Systems Covered:
Engine, Transmission, Drivetrain, Fuel System, Ignition System, Electrical System, Suspension, Brakes, Chassis, Bodywork, Controls, Maintenance, Troubleshooting, Diagnostics
Wiring Diagrams:
Comprehensive color-coded electrical schematics for all systems, aiding in troubleshooting and repair of electrical faults.
Pages:
Extensive (specific count not provided, but typical workshop manuals are 500+ pages)
Type:
Complete Workshop Service Repair Manual
Manual Scope:
Covers all aspects of service, repair, maintenance, and diagnostics for the specified model and year.
Format:
Downloadable (likely PDF)
Engine:
Twin Cam 103™ V-Twin, disassembly, assembly, inspection, and repair of all engine components including cylinders, pistons, crankshaft, camshafts, valves, and lubrication system.
Transmission:
6-speed Cruise Drive transmission, removal, installation, inspection, and repair of gears, bearings, shift mechanism, and clutch components.
Drivetrain:
Primary drive, belt drive, clutch operation, final belt drive system maintenance and adjustment.
Fuel System:
Electronic Sequential Port Fuel Injection (ESPFI), throttle body, fuel pump, injectors, pressure regulator, and diagnostic procedures.
Ignition System:
Ignition module, spark plugs, ignition coils, and troubleshooting of ignition faults.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instrumentation, and accessory circuits with wiring diagrams.
Suspension:
Front fork (telescopic) disassembly, assembly, fluid replacement, and rear shock absorber maintenance and adjustment.
Brakes:
Front and rear brake systems, hydraulic lines, calipers, master cylinders, brake pads, rotors, and bleeding procedures.
Chassis:
Frame inspection, steering head bearing adjustment, and wheel bearing maintenance.
Bodywork:
Fenders, fuel tank, seat, handlebars, and trim component removal and installation.
Controls:
Throttle cables, clutch cable, brake levers, shifter linkage, and control lever adjustments.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication, brake fluid replacement, tire pressure checks, belt tension checks.
Repair:
Complete disassembly and reassembly procedures for all major components, including engine rebuilds, transmission overhauls, and electrical system repairs.
Troubleshooting:
Step-by-step diagnostic guides for common and uncommon issues, fault code lookup, and resolution strategies.
Installation:
Procedures for installing genuine Harley-Davidson parts and accessories.
Diagnostics:
Detailed diagnostic trees, symptom-based troubleshooting, use of Harley-Davidson diagnostic tools (e.g., Digital Technician), and interpretation of diagnostic trouble codes (DTCs).
Wheel Assembly And Alignment:
Procedures for wheel removal, installation, tire mounting, balancing, and spoke tension adjustment (if applicable to wheel type).
Depth:
Comprehensive from basic maintenance to full engine and transmission rebuilds, including detailed torque specifications, clearances, and diagnostic procedures.
Torque Specifications:
Precise torque values for all fasteners, ensuring correct assembly and preventing component damage.
Clearances And Tolerances:
Specifications for piston-to-cylinder wall clearance, ring end gap, valve lash (if applicable to engine design), bearing clearances, and more.
Engine Type:
Air-cooled, Twin Cam 103 V-Twin
Displacement:
1690 cc (103 cubic inches)
Bore X Stroke:
3.875 in. x 4.38 in. (98.4 mm x 111.1 mm)
Valve Train:
Pushrod actuated, overhead valves with two valves per cylinder
Cooling System:
Air-cooled
Engine Oil Type Specification:
Meets Harley-Davidson Engine Oil Specification: H-D 360 SAE 20W-50, or Harley-Davidson Genuine V-Twin Synthetic SAE 20W-50.
Torque:
Approximately 98 ft-lbs @ 3,500 RPM (manufacturer data may vary)
Horsepower:
Not officially published by Harley-Davidson, typically estimated around 70-80 HP at the crankshaft.
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane
Fuel Capacity:
5.0 gal (18.9 L)
Oil Change Interval:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first. Refer to the specific manual for detailed procedures and oil specifications.
Primary Chain Tension:
Check and adjust every 10,000 miles (16,000 km).
Spark Plug Replacement:
Typically recommended every 10,000-20,000 miles (16,000-32,000 km), depending on usage and spark plug type.
Engine Oil:
Harley-Davidson Genuine V-Twin 20W-50 Synthetic (or equivalent meeting Harley-Davidson specification).
Primary Chain Case Oil:
Harley-Davidson Genuine Primary Chain Case Oil or Harley-Davidson Syn3 Full Synthetic Transmission, Primary Drive, and Engine Oil.
Transmission Fluid:
Harley-Davidson Genuine Formula + Transmission, Primary Drive, and Engine Oil (or equivalent meeting Harley-Davidson specification).
Fork Oil:
Refer to manual for specific type and viscosity (e.g., Harley-Davidson Spectro Big Twin Fork Oil).
Common Issues:
Some owners report potential issues with clutch slave cylinder leaks, charging system components (stator/regulator), and occasional oil leaks from the primary or transmission seals. Proper maintenance as outlined in the manual is key to mitigating these.
Engine Oil Capacity:
Approximately 4.0 US quarts (3.8 L) with filter change.
Primary Chain Case Capacity:
Approximately 1.0 US quart (0.95 L).
Transmission Capacity:
Approximately 2.8 US pints (1.3 L).