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