Harley Davidson Evolution Motorbike manuals Winch Books

Harley Davidson Evolution Motorbike manuals

The machine construction regarding the Harley-Davidson Sportster, which has essentially already been unchanged since their inception whilst the side-valve 750cc "K" Model in 1952, was retained with the development engine improvement in 1986, causing a unique valve train configuration. The Sportster

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FXRS-SP FXRS-CONV FXLR FXRD FXRT 1340cc 1982 - 1999 * FXB FXD FXE FXDG FXDL FXDWG FXDS-CONV FXEF FXS FXSB FXWG FXST FXSTC FXSTS FLST FLST-SP FLSTC FLSTF FLSTN 1340cc 1979 - 1999 * FXD FXDB FXDC FXDL FXDS-CONV FXDWG 1340cc 1991 - 1998 Please note: This manual DOES NOT include police models. Contents: * Living With Your HARLEY-DAVIDSON BIG TWIN Introduction: Miwaukee magic; Ackowledgements; About this manual; Identification numbers: buying spare parts; decoding the Vehile Identification Number (VIN); Safety first! * Daily (Pre-Ride) Checks: Engine oil level check; Suspension steering and final-drive checks; Tyre checks. * Maintenance Routine Maintenance and Servicing: Specifications; Recommended lubricants and fluids; Component locations; Maintenance schedule; Maintenance procedures. * Repairs And Overhaul Engine Transmission and Associated Systems: Engine; Clutch primary drive and transmission; Fuel and exhaust systems; Ignition system. * Chassis and Bodywork Components: Steering; Suspension; Final drive; Wheels; Brakes; Tyres; Frame and bodywork. * Electrical System * Wiring Diagrams (In Colour) click here.....

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(1996-1998) * FLHTC-U Electra Glide Classic-Ultra & Anniversary (1989-1997) * FLHTC-UI Electra Glide Classic-Ultra & Anniversary (1996-1998) * FLTC Tour Glide (1984-1991) * FLTC-U Tour Glide-Ultra Classic (1989-1995) * FLTC-UI Tour Glide-Ultra Classic (1996) * FLTR Road Glide (1998) * FLTR-I Road Glide (1998) * FXEF Fat Bob (1985) * FXLR Low Rider Custom & Anniversary (1987-1994) * FXR Super Glide (1986-1994) * FXR2 & FXR3* Super Glide (*Limited edition models available only in 1999) * FXRD Super Glide Grand Touring (1986) * FXRS Low Rider & Convertible (1984-1992) * FXRS-Con Low Rider-Convertible (1991-1993) * FXRS-SP Low Rider-Sport Edition (1988-1993) * FXRT Sport Glide (1984-1992) * FXSB Low Rider (1985) * FXWG Wide Glide (1985-1986) Contents: * Quick Reference Data * General Information Manual Organization / Warnings Cautions And Notes / Safety / Serial Numbers / / Fuel Tank Gauge / Fuel Tank / Non-Vacuum-Operated Fuel Shutoff Valve / Vacuum-Operated Fuel Valve / Fuel Pump And Filter / Exhaust System / Evaporative Emission Control System / Specifications * Electrical System Battery / Charging System / Ignition System / Ignition Module / Electronic Control click here.....

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following Models: * FXDB Dyna Glide (1991-1992) * FXDC Dyna Custom (1992) * FXDL Dyna Low Rider (1993-1998) * FXDWG Wide Glide (1993-1998) * FXD Dyna Super Glide (1995-1998) * FXDS-CONV Dyna Low Rider Convertible (1995-1998) Contents: * QUICK REFERENCE DATA * GENERAL INFORMATION Manual organization / Notes cautions and warnings / Safety first / Service hints / Serial Numbers / Parts replacement / Torque specifications / Fasteners / Lubricants / Sealants cements and cleaners / Expendable supplies / Basic hand tools / Test equipment / Measuring tools / Special tools / Mechanic * TROUBLESHOOTING Operating requirements / Troubleshooting instruments / Testing electrical equipment / Engine performance / Electric starting system / Charging system / Ignition system / Fuel system / Engine noises / Engine lubrication / Clutch / Transmission / Electrical problems / filter change / Lifter oil screen cleaning / Transmission oil change / Primary chaincase oil change / Front fork oil change / Throttle control grip lubrication / Speedometer cable lubrication / Transmission oil change / Periodic maintenance / Primary chain adjustment / Final drive belt related info

