Engine:
Complete engine overhaul, troubleshooting, diagnostics, performance tuning, internal components (pistons, cylinders, crankshaft, camshafts, valves, timing, oil pump, etc.)
Transmission:
Service and repair of the transmission (e.g., 6-speed Cruise Drive), clutch, primary drive, secondary belt drive system.
Fuel System:
Fuel injection system (EFI - likely Delphi or Magneti Marelli for this era), fuel pump, injectors, throttle body, sensors, fuel tank, lines.
Ignition System:
Ignition module, spark plugs, coils, wiring, troubleshooting ignition faults.
Electrical System:
Comprehensive coverage of the motorcycle's electrical system, including battery, charging system (stator, regulator/rectifier), starter system, lighting (headlight, taillight, turn signals), instruments, switches, and accessory circuits.
Chassis:
Frame, swingarm, forks, triple clamps, steering head bearings, wheel bearings, suspension components (front and rear), brake system (master cylinders, calipers, rotors, lines, bleeding), wheel and tire service.
Bodywork:
Fenders, fuel tank, seat, fairings (if applicable to FXSTC), fenders, console, chrome parts, mounting hardware, removal and installation procedures.
Diagnostics:
Diagnostic trouble codes (DTCs), troubleshooting charts, fault finding procedures for various systems.
Routine Maintenance:
Oil changes, filter replacement, air filter service, spark plug replacement, drive belt inspection and adjustment, brake fluid changes, tire pressure checks, lubrication points.
Major Repairs:
Engine rebuilds, transmission overhaul, clutch replacement, brake system overhauls, suspension fork rebuilds, wheel bearing replacement.
Troubleshooting:
Systematic troubleshooting guides for common and uncommon problems, diagnostic flowcharts.
Electrical Troubleshooting:
Wiring diagrams, circuit tracing, component testing, fault diagnosis for all electrical systems.
Parts Identification:
Exploded views of all major assemblies with part numbers and descriptions, crucial for ordering correct replacement parts.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics and factory specifications.
Format:
Likely PDF, optimized for digital viewing and printing. Searchable text is a high probability.
Quality:
High resolution, clear diagrams, and readable text suitable for workshop environments.
Type:
Not applicable for digital format, but if a printed version were sold, it would typically be a spiral-bound or comb-bound format for lay-flat use.
Type:
Not applicable for digital format, but for a printed manual, would be durable, possibly coated paper to withstand workshop conditions.
Engine Type:
V-Twin, 4-Stroke, Air-Cooled, OHV (Overhead Valve)
Displacement:
1584 cc (96 cubic inches)
Bore X Stroke:
3.75 in. x 4.38 in. (95.25 mm x 111.25 mm) (Typical for Twin Cam 96)
Compression Ratio:
9.2:1 (Typical for Twin Cam 96)
Horsepower:
Approximately 70-75 HP (Estimated, specific figures vary by year and tuning)
Torque:
Approximately 85-95 ft-lbs (Estimated, specific figures vary by year and tuning)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded Gasoline, minimum 91 Octane (AKI) recommended.
Oil Type:
Harley-Davidson SYN3 (SAE 20W50 Full Synthetic) or equivalent API CG-4 rated motorcycle oil.
Oil Capacity:
Approximately 4.0 US quarts (3.8 L) with filter change.
Cooling Method:
Air-cooled
Engine Family:
Twin Cam 96 (Engine code designation often HD-21505-07 for 96ci Twin Cam)
Transmission Type:
6-Speed Cruise Drive Manual Transmission
Primary Drive:
Duplex chain, hydraulic tensioner
Secondary Drive:
Carbon fiber reinforced belt
Clutch Type:
Multi-plate, wet clutch, hydraulically actuated
Transmission Fluid:
Harley-Davidson Primary Chaincase Lubricant (Formula +) or equivalent.
Transmission Fluid Capacity:
Approximately 30 US fluid ounces (0.9 L)
Safety Features:
N/A (Motorcycles typically do not have standardized crash ratings like cars. Safety focus is on braking, handling, and rider control.)
Braking System:
Hydraulically actuated front and rear disc brakes. Front: 4-piston calipers. Rear: 2-piston caliper. ABS (Anti-lock Braking System) was often an optional feature during these years for Harley-Davidson models.
Lighting:
Halogen headlight, LED taillight and brake light, incandescent turn signals (depending on market and year). Hazard warning lamps may be standard or optional.
Frame Construction:
Steel, cradle frame design with concealed rear shock absorbers for the Softail appearance.
First Service:
Typically at 1,000 miles (1,600 km) or 6 months, whichever comes first. Includes engine oil and filter change, primary chaincase oil change, chassis lubrication, inspection of brakes, tires, lights, and all fasteners.
Subsequent Services:
Scheduled every 5,000 miles (8,000 km) or 12 months. Includes engine oil and filter change, primary chaincase oil change, inspection of all systems, and adjustments as needed. Air filter service typically every 10,000 miles.
Brake Fluid Service:
Recommended every 24 months regardless of mileage, or as needed based on inspection. Use DOT 4 HD specification brake fluid.
Drive Belt Tension:
Check and adjust every 5,000 miles (8,000 km) or as specified in the manual. Proper tension is critical for belt and pulley life.
Engine Oil:
Harley-Davidson SYN3 (SAE 20W50 Full Synthetic) or equivalent API CG-4 rated motorcycle oil.
Primary Chaincase Oil:
Harley-Davidson Primary Chaincase Lubricant (Formula +) or equivalent.
Transmission Oil:
Harley-Davidson Transmission Fluid (SAE 80W-90 API GL-5) or equivalent.
Brake Fluid:
DOT 4 HD specification (non-silicone based).
Common Issues 2007-2010 Twin Cam:
Potential oil leaks from engine seals, primary chain tensioner wear (especially with the earlier spring-loaded type), starter clutch issues, some charging system components (regulator/rectifier), and catalytic converter concerns on models equipped with them. The 6-speed transmission is generally robust.
Tire Wear:
As with many cruisers, tire wear can be significant depending on riding style and tire choice. The manual will provide recommended tire pressures and maintenance.
Heritage:
Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903, known for its V-twin engines, distinctive styling, and strong rider community.
Softail Lineage:
The Softail platform, introduced in 1984, is characterized by its rigid frame appearance with horizontally mounted rear shock absorbers concealed beneath the transmission. The FXSTC (Custom) variant typically featured more elaborate styling, chrome accents, and custom paint schemes compared to standard Softail models.
Production Years:
The Softail Custom FXSTC was produced for multiple years, with this manual covering the 2007-2010 model years, which primarily featured the Twin Cam 96 engine and 6-speed transmission.
