Harley-Davidson · Harley-Davidson Evolution big twin (1984-1999)

Softail (Evolution)

Library entry covers 1984-1999

37 factory 23 guideline

Published source

Harley-Davidson Service Manual 1985 to 1990 FX/Softail Models (Official Factory Manual, 1989), Regular Maintenance Intervals, p.1-2

Factory workshop manual. Covers 1985-1990 FX/Softail (factory service manual).

Open the source

60 items for a 1999 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Dry sump (separate oil tank)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Hydraulic lifters (no routine clearance adjustment)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Air / oil cooled
Primary drive: Chain in oil-bath case with its own oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, cable
Final drive: Toothed belt
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

1999 Harley-Davidson Softail (Evolution)

On the road: every 300 km

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

1 item

Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 4,000 km

1 item

Check lights, horn, brake light switches

Pre-ride / on the road

Factory

Manual: Operation of all electrical equipment and switches: inspect. Factory: I pre-ride and every 2500 mi. p.1-2

Every 4,000 km or 12 months

1 item

Check battery electrolyte, top up with distilled water

Ignition and electrics

Factory

Manual: Battery fluid level, connections: inspect. Factory: I at 500 then every 2500 mi; also annually. p.1-2

Every 4,000 km

6 items

Engine low and fast idle speed: inspect

Engine

Factory

Factory: I pre-ride and every 2500 mi. p.1-2
Engine oil: inspect

Engine

Factory

Factory: I at 2500 mi columns between changes. p.1-2
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Operation of throttle and choke/enrichener controls: inspect. Factory: I pre-ride and every 2500 mi. p.1-2
Fuel valve, lines and fittings: inspect for leaks

Fuel and air

Factory

Factory: I at 500 then every 2500 mi. p.1-2
Check brake pads and discs

Brakes

Factory

Manual: Brake pad linings and discs: inspect for wear. Factory: I at 500 then every 2500 mi. p.1-2
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tire pressure and tire wear/damage: inspect. Factory: I pre-ride and every 2500 mi. p.1-2

Every 5,000 km or 12 months

4 items

Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 8,000 km or 12 months

4 items

Change engine oil

Engine

Factory

Manual: Engine oil: replace. Factory: R every 5000 mi, inspect at 2500s; also annually. p.1-2
Change gearbox oil

Primary and gearbox

Factory

Manual: Transmission lubricant: replace. Factory: R every 5000 mi, inspect at 2500s; also annually. p.1-2
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Rear fork bearing: lubricate. Factory: L at 500 then every 5000 mi; also annually. p.1-2
Brake fluid level and condition: inspect

Brakes

Factory

Factory: I at 500 then every 5000 mi; also annually. p.1-2

Every 8,000 km

20 items

All fasteners except engine head bolts: tighten

Engine

Factory

Factory: T at 500 then every 5000 mi. p.1-2
Check engine mounting bolts and plates

Engine

Factory

Manual: Engine mounting bolts: inspect. Factory: I at 500 then every 5000 mi. p.1-2
Clean oil strainers / mesh screens

Engine

Factory

Manual: Tappet oil screen: inspect. Factory: I at 500 then every 5000 mi. p.1-2
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plugs: inspect. Factory: I at 5000, 15000; R at 10000, 20000 mi. p.1-2
Replace oil filter

Engine

Factory

Manual: Oil filter: replace. Factory: R at 500 then every 5000 mi. p.1-2
Clean / inspect air filter

Fuel and air

Factory

Manual: Air cleaner: inspect, lubricate. Factory: IL at 500 then every 5000 mi. p.1-2
Check / set ignition timing

Ignition and electrics

Factory

Manual: Ignition timing and V.O.E.S.: inspect. Factory: I at 500 then every 5000 mi. p.1-2
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch adjustment. Factory: A at 500 then every 5000 mi. p.1-2
Change primary chaincase oil

Primary and gearbox

Factory

Manual: Primary chaincase lubricant: replace. Factory: R at 500 then every 5000 mi. p.1-2
Check / adjust primary chain

Primary and gearbox

Factory

Manual: Primary chain: inspect. Factory: I at 500 then every 5000 mi. p.1-2
Inspect drive belt, pulleys and tension

Final drive

Factory

Manual: Rear belt/chain: adjust. Factory: A at 500 then every 5000 mi; inspect pre-ride. p.1-2
Check steering head bearing adjustment

Front end

Factory

Manual: Front fork bearing adjustment: inspect. Factory: I at 500 then every 5000 mi; IL at 10000s. p.1-2
Rear fork pivot nut: inspect

Front end

Factory

Factory: I at 500 then every 5000 mi, if applicable. p.1-2
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Factory

Manual: Rear brake and shifter linkage: inspect, lubricate. Factory: IL every 5000 mi, if applicable. p.1-2
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Condition of rear shock absorbers: inspect. Factory: I at 500 then every 5000 mi. p.1-2
Rear brake caliper mounting pins and boots: inspect, lubricate

Brakes

Factory

Factory: IL every 5000 mi. p.1-2
Rear brake pedal height adjustment and freeplay: inspect

Brakes

Factory

Factory: I at 500 then every 5000 mi, if applicable. p.1-2
Check spoke tension and wheel true

Wheels and tires

Factory

Manual: Wheel spoke tightness: inspect. Factory: I at 500 then every 5000 mi, if applicable. p.1-2
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Front brake lever, throttle, choke and clutch cables and lever: lubricate. Factory: L at 500 then every 5000 mi. p.1-2
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Factory

Manual: Throttle control grip sleeve, speedometer cable: lubricate. Factory: L every 5000 mi. p.1-2

Every 9,500 km or 12 months

3 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline

Every 16,000 km or 12 months

1 item

Repack / replace wheel bearings

Wheels and tires

Factory

Manual: Wheel bearings: inspect, lubricate. Factory: IL every 10000 mi; also annually. p.1-2

Every 16,000 km or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 16,000 km

4 items

Replace spark plugs

Engine

Factory

Manual: Spark plugs: replace. Factory: R every 10000 mi. p.1-2
Change fork oil

Front end

Factory

Manual: Front fork oil: replace. Factory: R every 10000 mi, if applicable. p.1-2
Check springer rocker stud play and spring condition

Front end

Factory

Manual: Springer rocker bearings: adjust. Factory: A every 10000 mi, if applicable. p.1-2
Repack / replace steering head bearings

Front end

Factory

Manual: Front fork bearing: inspect, lubricate. Factory: IL every 10000 mi. p.1-2

Every 19,500 km or 2 years

1 item

Replace air filter element

Fuel and air

Guideline

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 80,500 km

1 item

Replace drive belt (wear or damage based)

Final drive

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

3 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.