Primary Coverage:
Service, Repair, Maintenance, Troubleshooting, Diagnostics
Model Variations:
All Harley-Davidson Touring models (e.g., Road King, Street Glide, Electra Glide, Road Glide, Ultra Classic)
Estimated Page Count:
1000+
Type:
Factory Service Manual / Workshop Manual
Format:
PDF (Digital Download)
Engine:
V-Twin engine service, tuning, internal components, cylinder heads, crankshaft, camshafts, oil pump, lubrication system, cooling (air-cooled design principles).
Fuel System:
Fuel injection (EFI) system diagnosis and repair, throttle body service, fuel pump, fuel lines, injectors, evaporative emissions control (EVAP).
Transmission:
Six-speed Cruise Drive transmission overhaul, clutch service, primary drive, gears, bearings, seals, lubrication.
Electrical System:
Battery, charging system (alternator, regulator), starter, ignition system, lighting, instruments, switches, wiring diagrams, diagnostics, ECM (Engine Control Module), security system.
Chassis And Suspension:
Frame inspection, front fork service (lubrication, seal replacement, disassembly), rear shock absorber replacement and adjustment, swingarm, wheel bearings, steering head bearings.
Braking System:
Brake caliper service, master cylinders, brake lines, fluid replacement and bleeding, rotor inspection and replacement, ABS (Anti-lock Braking System) troubleshooting (if equipped).
Bodywork And Trim:
Fairing removal and installation, fenders, saddlebags, tour-pak, seat service, controls, mirrors, wind screen, cosmetic repairs, detailing.
Diagnostics And Troubleshooting:
Systematic diagnostic procedures, fault code retrieval and interpretation, common problems and solutions, wiring schematic interpretation.
Maintenance:
Scheduled maintenance, oil and filter changes, spark plug replacement, air filter service, brake fluid flush, drive belt inspection and adjustment, battery maintenance.
Repair:
Complete engine rebuilds, transmission overhauls, suspension component replacement, electrical system repairs, brake system servicing, bodywork repair.
Disassembly And Reassembly:
Detailed step-by-step instructions for component removal and installation with torque specifications.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Depth:
Comprehensive, covering everything from basic rider maintenance to complete engine and transmission rebuilds, including electrical diagnostics.
Engine Family:
Twin Cam 96 (1584cc)
Engine Type:
Air-cooled, 45-degree V-twin, pushrod actuated overhead valves
Bore X Stroke:
3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)
Displacement:
96 cu. in. (1584 cc)
Horsepower:
Approx. 70-75 HP (Varies by model and tuning)
Torque:
Approx. 92-96 ft-lbs @ 3500 RPM (Varies by model and tuning)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded premium gasoline, minimum octane rating of 91
Ignition Type:
High-performance electronic ignition
Cooling Method:
Air-cooled
Oil Type:
Harley-Davidson SYN3 (Synthetic) SAE 20W-50 or approved alternatives
Oil Capacity:
Approx. 4.0 U.S. quarts (3.8 L) (with filter)
Transmission Type:
Six-speed Cruise Drive
Gear Ratios:
1st: 9.315, 2nd: 6.521, 3rd: 4.793, 4th: 3.882, 5th: 3.307, 6th: 2.790
Clutch Type:
Clutch Assist, Wet, multi-plate
Primary Drive:
Duplex chain, hydraulic tensioner
Final Drive:
Carbon fiber belt, 1.125" wide
Transmission Oil Type:
Harley-Davidson Formula+ or approved alternatives
Transmission Oil Capacity:
Approx. 2.8 U.S. quarts (2.6 L)
Length:
Varies by model, typically 98.5 - 101.0 inches (2502 - 2565 mm)
Wheelbase:
Varies by model, typically 63.5 - 64.5 inches (1613 - 1638 mm)
Ground Clearance:
Approx. 5.1 - 5.5 inches (130 - 140 mm)
Dry Weight:
Varies by model, typically 770 - 850 lbs (350 - 386 kg)
Gross Vehicle Weight Rating:
Approx. 1360 lbs (617 kg)
Audio System:
Harley-Davidson Advanced Audio System with AM/FM/WB, CB/Intercom, and optional CD player or iPod interface.
Display:
Analog gauges with a multi-function LCD display for odometer, trip meter, clock, gear indication, and diagnostic codes.
Cruise Control:
Electronic cruise control standard on many Touring models.
Diagnostics Port:
Diagnostic connector for use with Harley-Davidson Digital Technician tool for fault code reading and system analysis.
Engine Oil Change:
Every 5,000 miles or 12 months, whichever comes first.
Transmission Oil Change:
Every 10,000 miles or 24 months.
Drive Belt Inspection:
Every 5,000 miles or 12 months. Check tension and condition.
Spark Plug Replacement:
Every 10,000 - 20,000 miles (depending on plug type and usage).
Brake Fluid Flush:
Every 24 months or as needed.
Brake Fluid Type:
DOT 4 compatible (check specific model for exact requirements)
Twin Cam Oil Leaks:
Potential for leaks at primary cover, rocker boxes, and oil filter housing due to seal degradation.
Starter Solenoid:
Occasional failure of the starter solenoid leading to no-crank condition.
Cam Chain Tensioners:
Early Twin Cam models (pre-2007) used plastic cam chain tensioners that could wear out, potentially damaging the engine. 2009 models have improved hydraulic tensioners.
Cruise Control Failure:
Intermittent issues with cruise control functionality on some models, often related to wiring or switch components.
Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and touring capabilities.
Touring Lineage:
The Touring line represents Harley-Davidson's commitment to long-distance comfort and performance, evolving from early FL models to the modern Twin Cam platform.
Manufacturing Location:
York, Pennsylvania, USA and Milwaukee, Wisconsin, USA
