🏷️ Basic Information

Make:

Harley-Davidson

Model:

Softail

Year:

2008-2010

Product Type:

Repair Service Manual

👋 Introduction

Positioning:

The Harley-Davidson Softail line represents a significant segment of the cruiser motorcycle market, known for its classic styling, V-twin engine heritage, and rider comfort. This manual serves the owners and technicians working on these iconic machines.

Comparison:

In the 2008-2010 model years, the Softail competed against other large-displacement cruisers from manufacturers like Indian, Victory, and some Japanese brands offering similar styling and engine configurations. Harley-Davidson's brand loyalty and distinct V-twin character are key differentiators.

Model Features:

Softail models from this era are characterized by their rigid frame appearance, concealed rear suspension, prominent V-twin engines, and a wide array of customization options. Key models within the Softail family include the Fat Boy, Heritage Softail Classic, Night Train, and Rocker.

Value Proposition:

This comprehensive service manual provides the essential technical information required for maintaining, diagnosing, and repairing Harley-Davidson Softail motorcycles from 2008 to 2010, enabling owners and independent shops to perform work with factory-level precision.

📋 Manual Details

Engine Coverage:

Comprehensive coverage of all engine variants for the specified years, including Twin Cam 96 and Twin Cam 103 engines.

Transmission Coverage:

Detailed information on the 6-speed Cruise Drive transmission, including disassembly, assembly, and troubleshooting.

Chassis Coverage:

Full coverage of the Softail frame, suspension (front forks, rear shocks), wheels, tires, and steering components.

Electrical Coverage:

Extensive diagrams and troubleshooting for the entire electrical system, including ignition, lighting, charging, starting, and fuel injection systems.

Brake Coverage:

Service procedures for front and rear braking systems, including hydraulic components, pads, rotors, and bleeding procedures.

Bodywork Coverage:

Information on body panels, fenders, fuel tank, seat, and related trim components, including removal and installation.

Model Variants Covered:

Includes coverage for common Softail models such as Fat Boy, Heritage Softail Classic, Night Train, Cross Bones, Rocker, Rocker C, and custom variants utilizing the 2008-2010 platform.

Estimated Page Count:

Approximately 800-1000 pages (typical for comprehensive Harley-Davidson service manuals).

Type:

Factory-Authorized Repair Service Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Systems:

Engine teardown, assembly, piston and cylinder service, valve train, cam timing, oil pump, lubrication system, cooling system (air-cooled components), and fuel delivery.

Transmission Systems:

Clutch operation, primary drive, transmission gear engagement, shift mechanism, and final drive belt service.

Electrical Systems:

Ignition system (ignition modules, spark plugs, coils), charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), battery maintenance, lighting (headlights, taillights, turn signals), instrumentation, and accessory wiring.

Fuel Injection Systems:

EFI system components (ECU, throttle body, injectors, fuel pump, sensors), diagnostic procedures, and idle speed adjustment.

Suspension Systems:

Front fork disassembly, seal replacement, oil level and type specifications, rear shock absorber removal, installation, and adjustment.

Brake Systems:

Brake fluid specifications (DOT 4), caliper service, pad replacement, rotor inspection, and bleeding procedures.

Suspension And Steering:

Front fork servicing, rear shock absorber inspection and replacement, steering head bearing adjustment and replacement, wheel bearing service, and tire specifications.

Fuel System:

Fuel tank removal and installation, fuel pump and filter service, fuel line inspection and replacement, and fuel pressure testing.

Maintenance Procedures:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, tire pressure checks, brake pad inspection, and drive belt adjustment.

Diagnostic Procedures:

Troubleshooting guides for common problems, symptom-based diagnostics, and identification of fault codes.

Repair Procedures:

Step-by-step instructions for major component overhauls, component replacements, and system repairs.

Rebuild Procedures:

Detailed instructions for rebuilding the engine, transmission, and other key mechanical components.

Electrical Troubleshooting:

Wiring diagrams, circuit analysis, testing procedures for electrical components, and common electrical faults.

Diagnostics For Efi:

Detailed diagnostic flowcharts and testing procedures for the Electronic Fuel Injection (EFI) system, including sensors, actuators, and the Engine Control Module (ECM).

Wheel And Tire Service:

Tire mounting and balancing, wheel alignment checks, and wheel bearing maintenance.

Depth:

Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical system troubleshooting.

Torque Specifications:

Extensive list of critical torque specifications for engine, transmission, chassis, and component assembly.

Special Tools:

Identification and application of specialized Harley-Davidson tools required for specific repair and maintenance procedures.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text for easy navigation and information retrieval.

Printability:

Printable pages for workshop use.

Image Clarity:

High-resolution images, diagrams, and schematics ensuring clarity of visual information.

Binding:

N/A (Digital Format)

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

Air-cooled, 45-degree V-twin, pushrod actuated overhead valves.

Engine Displacement:

Commonly 96 cubic inches (1584cc) and 103 cubic inches (1690cc) for CVO models.

