Engine:
Detailed coverage of the Twin Cam 88 engine, including assembly, disassembly, inspection, and troubleshooting.
Fuel System:
Injection system (EFI), fuel pump, fuel filter, fuel lines, fuel tank maintenance and troubleshooting.
Ignition System:
Ignition module, spark plugs, ignition coils, timing, troubleshooting ignition faults.
Transmission:
5-speed constant mesh transmission, clutch operation, gear engagement, lubrication, and repair.
Drivetrain:
Primary drive, final drive belt, belt tension, sprocket inspection, and replacement.
Brakes:
Front and rear hydraulic brake systems, brake caliper service, master cylinder, brake pads, brake fluid specifications, bleeding procedures.
Suspension:
Front fork (telescopic), rear shock absorbers, fork oil specifications, seal replacement, preload adjustment.
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator), lighting, horn, starter motor, switches, circuit protection (fuses, breakers).
Chassis And Frame:
Frame inspection, steering head bearing service, wheel bearings, swingarm pivot, and general chassis maintenance.
Bodywork And Trim:
Fender removal/installation, fuel tank mounting, seat service, electrical component access, cosmetic trim.
Wheels And Tires:
Tire inspection, tire pressures, wheel removal/installation, balancing, and general tire care.
Scheduled Maintenance:
Detailed schedules for oil changes, filter replacements, spark plug checks, and other routine servicing.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults across all major vehicle systems.
Engine Rebuild:
Comprehensive instructions for engine disassembly, inspection of components (pistons, rings, cylinders, valves), and reassembly.
Transmission Overhaul:
Detailed steps for transmission disassembly, gear inspection, bearing replacement, and reassembly.
Electrical Diagnostics:
Using wiring diagrams to trace faults, test electrical components, and diagnose electrical system issues.
Brake System Service:
Brake pad replacement, caliper servicing, rotor inspection, and brake fluid flushing/bleeding.
Suspension Adjustment And Repair:
Fork seal replacement, shock absorber servicing, and steering head bearing adjustments.
Fuel System Cleaning And Testing:
Fuel injector cleaning, fuel pressure testing, and fuel line checks.
Wheel And Tire Mounting:
Proper procedures for tire mounting and balancing.
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including in-depth electrical diagnostics and troubleshooting.
Engine Type:
Air-cooled, Twin Cam 88 V-Twin
Displacement:
1450 cc (88 cubic inches)
Bore X Stroke:
3.75 in x 4.00 in (95.25 mm x 101.6 mm)
Valvetrain:
Overhead valve (OHV), 2 valves per cylinder, pushrod actuated.
Horsepower Approx:
Approximately 65-70 HP (peak horsepower figures vary and are often not officially stated by Harley-Davidson in owner's manuals, but service manuals will provide diagnostic ranges).
Torque Approx:
Approximately 75-80 ft-lbs at 3000 RPM.
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first (engine oil and filter).
Primary Chain Tensioner Check:
Inspect and adjust primary chain tensioner at 1,000 miles and every 5,000 miles thereafter. Crucial for longevity of the compensator and transmission.
Spark Plug Inspection:
Inspect at 10,000 miles. Replace as needed.
Brake Fluid Flush:
Every 2 years or as per manual recommendation.
Engine Oil Type:
Harley-Davidson SYN3 (Synthetic) or a high-quality SAE 20W-50 motorcycle oil meeting Harley-Davidson specifications.
Engine Oil Capacity:
Approximately 4 quarts (3.8 liters) with filter change.
Primary Chain Case Fluid Type:
Harley-Davidson Formula Plus (or equivalent SAE 50 motorcycle specific transmission oil)
Primary Chain Case Fluid Capacity:
Approximately 2.5 pints (1.2 liters).
Brake Fluid Type:
DOT 4 (per Harley-Davidson specifications for 2006 models).
Primary Chain Tensioner:
The automatic primary chain tensioner used in this era could wear, leading to noise and potential damage. Manual inspection and replacement with upgraded components is common.
Cam Chain Tensioners:
The cam chain tensioners (internal to the engine) are wear items and a known issue, particularly on earlier Twin Cam engines. Inspection and replacement with hydraulic tensioners is a common upgrade.
Idle Speed Control:
EFI models can sometimes exhibit rough idling or stalling, potentially related to throttle body cleanliness or idle air control passages.