Engine:
Twin Cam 88B, Twin Cam 95 (if applicable to specific FLST/FXST variants in 2004), engine disassembly, assembly, troubleshooting, performance tuning, internal components (pistons, rings, valves, camshafts, crankshaft, oil pump), cooling system (air-cooled with oil cooling components)
Fuel System:
Carbureted fuel systems (Keihin CV 40mm carburetor), fuel injection (if applicable to specific models), fuel pump, fuel lines, fuel filter, throttle controls, diagnostics
Ignition System:
Electronic ignition, spark plugs, ignition coils, ignition module, timing, troubleshooting
Transmission:
5-speed constant mesh transmission (4-speed for earlier models if variants exist), clutch assembly, primary drive, secondary drive (belt drive), gearbox disassembly, assembly, lubrication, troubleshooting
Electrical System:
Battery, charging system (stator, regulator/rectifier), lighting (headlight, taillight, turn signals), instrumentation, starter system, wiring diagrams, fuses, relays, diagnostic codes
Brakes:
Front and rear hydraulic disc brakes, brake calipers, master cylinders, brake lines, brake pads, brake fluid specifications, bleeding procedures, troubleshooting
Suspension:
Front fork (telescopic), rear shock absorbers, suspension adjustments, fork oil specifications, seal replacement, rebuilding procedures
Frame And Body:
Frame construction, bodywork components, fenders, fuel tank, seat, handlebars, controls, mounting hardware, painting and finishing
Wheels And Tires:
Wheel types (spoked, cast), bearings, tire specifications, pressure recommendations, balancing, replacement
Routine Maintenance:
Oil changes, filter replacement, air filter cleaning/replacement, chain adjustment (if applicable), brake checks, tire pressure checks, lubrication points
Major Repairs:
Engine rebuilds, transmission overhauls, clutch replacement, fork seal replacement, brake system overhauls, electrical system troubleshooting and repair
Troubleshooting:
Detailed diagnostic procedures for all major systems, common problem identification and solutions
Special Tools:
Identification and usage of specialized tools required for specific repair and maintenance procedures
Torque Specifications:
Precise torque values for all critical fasteners and components
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including detailed troubleshooting guides and diagnostic procedures.
Engine Family:
Harley-Davidson Twin Cam
Displacement Options:
88 cubic inches (1450cc) and 95 cubic inches (1550cc) for CVO models or those with factory upgrades.
Configuration:
Air-cooled, V-twin, pushrod-actuated overhead valves
Bore X Stroke 88Ci:
3.75 in. x 4.00 in. (95.25 mm x 101.60 mm)
Bore X Stroke 95Ci:
3.75 in. x 4.25 in. (95.25 mm x 107.95 mm) (typical)
Compression Ratio 88Ci:
Approximately 8.8:1
Compression Ratio 95Ci:
Approximately 9.0:1 or higher (depending on variant)
Horsepower 88Ci:
Approximately 65-70 HP (estimated at crank)
Torque 88Ci:
Approximately 75-80 lb-ft @ 3200 RPM (estimated at crank)
Carburetor Type:
Keihin CV 40mm (Constant Velocity)
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended
Oil Capacity:
Approximately 4 US quarts (3.8 Liters) for Twin Cam 88B/95, check specific model for exact capacity
Oil Type Recommendation:
Harley-Davidson Syn3 (20W-50) or equivalent API CI-4 or higher rated diesel engine oil (15W-40) or motorcycle-specific 20W-50
Instrumentation:
Analog speedometer, tachometer (optional on some models), odometer, trip meter, fuel gauge (tank mounted), indicator lights (oil pressure, battery, neutral, turn signals, high beam).
ABS:
Anti-lock Braking System (ABS) was not standard equipment on most 2004 Softail models. Manual will cover brake system diagnostics without ABS.
Diagnostic Ports:
Proprietary diagnostic connector for electronic troubleshooting using the Harley-Davidson Digital Technician tool (or equivalent aftermarket scan tool).
First Service:
1000 miles (1600 km) or 6 months, whichever comes first.
Subsequent Service:
Every 5000 miles (8000 km) or 12 months, whichever comes first. Engine oil and filter change every 2500 miles (4000 km) or 6 months is recommended by many owners/technicians for optimal engine life.
Engine Oil:
Harley-Davidson Syn3 (20W-50) or equivalent API CI-4 or higher rated diesel engine oil (15W-40) or motorcycle-specific 20W-50.
Transmission Oil:
Harley-Davidson transmission oil or equivalent API GL-4, 75W-90 gear oil.
Brake Fluid:
DOT 4 brake fluid (DOT 5 silicone fluid for older models, verify with manual if system was ever converted).
Primary Chain Case Oil:
Harley-Davidson Primary Chain Lubricant or equivalent motorcycle primary lubricant. Capacity approx. 24-26 oz (0.71-0.77 L).
Crankshaft Runout:
Early Twin Cam engines could be susceptible to crankshaft runout issues if not properly manufactured or maintained; the manual will detail checks and potential fixes.
Cam Chain Tensioner:
The hydraulic cam chain tensioners can wear over time, requiring inspection and replacement. Manual will provide procedure.
Oil Leaks:
Common areas for oil leaks include primary cover gasket, derby cover, and crankcase seals. Manual details seal replacement procedures.