The machine construction regarding the Harley-Davidson Sportster, which has essentially already been unchanged since their inception whilst the side-valve 750cc "K" Model in 1952, was retained with the development engine improvement in 1986, causing a unique valve train configuration. Unlike virtually any more system in manufacturing these days, the Sportster development utilizes one cam per system overhead-valve, resulting in four specific, single-lobe, gear-driven camshafts. The cam lobes are therefore all positioned one behind another, and pushrods is arrayed in pairs parallel towards cylinder axis thus. This allows each lifter and pushrod to deflect from cam lobes perpendicular to your lobe plane. This configuration try friendly to radical, high-output cams, creating the Sportster Evolution an all-natural choice for the as soon as Harley-Davidson possessed distinct Buell bike business sportbikes from 1986 up to late 2009.

The Sportster Evolution motor has stayed mainly unchanged from 1986 for this time, though changes into the transmission, final drive and motor mounts posses necessitated adjustment towards the Sportster Evolution case. Construction is almost completely similar between 883 cc and 1,200 cc variations; the principle distinction between the two was an inferior bore on the 883 cc, with a little different heads. Conversion rates from 883 cc to 1,200 cc tend to be relatively affordable and commonplace, and cheaper than the price premium going from an 883 to 1,200 motor on a unique cycle. Carburetors had been standard on Sportster motors until 2007, if they were replaced by the Delphi Electronic Sequential-Port gas Injection system.

A simplified derivative of the motor is used on the Buell Blast entry-level motorcycle from 2000 to 2009. The Sportster engine as utilized on the Buell Blast was at more methods much like the one used on Sportsters, albeit with the rear cylinder eliminated, and also other concessions to reduce general price and upkeep.

The Evolution engine are an air-cooled, 45-degree, V-twin system made of 1984 by Harley-Davidson for organization's motorcycles. It was made in the 1,340 cc displacement for Harley-Davidson Big V-twins bikes, replacing the Shovelhead engine until 2000 once the final EVO was placed in a production factory custom FXR4. In 1999, it was changed by the Harley-Davidson Twin Cam 88 when you look at the Touring and Dyna model and in 2000 within the Softail products. Furthermore obtainable in the Sportster model beginning in 1984, it absolutely was built in the 1,100 cc displacement until 1988 and is still made in the 883 cc and 1,200 cc displacements when it comes to Harley-Davidson Sportster, changing the ironhead Sportster motor.

More analysts look at the development becoming the engine it saved the reorganized Harley-Davidson providers from certain bankruptcy. Harley-Davidson's formal title the motor is likely related to the company's make an effort to reform its image following the 1981 management buyout from earlier holder American Machine and Foundry.

Both heads and cylinders for the advancement engine are produced from aluminum to lessen pounds compared to a cast-iron build. Atmosphere cooling efficiency was enhanced as aluminum try an excellent thermal conductor to cast iron. The blocky rocker containers, aluminum minds and cylinders would be the best an element of the advancement engine that can be considered crucial; the major Twin and Sportster incarnations of development is substantially different.

Harley recommended an innovative new engine so superior to just what choose to go before that their particular character will be restored. It should be reliable, powerful, and cool-running, capable of additional developing. It should make use of almost no oils.

In the shovel engine, while the aluminum head warmed up and broadened, they slid imperceptibly throughout the low-expansion iron cylinder, shearing and deteriorating your head gasket. Strobe studies made regarding the dyno showed the big inertia of the metal cylinders causing them to “walk” to their base gaskets. For these reasons the cylinders associated with the new advancement engine could be aluminum, with metal liners. Today heads, cylinders, and crankcase would all be aluminum, with alignment dowels to help keep all parts from relative movement, gasket circumstances and sealing would markedly develop.


The main issue of keeping the clamp load on head gaskets had been the use of brief mind bolts on earlier models. The shorter the bolt, the less you can stretch it before they yields, so a high-expansion aluminum mind, retained by brief head bolts, can completely extend those bolts by overheating—leading to poor gasket sealing, oils leakage, or gasket failure. Evo’s design retained both head and cylinder by lengthy through-studs whoever greater capacity to stretch elastically let the “stack” to grow from temperature without completely stretching the more flexible longer through-studs. Mechanics needed to learn how to avoid the temptation to get a disassembled situation 1 / 2 by their studs like these people were the handle of a skillet; achieving this could fold the level 9 studs, compromising their particular energy.


