Market Segment:
Premium Grand American Touring Motorcycles
Target Audience:
Owners and professional mechanics focused on maintaining and repairing Harley-Davidson Touring motorcycles
Key Competitors:
Indian Motorcycles, BMW R-series, Honda Gold Wing
Manual Focus:
Detailed repair procedures, extensive troubleshooting, factory specifications
Utility:
Essential resource for diagnosing and rectifying issues, performing scheduled maintenance, and undertaking complex repairs.
Engine:
Twin Cam 96 engine overhaul, disassembly, assembly, diagnostics, tuning
Transmission:
6-speed Cruise Drive transmission service, repair, and overhaul
Clutch:
Hydraulic clutch system inspection, service, and replacement
Fuel System:
Fuel injection (EFI) system diagnostics, components, throttle body, injectors, fuel pump
Ignition System:
Ignition system components, troubleshooting, spark plugs
Electrical System:
Wiring diagrams, lighting, charging system (alternator, regulator), starting system (starter, battery), instrumentation, security system
Suspension:
Front fork service (oil change, seal replacement), rear shock absorber inspection and replacement
Brakes:
Front and rear brake system service, hydraulic lines, calipers, master cylinders, brake fluid specifications and bleeding procedures
Wheels And Tires:
Wheel bearing service, tire mounting and balancing, tire pressure recommendations
Chassis And Frame:
Frame inspection, steering head bearing service
Bodywork And Trim:
Fairing removal and installation, saddlebag service, body panel repair and replacement
Heating And Cooling:
Engine oil cooling, ambient temperature considerations
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, brake fluid flushes, lubrication points
Troubleshooting:
Diagnostic charts and procedures for common issues, fault code interpretation (if applicable via diagnostic tools)
Repair:
Step-by-step repair procedures for all major and minor components
Overhaul:
Complete engine and transmission overhaul instructions
Diagnostics:
Component testing and diagnostic procedures for electrical and mechanical systems
Wiring Diagrams:
Detailed, color-coded wiring schematics for all model variations
Depth:
Comprehensive, suitable for professional technicians and advanced DIY mechanics. Covers everything from basic adjustments to complete engine rebuilds.
Engine Type:
Air-cooled, Twin Cam 96
Displacement:
96 cubic inches (1584 cc)
Bore X Stroke:
3.75 in. x 4.38 in. (95.3 mm x 111.3 mm)
Valve Train:
Pushrod-actuated overhead valves with hydraulic lifters
Fuel System:
Electronic Sequential Port Fuel Injection (ESPFI)
Torque:
Approx. 92.6 ft-lbs @ 3500 RPM (may vary slightly by model)
Horsepower:
Not officially stated by H-D in a single figure, but performance metrics focus on torque
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Engine Oil Capacity:
Approx. 4 quarts (3.8 liters) with filter change
Transmission Oil Capacity:
Approx. 1 quart (0.95 liters)
Primary Chain Case Oil Capacity:
Approx. 1 quart (0.95 liters)
Transmission Type:
6-speed Cruise Drive
Gear Ratios:
Specific gear ratios detailed in manual for each gear
Transmission Fluid:
Harley-Davidson Transmission Fluid, or equivalent API GL-5, SAE 85W-140 gear oil
Primary Chain Case Fluid:
Harley-Davidson Primary Chaincase Lubricant, or equivalent SAE 20W-50 motorcycle oil (check manual for specific viscosity and specification)
Safety Certification:
DOT, EPA, CARB compliance as applicable
Brakes:
Dual front disc brakes, Single rear disc brake with hydraulic actuation.
Lighting:
Halogen headlamp, auxiliary passing lamps (model dependent), LED tail lamp and turn signals
Chassis Design:
Robust steel frame and swingarm for stability
Audio System:
AM/FM/WB stereo with CB and passenger intercom, CD player (model dependent), auxiliary input for MP3 players.
Display:
Integrated display for radio, navigation (optional), and vehicle information.
Cruise Control:
Electronic cruise control standard on most Touring models.
Data Port:
Diagnostic port for accessing vehicle data and tuning (requires specific Harley-Davidson diagnostic tools like SERT or similar).
Initial Service:
First service typically at 1,000 miles (1600 km)
Regular Maintenance:
Intervals for oil changes, transmission service, and primary chaincase service are typically every 5,000 miles (8,000 km) or annually, whichever comes first (refer to manual for specifics).
Brake Fluid Flush:
Recommended every 2 years
Engine Oil Type:
Harley-Davidson SYN3 Full Synthetic Motorcycle Oil (SAE 20W-50) or equivalent V-Twin specific 20W-50 API CI-4 or higher oil.
Common Wear Items:
Clutch plates, brake pads, wheel bearings, fork seals.
Potential Concerns 2009:
Some models may experience issues with charging systems (stators/regulators), or minor electrical gremlins, particularly related to sensor failures. Proper maintenance of the battery and connections is crucial.
Fuel System Maintenance:
Ensuring clean fuel and regular injector cleaning can prevent performance issues.
Brand Origin:
Founded in 1903 in Milwaukee, Wisconsin, USA
Brand Reputation:
Iconic American motorcycle manufacturer known for its V-twin engines, touring comfort, and customization.
Touring Lineage:
The Touring line has evolved from early models like the FL models, continually refining comfort, capacity, and performance for long-distance travel.
Twin Cam Introduction:
The Twin Cam engine platform was introduced in 1999, becoming the dominant engine for Harley-Davidson's large motorcycles, including the Touring models.
Manufacturing Location:
Primarily York, Pennsylvania, USA, and Milwaukee, Wisconsin, USA
