100%(5)100% found this document useful (5 votes) 5K views521 pagesHarley Davidson FLT 1995-96 Carb Service
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1995-1996
FLT
1340cc 5-SPEED
MODELS
SERVICE
MANUAL
Tho maintenance and repair information in this manual
‘applies to all 1995-1996 FLT models.
COPYRIGHT 1985
HARLEY-DAVIDSON MOTOR COMPANY
‘ALL RIGHTS RESERVED
PLN. 99483-96A
CMM 3M - 6°95
PRODUCT
CHASSIS
ENGINE
FUEL SYSTEM
DRIVE 6 a
TRANSMISSION 1G 4
ELECTRICAL 8 a
FUEL INJECTION 9 I
Printed in USA.
(on Hecycled Paper SECTION 1- PRODUCT
Service
‘Break-In Maintenance
Check at First 590 Mies (600 km) «
Safe Operating Maintenance
Service Maintenance Intervals
Broadsides
‘1999 FLIGU
1996 FLTCU-\
4995 FLHTC
1996 FLTC
1995 FLHTCU
1996 FLHTCU
4995 FLHT
41996 FLHT
1995 FLHR,
1995 FLHR
Sworage
Removal irom Storage -
Fluid Requirements
General
Unites States System
British Imperial System
Metric System.
‘Whoo! Bearing Grease.
Silicone Brake Fluid «
Front Fork Ol
Engine Oil,
Ful.
Fastener Torque Values
English ..
Equivalens tor Engish Fasteners
Mesrie Conversion Table
Troubleshooting
Goneral
Engine «
Lupricaton System
Electical System.
Carburetor
Transmission
Brakes,
Hanging
Shop Practices
Reoair Notes
Fepair and Repiacament Procedures
Cleaning
Tool Safety
AirToos
‘Wrenches
Pliss/CutorsPrybare
Herners
PunchesiChisels
Serewerivers.
TABLE OF CONTENTS
Page No.
Ratchots and Handles
Sockets
Storage Units
"1
11 Tools
"i
1 SECTION 2~CHASSIS
+2 Specifications
4-4 Dimensions
+5 Weight
1-6 Capacities
17 Adjustments
18 Tie Data...
1-8 Rear Whee! Sprocket
+10 Torques
4-11 Vehicle lentiiation Number (VIN)
442
443. Front Wheel
1-13 General
Removal
Disascombly
1418 Cleaning, Inspection and rene
145 Assembly
115 Installation
+45
435 Rear Wheel
145 amor
115 Desssomby
115 Geaning, epecton and evar
Assembly
Installation
13 Lacing Wheels - 16 Inch
v7
‘Truing Laced Wheel
118 Checking Cast Rim Runout.
+18
+19 Tires and Tubes
119 General
119 Removal.
419 Clearing, inspection and Reoar
4-20 nstalaton
+20
Vehicle Alignment
Th Brakes
13 ceneat
Adjustment
+29 Front Brake Master Cylinder= 1995
1-23 Genera)
1-23 Removal/Disassembly
4-23 Gleaning, Inspection and Repair
1-23 Ascembly
1-23 Installation
Page No.
124
428
+24
425
24
24
26
26
26
28
28
28
28
ant
242
ana
248
245
245
245
222
222
223
223
223
223
224
a, Page No.
Front Brake Master Ses 1996
General 226
RemovaliDisassemby. 2.26
Gleanig, Inspection and Repair 2.28
Assemblyiirstallaion 228
Rear Master Cytinder
z x 290
: 220
Clearing, Inspection and Repair. Sittecn E
Assembly... +... ae 292
Installation... skate en eee POLED
Front Brake Caliper
RotiovalDisassemby 233
Cleaning, Inspection and Repair. Be
Assembly 234
Instafation 2.35
Rear Brake Caliper
Removal/Disassembly 236
Cleaning, Inspection and Repair 2.97
‘Assembly. 2.97
Bleeding the Hydraulic System... 28
Stoplight Switches
Front Stoplight Switch 259
Rear Stoplight Switch . 240
Brake Discs
Removal .....- a an 241
Inspection oe Bal
Front Forks
Goneral BAU eee
Changing Fork Cit : 242
Removal er
Disassembly i ‘il 243
Clearing, inspaction and Reasir 2.43
Assomty. as
Insialaton. a 23
Front romney & Shock Air Control
Glonoral. es spvere BMS
Front Air Suspension «0.2... 245
Fear Air Suspension 248
‘System Testing... 3 246
Removal 248
Disassombly, Inspection and Ropar 246
‘Assembly. : ‘ 247
Instalaton Le Bag
Fork Stem and Bracket Ae
Lbrication 249
Adjustment + 249
Removal... sothateos eerie
‘Cleaning, inspection and Repair 250
Assembly... “ 250
w.
Installation
Steering Head Bearing Hace Removal
Rear Swing Arm
Removal
Disascemly i
Assembly ae
instalation .
Engine Front Rubber Mount
Rear Shock Absorber
Adjustment...
Removal... ae
Disassembly Vea
Cleaning, inspection and Repair
Assembly
Instafation :
Throttle Control
General
Disassembly...
Cleaning, Inspection and Repair
‘Assembly
Adjustment ‘ aie
‘Throtle Cable Lubtication
Clutch Control
Removal
Installation
Instruments and Gauges
“Toubieshootng (Al Models)
Instruments - 1995,
FLTCU
FLTC... > :
Replacing Gauges f
Instruments (FLHT/C/U) - 1996
Gauges - Fuel Pressure, Fuel Level, Voltmeter
‘and Ambient Air Temperature.
‘Speedometer/Tachorneter
Indicator Lamps
Fuel Gauge
Al Models Excopt FLHRL
FLHRWodes
Electronic Srasdoneter (FLHR)
DUS es coce hice
Troubleshooting
‘Speed Sensor Rerrovalinstallation
Speedometer Removal/installation
IndicatoSpeedomater Lamp Replacerrort
Handlebar Switches - 1995
{wits Sound Baten Contois
General... eas
Removal ;
Inetallation
263
265
205
268
270
an
2
273
273
275
278
278
278
278
