Model Segment:
Cruiser/Custom Motorcycle
Target Audience:
Harley-Davidson owners, independent mechanics, and enthusiasts seeking in-depth maintenance and repair knowledge.
Primary Competitors 2009:
Other Harley-Davidson Softail models, Indian Motorcycles, and select Japanese cruisers (e.g., Yamaha V-Star, Honda Shadow).
Distinctive Styling:
Blacked-out components, low-profile design, hardtail appearance with hidden rear suspension.
Engine Platform:
Harley-Davidson's reliable Twin Cam 96B engine.
Manual Value Proposition:
Provides DIY capability for maintenance and repairs, saving costs and ensuring proper upkeep of a premium motorcycle.
Engine Service And Overhaul:
Detailed procedures for Twin Cam 96B engine (1584cc), including disassembly, inspection, assembly, torque specifications, and adjustments.
Fuel System And Controls:
Fuel injection system (EFI), throttle body, fuel pump, injectors, fuel lines, and fuel tank servicing.
Transmission And Drivetrain:
Six-speed Cruise Drive transmission, clutch operation, primary drive, final drive belt maintenance, and gearbox overhaul.
Suspension And Steering:
Front fork (39mm telescopic) service, rear shock absorber replacement, swingarm service, and steering head bearing maintenance.
Brake System:
Front and rear brake calipers, master cylinders, brake lines, pads, rotor inspection, and bleeding procedures.
Electrical System:
Wiring diagrams, ignition system, starting system, charging system (alternator/stator, regulator/rectifier), lighting, and accessory wiring.
Bodywork And Frame:
Fender removal/installation, fuel tank mounting, seat adjustments, chassis inspection, and frame specifications.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, and general inspection points.
Troubleshooting Guides:
Diagnostic charts and step-by-step procedures for common issues related to starting, running, electrical faults, and braking.
Major Component Rebuilds:
Detailed instructions for engine, transmission, and brake caliper overhauls and rebuilds.
Suspension Tuning And Repair:
Front fork seal replacement, oil changes, and rear shock absorber adjustments or replacements.
Electrical Diagnostics And Repair:
Fault finding for ignition, charging, lighting, and accessory circuits with wiring schematics.
Depth Of Coverage:
Comprehensive, covering routine maintenance, diagnostics, component-level repair, and complete unit overhauls.
Diagnostic Capabilities:
Includes troubleshooting flowcharts and symptom-based diagnostics.
Special Tools:
Lists required Harley-Davidson specialty tools for specific procedures.
Engine Type:
Air-cooled, Twin Cam 96B
Displacement:
1584 cc (96.7 cubic inches)
Bore X Stroke:
95.25 mm x 111.25 mm (3.75 in x 4.38 in)
Valve Train:
Overhead valves (OHV), 2 valves per cylinder
Horsepower Est:
Approx. 70-75 HP (at crankshaft, unconfirmed factory spec)
Torque Est:
Approx. 88-90 ft-lbs (at crankshaft, unconfirmed factory spec)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Premium unleaded gasoline
Oil Type:
Harley-Davidson 20W-50 SYN3 Synthetic Motorcycle Oil recommended, or equivalent API SG or higher.
Engine Oil Capacity:
3.0 US qt (2.8 L)
Transmission Type:
6-speed Cruise Drive
Gear Ratios:
1st: 9.31, 2nd: 6.45, 3rd: 4.77, 4th: 3.77, 5th: 3.24, 6th: 2.79
Optional Transmissions:
N/A for this model year and trim.
Primary Drive:
Plated, off-center, helical cut, single row chain
Final Drive:
Carbon belt, 1.00 ratio
Transmission Oil Type:
Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant, or equivalent.
Transmission Oil Capacity:
1 US qt (0.95 L)
Crash Test Ratings:
N/A (Motorcycles typically do not undergo formal crash test ratings like cars.)
Braking System:
Dual-action, four-piston front caliper, two-piston rear caliper with floating rotor.
Lighting:
Halogen headlamp, LED taillight, incandescent front/rear turn signals.
Chassis Construction:
Steel frame and swingarm.
Operator Control:
Handlebar controls for throttle, brakes, clutch, and indicators.
Initial Service:
1000 miles (1600 km) or 6 months, whichever comes first.
Subsequent Service:
Every 5000 miles (8000 km) or 12 months, whichever comes first.
Brake Fluid Flush:
Recommended every 2 years, regardless of mileage.
Drive Belt Tension Check:
Check at every 5000-mile service.
Primary Chaincase Oil:
Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant
Brake Fluid:
DOT 4 (refer to specific manual chapter for exact type/color code)
Fork Oil:
Harley-Davidson Genuine Formula 20W (or equivalent spec like Spectro Big Twin Fork Oil)
Common Wear Items:
Clutch plates, brake pads, tires, wheel bearings, steering head bearings.
Potential Electrical Faults:
Issues with stator, regulator/rectifier, or wiring harness connections due to vibration and heat.
Fuel System Considerations:
Occasional throttle position sensor (TPS) issues or injector clogging if fuel is not kept fresh.
Transmission Noise:
Some Twin Cam transmissions can exhibit characteristic mechanical noise; this manual will help differentiate normal from problematic sounds.
Harley Davidson Founding:
Founded in 1903, Milwaukee, Wisconsin.
Brand Philosophy:
Emphasizes American craftsmanship, V-twin engines, and a distinct riding culture.
Softail Lineage:
The Softail platform, introduced in 1984, is known for its hidden rear suspension mimicking a rigid frame, offering a classic look with modern ride comfort.
Fxstb Introduction:
The Night Train variant was introduced to cater to a darker, more custom aesthetic, often featuring blacked-out components and a sleek profile.
Production Years Fxstb:
2000-2011 (with variations in styling and engines)
Manufacturing Location:
United States (various Harley-Davidson facilities)