The advancement system was the result of seven many years of developing for Harley-Davidson, and created most energy at every rate, plus went cooler and cleaner.



A problem of past Big Twins was piston fit and piston air conditioning. Because an aluminum piston expands more and faster than an iron cylinder, it must be offered adequate approval. But piston cooling needed personal communications between hot piston and cooler cylinder. It was difficulty without an actual option. In adopting an aluminum cylinder on Evo engine, it became possible to operate at a great deal better piston clearance – in examinations, Harley could actually sustain full throttle process with clearance as low as .0004 inch. How? First of all, the aluminum cylinder expanded in action using piston, as soon as the piston made experience of the wall, the air conditioning aftereffect of wide-area contact stopped further piston growth. They were German-made Mahle pistons, containing 12 per cent silicon to reduce growth. Manufacturing piston clearance is ready at .0014 inches. The most notable piston ring is a chrome-plated barrel-face means, the 2nd ring a 2-degree taper face, and the oils scraper a three-piece type.

Burning chambers were made shallower by a further decrease in device included position to 58 levels. This, by reducing the area of combustion chamber and piston crown additionally slice the movement of temperature into those section.

Within the stage between the two world wars a sizable valve included perspective of 90-100 degrees had been considered crucial as it made room within the burning chamber for huge valves. It was planning especially essential in long-stroke engines whoever small bores would usually restrict device dimensions. But circumstances change—valuable perform by airflow experts like Jerry department, Kenny Augustine, among others have significantly increased the circulation that will go through modest valves. Because their particular work furthermore boosted intake velocity, flow have the energy to continue moving into the cylinders after bottom center. In this way, small valves, ready at reduced included sides, became in a position to supply additional atmosphere compared to the bigger valves of early in the day designs.

For this reason the old rehearse of “hogging out” intake and exhaust ports leads to less torque and power. Today’s small ports are that dimensions for a reason.

One other way to lessen temperatures flow into piston and mind is always to speed-up burning, reducing the full time visibility of this material areas to combustion fire. Fire try spreading from the sparkplug outward by fast, turbulent movement for the fuel-air mixture—motion produced initially by large intake velocity. To “refresh” that movement while the piston nears TDC, one side of each and every burning chamber had been filled-in to be extremely near to the piston top at top center. Combination between piston and mind are rapidly squeezed from this squish room, developing a jet that stirs and accelerates the burning techniques.

One other prime source of cylinder head heating is the exhaust interface, for which perfect circumstances for super-fast temperature transfer exist; exceedingly hot gases, moving at high speed, in a turbulent state. Way back when, temperature movement experiments showed that half of the heat picked up because of the cylinder mind originates from the exhaust interface. That being therefore, Evo’s exhaust harbors had been deliberately made as quick as possible.

The relative movement of cylinders was acknowledged as confirmed of V-twin process, so the Evo engine’s intake Y-manifold ended up being made to put on flexible rubber couplings from the cylinders. Pratt & Whitney needed to make flexible intake connections on it 28-cylinder R-4360 radial, after prototypes tore their intake contacts to components.

To make engine-in-frame maintenance possible, the rocker framework, its spacer, and cap had been made as layers slim adequate to feel slid laterally, out from beneath the framework rails. Making it furthermore possible to remove the minds, they certainly were fastened towards the through men with bolts equal in length towards the head’s depth. With these bolts eliminated, the minds might be slid sideways and removed also.

An important Evo development objective is capability to endure a 100-hour full-throttle test. Evo system examination totaled 5600 time, road testing 750,000 kilometers. Having its brand-new soothing ability, oil-tightness, and mechanical stability, these devices could routinely feel ridden coast-to-coast.


1983 in order to avoid betting the farm on Evo, the shovel is held in manufacturing for a time. Early Evolution heads had been sand-cast in alloy 242. This product, containing copper, nickel, and magnesium, forms difficult intermetallic compounds since it cools and ages, providing it outstanding hot strength.

1984 deals become 38,741—up 31 per cent. Last solid-mounted Shovel motors leave the line June this current year. 1340cc development engine in five designs is 20 pounds light than earlier.

1985 last drives are typical tooth buckle today. At mid-year, the interim utilization of sand-cast cylinder heads offered solution to die-casting.

