Engine Mechanical:
Engine overhaul, top end, bottom end, cylinders, pistons, crankshaft, camshafts, valve train
Fuel System:
Carburetor (Keihin CV) tuning and overhaul, fuel pump, fuel lines, fuel tank maintenance
Ignition System:
Ignition module, coil, spark plugs, wiring diagrams
Transmission:
5-speed Cruise Drive transmission service, clutch, primary drive, gearbox overhaul
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator), starting system (starter motor), lighting, instrumentation, switches, relays
Braking System:
Front and rear brake caliper service, master cylinders, brake lines, brake fluid changes, disc inspection
Suspension:
Front fork (39mm Conventional) overhaul, fork oil change, rear shock absorber service, swingarm and bearings
Wheels And Tires:
Wheel bearing replacement, tire mounting and balancing, spoke tensioning (if applicable)
Frame And Bodywork:
Frame inspection, fender removal/installation, fuel tank mounting, seat removal, handlebars, control levers
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, lubrication points, spark plug checks
Troubleshooting:
Diagnostic charts for common running issues, electrical faults, and mechanical problems
Rebuilds:
Complete engine and transmission rebuild procedures
Tune Ups:
Carburetor tuning, ignition timing checks, idle speed adjustment
Wiring Diagrams:
Detailed electrical schematics for all systems
Chassis Components:
Steering head, swingarm pivot, wheel bearings, final drive sprocket installation/removal
Fuel System Repair:
Carburetor cleaning, rebuilding, jetting, fuel tank sealing and cleaning
Exhaust System:
Exhaust pipe and muffler replacement, gasket inspection and replacement
Instrumentation And Controls:
Speedometer, tachometer, indicator lights, handlebar controls, cables, levers
Depth Level:
Comprehensive (from basic maintenance to full engine rebuilds and advanced diagnostics)
Diagnostic Codes:
Information on interpreting diagnostic codes and troubleshooting procedures.
Special Tools:
Lists and descriptions of necessary special tools for specific repair procedures.
Engine Type:
Air-cooled, Evolution (V-Twin)
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.50 in x 4.47 in (88.9 mm x 113.5 mm)
Valvetrain:
Overhead valve (OHV), 2 valves per cylinder
Horsepower:
~60 HP @ 5200 RPM (estimated, varies by model/tuning)
Torque:
~73 lb-ft @ 3200 RPM (estimated, varies by model/tuning)
Fuel Delivery:
Keihin 38mm CV (Constant Velocity) carburetor
Fuel Type:
Unleaded premium gasoline (91 octane or higher recommended)
Type:
5-speed manual, constant mesh
Primary Drive:
Duplex chain, 34/46 ratio
Clutch:
Wet, multi-plate, diaphragm spring
Gear Ratios:
1st: 9.312, 2nd: 6.437, 3rd: 4.746, 4th: 3.727, 5th: 3.150 (typical ratios, may vary slightly)
Engine Oil Change:
Every 5,000 miles or 6 months, whichever comes first (refer to manual for specifics)
Transmission Oil Change:
Every 10,000 miles or 12 months
Primary Chain Case Oil Change:
Every 5,000 miles or 6 months
Spark Plug Replacement:
Every 10,000 - 15,000 miles (refer to manual for specific plug type and gap)
Engine Oil:
Harley-Davidson Genuine V-Twin 20W-50 or equivalent API SG, SF/CD approved
Transmission Oil:
Harley-Davidson Genuine Formula+ Transmission Fluid (or Syn3)
Primary Chain Case Oil:
Harley-Davidson Genuine Formula+ Transmission Fluid (or Syn3)
Fork Oil:
Slightly heavier than ATF, HD P/N 99882-82 (e.g., Spectro Heavy Duty ShockProof)
Common Wear Items:
Clutch friction plates, brake pads, wheel bearings, neck bearings, fork seals
Engine Specific Notes:
Potential for cam chain tensioner wear (especially on earlier models, though 2003 models may have updated designs), carburetor jetting sensitivity to altitude and modifications.
