Engine Mechanical:
Engine disassembly, assembly, diagnostics, troubleshooting, performance tuning, lubrication, cooling systems (air-cooled)
Fuel System:
Fuel injection (EFI), carburetors (where applicable for specific models), fuel pumps, fuel lines, evaporative emissions control
Ignition System:
Ignition modules, spark plugs, ignition coils, wiring, timing
Transmission:
Clutch, primary drive, transmission gears, shifter linkage, lubrication, troubleshooting
Drivetrain:
Belt drive systems, final drive belts, pulleys, bearings
Suspension:
Front fork (telescopic, cartridge type), rear shock absorbers, adjustments, rebuild procedures
Brakes:
Hydraulic brake systems (front and rear), brake calipers, master cylinders, brake lines, brake fluid specifications, bleeding procedures, ABS (Anti-lock Braking System) diagnostics and service
Electrical System:
Battery, charging system (alternator, regulator), starter motor, lighting (headlights, taillights, turn signals), instrumentation, fuses, relays, wiring diagrams, diagnostics
Chassis And Frame:
Frame inspection, steering head bearings, swingarm, wheel bearings, alignment
Bodywork And Fittings:
Fairings, saddlebags, seat assembly, fuel tank, fenders, trim components, removal and installation
Routine Maintenance:
Oil changes, filter replacements, tire pressure checks, chain/belt tension, brake inspection, fluid level checks
Scheduled Maintenance:
Detailed service intervals for all major components
Troubleshooting:
Diagnostic flowcharts and common problem resolution for all systems
Repair Procedures:
Step-by-step instructions for disassembly, repair, and reassembly of all components
Diagnostic Procedures:
Using Harley-Davidson diagnostic tools (e.g., Digital Technician), fault code interpretation
Electrical Diagnostics:
Detailed wiring diagrams, component testing, and troubleshooting for all electrical circuits.
Depth:
Comprehensive: Covers everything from basic maintenance to full engine rebuilds and electrical system diagnostics
Detail Level:
Mechanic-grade detail, including torque specifications, special tool requirements, and service limits
Special Tools:
Lists and describes necessary special tools for specific repair and diagnostic procedures.
Engine Family:
Twin Cam 96 (1584cc)
Engine Displacement:
1584 cc (96 cubic inches)
Engine Configuration:
Air-cooled V-twin
Bore X Stroke:
3.75 in x 4.38 in (95.25 mm x 111.25 mm)
Compression Ratio:
8.9:1 (typical)
Fuel System:
Electronic Sequential Port Fuel Injection (ESPFI)
Horsepower Estimate:
Approximately 70-75 HP (at crankshaft, model dependent)
Torque Estimate:
Approximately 90-95 ft-lbs @ 3500 RPM (at crankshaft, model dependent)
Cooling Method:
Air-cooled
Valvetrain Type:
Overhead valves (OHV), 2 valves per cylinder
Lubrication System:
Dry sump oiling system with remote oil reservoir.
Wheelbase:
Approx. 63.5 - 64.5 inches (1613 - 1638 mm), model dependent
Seat Height:
Approx. 27.1 - 28.2 inches (688 - 716 mm), unladen, model dependent
Dry Weight:
Approx. 768 - 818 lbs (348 - 371 kg), model dependent
Gross Vehicle Weight Rating Gvwr:
Approx. 1260 lbs (572 kg)
Saddlebag Capacity:
Integrated hard saddlebags with substantial storage capacity
Engine Oil Change:
Every 5,000 miles or annually. Manual specifies exact procedure and oil type.
Primary Chain Tension:
Check and adjust every 10,000 miles. Manual provides specifications.
Wheel Bearings:
Inspect every 20,000 miles, lubricate as needed. Manual details procedures.
Engine Oil:
Harley-Davidson 20W-50 SYN3 (or equivalent API SG or higher, JASO FD compliant).
Primary Chain Case Oil:
Harley-Davidson Formula + (or equivalent SE/CD SAE 50 type lubricant).
Transmission Oil:
Harley-Davidson Formula + (or equivalent SE/CD SAE 50 type lubricant).
Brake Fluid:
DOT 4 (for models equipped with ABS and standard).
Cam Chain Tensioners:
Early Twin Cam models experienced wear on hydraulic tensioners. Manual provides inspection and upgrade procedures.
Crankshaft Position Sensor:
Potential failure leading to starting or running issues. Manual covers testing and replacement.
Fuel Injector O-Rings:
Potential for leaks leading to performance issues. Manual covers inspection and replacement.
Engine Oil Capacity:
Approximately 4 quarts (3.8 L) with filter change. Manual provides exact capacity.
Primary Chain Case Capacity:
Approximately 1 quart (0.95 L). Manual provides exact capacity.
Transmission Capacity:
Approximately 2.6 quarts (2.5 L). Manual provides exact capacity.
Brand Legacy:
Harley-Davidson boasts a rich heritage dating back to 1903, synonymous with American motorcycle culture, customization, and touring.
Touring Line Introduction:
The Touring platform has evolved significantly over decades, designed for comfort, long-distance travel, and carrying luggage, becoming a flagship segment for the brand.
Manufacturing Location:
Primarily manufactured in York, Pennsylvania, USA.
