Engine Mechanical:
Engine assembly, disassembly, inspection, internal components, valve train, lubrication system, cooling system (air-cooled specific details).
Fuel System:
Fuel injection system (EFI), fuel pump, fuel injectors, fuel pressure regulator, fuel tank, fuel lines, throttle body.
Ignition System:
Ignition coils, spark plugs, crankshaft position sensor, ignition timing, electronic control module (ECM) related to ignition.
Transmission:
Primary drive, transmission assembly, gear selection, clutch operation, lubrication, maintenance, troubleshooting.
Electrical System:
Battery, charging system (alternator, regulator), starting system (starter motor), lighting system (headlight, taillight, turn signals), wiring diagrams, fuses, relays, horn.
Brakes:
Front and rear brake systems, hydraulic lines, brake calipers, master cylinders, brake pads, brake fluid specifications, bleeding procedures, ABS (if equipped).
Suspension:
Front forks (telescopic), rear shock absorbers, suspension adjustments, maintenance, fork oil specifications.
Wheels And Tires:
Wheel types, tire specifications, inflation pressures, wheel bearing maintenance, spoke adjustment (if applicable).
Frame And Bodywork:
Chassis components, frame inspection, body panel removal and installation, fairings, fenders, saddlebags, seat mounting.
Instruments And Controls:
Dashboard instruments, handlebar controls, throttle cables, clutch cables, brake levers, control cables.
Diagnostics And Troubleshooting:
Diagnostic trouble codes (DTCs), common problems and solutions, diagnostic tools, symptom-based troubleshooting.
Scheduled Maintenance:
Oil changes, filter replacements, spark plug replacement, chain adjustment (if applicable), belt checks, lubrication points.
Engine Overhaul:
Complete engine disassembly, inspection of critical components, reassembly procedures, torque specifications.
Transmission Service:
Clutch adjustment, transmission fluid changes, clutch plate replacement, transmission rebuild.
Electrical Troubleshooting:
Using wiring diagrams to diagnose electrical faults, testing components, replacing modules.
Brake System Maintenance:
Brake pad replacement, caliper service, master cylinder overhaul, brake fluid flush and bleeding.
Suspension Service:
Fork seal replacement, fork oil change, rear shock adjustment and replacement.
Fuel System Cleaning:
Throttle body cleaning, injector cleaning procedures.
Tire And Wheel Service:
Tire mounting and balancing, wheel bearing replacement.
Depth:
Comprehensive: Covers everything from routine maintenance and diagnostics to complete engine and transmission rebuilds, including detailed electrical schematics and troubleshooting guides.
Engine Type:
V-Twin, Air-Cooled, Twin-Cam 103 (High Output)
Bore X Stroke:
3.875 in x 4.375 in (98.4 mm x 111.1 mm)
Estimated Horsepower:
Approximately 75-80 HP (at crank, specific output varies slightly by year/tune)
Peak Torque:
Approximately 95-105 ft-lbs (at crankshaft, specific output varies)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane
Oil Type:
Harley-Davidson Genuine V-Twin 20W-50 (or equivalent high-quality motorcycle-specific 20W-50)
Oil Capacity:
Approximately 5 US quarts (4.7 liters) with filter change
Cooling Method:
Air-cooled
First Service:
Typically at 1,000 miles (1,600 km) or 1 month (whichever comes first) for initial break-in service.
Subsequent Oil Change:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first.
Belt Inspection And Tension:
Inspect and adjust belt tension every 5,000 miles (8,000 km).
Spark Plug Replacement:
Typically recommended every 10,000-15,000 miles (16,000-24,000 km).
Brake Fluid:
DOT 4 specification (refer to manual for specific Harley-Davidson approved fluid).
Primary Chaincase Lubricant:
Harley-Davidson Formula + or equivalent
Transmission Lubricant:
Harley-Davidson Formula + or equivalent
Common Wear Items:
Clutch plates (especially with aggressive riding), brake pads, tires, fork seals.
Potential Electrical:
Relay failures, stator/regulator issues can occur over time, though the Twin Cam era generally saw improvements.
Engine Performance Notes:
Twin Cam 103 engines are generally robust but can benefit from performance upgrades; tune-ups are critical for optimal running.