Bore X Stroke 96Ci:

3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)

Bore X Stroke 103Ci:

3.875 in. x 4.38 in. (98.4 mm x 111.25 mm)

Compression Ratio 96Ci:

9.0:1

Compression Ratio 103Ci:

9.2:1

Torque 96Ci:

Approx. 92 ft-lbs @ 3,000 RPM

Horsepower 96Ci:

Approx. 70 HP @ 5,200 RPM

Fuel System:

Electronic Sequential Port Fuel Injection (ESPFI) via Delphi Electronic Fuel Injection System.

Fuel Type:

Premium unleaded gasoline, minimum octane rating of 91.

Valve Train:

Pushrod Actuated Overhead Valves (OHV) with hydraulic lifters.

🔧 Transmission

Transmission Type:

6-speed Cruise Drive

Primary Drive:

Chain, 34/46 ratio.

Final Drive:

Belt drive, 32/66 ratio.

Gear Ratios 1-6:

1st: 9.312, 2nd: 6.420, 3rd: 4.774, 4th: 3.814, 5th: 3.145, 6th: 2.710

Clutch Type:

Hydraulic, multi-plate wet clutch.

📐 Dimensions

Length Overall:

Varies by model, e.g., Fat Boy ~94.5 inches (2400 mm).

Wheelbase:

Varies by model, e.g., ~64.5 inches (1638 mm).

Dry Weight:

Varies by model, typically between 650-700 lbs (295-318 kg).

Gross Vehicle Weight Rating Gvwr:

Typically around 1150 lbs (522 kg).

Fuel Capacity:

Typically 5.0 US gallons (19 L).

🛡️ Safety Features

Crash Safety:

Motorcycles are not subjected to the same crash testing regimes as automobiles. Safety is primarily dependent on rider skill, protective gear, and vehicle design integrity.

Braking System:

Dual-piston front and rear brake calipers with hydraulic actuation. ABS was an optional feature on some models during this period.

Lighting:

Halogen headlights, LED taillights and brake lights, and amber incandescent turn signals.

Frame Construction:

Steel, tubular frame with a concealed rear suspension system designed to mimic a hardtail look while providing ride comfort.

💡 Technology Features

Audio System:

Optional premium audio systems were available on some touring-oriented Softail models, featuring AM/FM radio, CD player, and auxiliary input. Communication systems like CB radios and intercoms were also available accessories.

ABS:

Anti-lock Braking System (ABS) was an optional safety feature for select models and model years, providing enhanced control during braking.

Diagnostic Ports:

On-board diagnostics through proprietary interfaces allowing for access to engine control module (ECM) data, fault codes, and sensor readings.

Gauge Cluster:

Includes speedometer, tachometer (on some models), fuel gauge, voltage meter, oil pressure indicator, and various warning lights.

🔧 Maintenance

First Service:

Initial service typically at 1,000 miles (1,600 km) or 6 months, including engine oil and filter change, primary chain case oil change, and inspection of all critical components.

Subsequent Oil Change:

Engine oil and filter change every 5,000 miles (8,000 km) or annually, whichever comes first. Primary chain case oil change every 10,000 miles (16,000 km).

Spark Plug Replacement:

Every 10,000 miles (16,000 km) or as needed based on inspection.

Drive Belt Inspection:

Inspect at every 5,000 mile service for wear and proper tension. Adjustments as per manual specifications.

Engine Oil:

Harley-Davidson Genuine V-Twin 20W-50 Synthetic or equivalent meeting Harley-Davidson P/N 99816-09.

Primary Chain Case Oil:

Harley-Davidson Genuine Primary Chain Lubricant or equivalent meeting P/N 99879-91.

Transmission Oil:

Harley-Davidson Genuine Formula+ Transmission & Primary Chain Case Lubricant or equivalent meeting P/N 99879-91.

Brake Fluid:

DOT 4 Synthetic Brake Fluid.

Fork Oil:

Harley-Davidson suspension fluid or equivalent, specific viscosity and quantity per model variant as detailed in the manual.

Common Wear Items:

Clutch plates, brake pads, fork seals, drive belt, and wheel bearings are typical wear items requiring periodic inspection and replacement.

Electrical Concerns:

Wiring harness chafing, regulator/rectifier failures, and starter solenoid issues have been noted on some models of this era. Proper diagnostic procedures are crucial.

Engine Performance Notes:

Some models may benefit from engine tuning upgrades to optimize performance, especially if exhaust or air intake modifications are made. This manual covers stock configurations and diagnostic paths for performance anomalies.

📚 Vehicle History

Brand Origin:

Harley-Davidson, founded in Milwaukee, Wisconsin in 1903, is one of the oldest motorcycle manufacturers in the world, renowned for its V-twin engines and iconic American cruiser style.

Softail Introduction:

The Softail platform was introduced in 1983, designed by Bill Davis, featuring a hidden rear shock absorber system that mimicked the look of rigid frames from earlier eras while providing a more comfortable ride. The line has undergone continuous development since its inception.

Manufacturing Location:

Harley-Davidson motorcycles for these model years were primarily manufactured in the United States (e.g., York, Pennsylvania and Kansas City, Missouri).

🏆 Awards & Recognition

Motorcycle Awards:

While specific awards for individual model years are varied, the Harley-Davidson Softail line is consistently recognized for its styling, rider experience, and enduring appeal in the cruiser motorcycle segment. Harley-Davidson as a brand has received numerous accolades for manufacturing quality and brand heritage.