).

Evolution Engine Repair

Compression and cylinder-leakage tests help distinguish valve leakage from piston-ring or head-gasket problems. Overhaul procedures extend to valve-guide replacement, valve-seat reconditioning, cylinder boring and honing, connecting-rod bearing work, and flywheel truing. Gearcase assembly includes the Timing Gears with Marks Aligned view and cam/pinion gear color-code selection.

The assembly cautions explain how rotating the engine before the hydraulic lifters bleed down can damage the valves.

Model-Year and Chassis Differences

Separate clutch procedures cover the 1997 assembly with its spring plate and the 1998 nine-plate clutch with its damper spring and narrow friction plate. The Clutch Pack Stack-Up (Cut-Away View) details the later assembly, whose size also changes the primary chaincase lubricant capacity.

The five-speed transmission section illustrates Transmission Power Flow and covers shifter-cam, shift-fork, and mainshaft/countershaft repairs. Pawl adjustment calls for HD-42465 for the FLSTS and HD-39618 for the other covered models.

Springer coverage distinguishes FLSTS front-wheel, brake-reaction-link, and steering-head fall-away procedures from FXSTS/FXSTSB work. Hydraulic-fork models have their own overhaul and steering-head instructions.

The brake sections cover front and rear caliper work and distinguish integral-reservoir and remote-reservoir rear master cylinders. They also warn that incorrect brake-lever or switch-housing removal can damage the front stoplight switch’s rubber boot and plunger.

Fuel and Electrical Diagnostics

Carburetor jetting data distinguish 49-state, California, and HDI versions. The California Evaporative Emissions Control System schematic maps the charcoal canister and vapor hoses, with separate tests for the air-cleaner butterfly-valve solenoid.

Ignition diagnosis includes the vacuum-operated electric switch (V.O.E.S.), coil, and cam-position sensor. Starter checks cover relay operation, solenoid testing, and current draw. The Charging Circuit Diagram supports alternator-stator and voltage-regulator diagnosis, while electronic-speedometer and turn-signal-canceler troubleshooting address instrument and signaling faults.

Both model years have main-harness, instrument, and lighting wiring diagrams for domestic and international models. Appendix A adds AMP Multilock, Deutsch, and Packard connector repair, terminal removal, crimping tables, and connector locations.

Specification Highlights

Factory reference data include component-specific torque tables, fluid capacities, engine wear limits, bearing clearances, ring gaps, gear end play, and electrical test values. Scheduled maintenance covers lubrication intervals, primary chain and belt adjustment, clutch adjustment, ignition timing, spark-plug service, and storage.

Always follow standard shop safety practices and verify your setup before handling high-tension electrical components or heavy chassis parts.