1986 brand new intake and exhaust techniques consider reduced noise. Connecting-rod big-end roller cages was in fact aluminum but had been now switched to M-section plated metallic cages. Pattern mag dynos a Softail’s Evo system, reading 56 hp at 5000 rpm, peak torque of 69 lb.-ft. at 3000. Keep in mind to bikers, torque is certainly not lots but instead a feeling. A “torquey” motor is certainly one that brings similarly highly at virtually any rpm—it just isn't peaky. Peak torque was torque calculated at their finest aim, but become torquey an engine really needs large torque everywhere.

1987 Harley dilemmas initial general public providing of inventory. Keihin 38mm carburetor. Unique cams with 24 % less intake length, 28 per cent less fatigue length, and 14 per cent less carry. The cooler-running Evo engine had been believed able to tolerate more compression and was presented with 8.5:1 by 1987. Presently there isn't any problem with running same ignition timing on forward and rear cylinders. As measured by sparkplug washer thermocouple, an Evo system runs 75 degrees F cooler than a shovel beneath the exact same problems.

Evo oils force light could flicker on hot times.
Harley-Davidson bike at Ny Stock-exchange.

1988 Keihin 38mm butterfly carb continues, as do 8.5:1 compression. Oil capacity are 3 quarts. Dyno output try 55 hp, 69.4 lb.-ft. of torque at 3000 rpm, brand-new 32 amp alternator.

An earlier VR1000 build integrate a gerotor oils pump regarding the crank, eliminating bearings, a shaft, and push gears. “Gerotor” means “generated rotor,” comprising two gear-like customers—an outer one with inward-facing “teeth” and an off-center internal rotor that drives it by complementary outward-facing “teeth.” Crank installing performedn’t work on the VR because their highest rpm triggered pump cavitation. But the concept had been remembered later on when it comes to P-22 venture.

1989 brand new 1.6-hp starter, new instance, for faster hot-starting. Electric cruise controls launched. Carburetor is currently Keihin CV, slips into plastic manifold versus old two-bolt mounting.

1990 New clutch, 40mm Keihin.

1993 Harley-Davidson manufacturing this year are 85,000 devices.

1995 gasoline injection becomes an alternative. Marelli EFI available 1995-2001. Carburetor alternative was Keihin CVK40. A carburetor are a passive gas system—running full of warm weather and leaner in cooler weather. EFI continually automatically readjusts fuel combination in reaction to rising or falling barometer and temperature—just like a trackside competition tuner do, using cardboard boxes of jets and needles.

The Harley-Davidson advancement V-twin provides the company into a brand new period of success and track record of dependable performance.

The Evolution gigantic Twin spotted a fifteen-year run-in Harley-Davidson's Dyna, Softail, FXR, and Touring structures, although a limited amount of Evolutions were utilized in the 2000 design 12 months CVO FXR4, and 1999 FXR2 and FXR3 brands. Whilst primary instance was just somewhat altered from previous Shovelhead motor, the most effective end was substantially enhanced.

The 1340cc development utilizes just one, four-lobe, gear-driven camshaft present right above the crankshaft axis. Although this simplifies camshaft substitution, they complicates the major Twin device train with tappet/lifters and pushrods that each deflect from the camshaft at wildly various perspectives. The major Twin pushrods need a definite helical look considering that the straight plane created by each cylinder's rockers is strictly perpendicular into straight jet created because of the cam lobes. The necessity for one lifter and pushrod set-to attain completely off to many outboard cam lobe brings increase to the Big Twin's tell-tale offset lifter assemblies, where in fact the forward lifter construction is found somewhat further away and rotated to enable the valve equipment to help make the reach.

The Big Twin is followed closely by a number of different primary drives and transmissions, both on production Harley-Davidson motorcycles as well as in personalized solutions. The aftermarket choice of accessories for these closely associated systems was wider, as it is for engine itself.

The Evolution gigantic Twin motor was, before the introduction of this Twin Cam motor, the past of distinct single cam, overhead valve motors tracing their lineage returning to the seminal Knucklehead build penned by creator Bill Harley. Additionally it is the biggest aftermarket supported Harley-Davidson build, currently, with clones regarding the engine being from third parties like S&S period and many other individuals. Harley reverted to just one cam design using the Milwaukee-Eight engine, very first launched for touring models in 2016.

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