Target Audience:
Harley-Davidson owners, independent repair shops, and motorcycle enthusiasts seeking to perform their own maintenance and repairs.
Value Proposition:
Provides expert-level guidance, enabling owners to save on dealership service costs and ensure quality of work. Crucial for maintaining peak performance and longevity of the motorcycle.
Diagnostic Tools:
Includes troubleshooting guides and diagnostic procedures, vital for identifying and resolving issues efficiently.
Technical Drawings:
Features detailed diagrams and illustrations for component identification and assembly.
Engine Mechanical:
Engine disassembly, assembly, troubleshooting, torque specifications, component identification, internal measurements.
Fuel System:
Carburetor (CV type) service, fuel injection (EFI) systems, fuel pump, fuel lines, fuel tank maintenance.
Ignition System:
Ignition module, spark plugs, ignition coils, timing adjustments, troubleshooting.
Transmission Drivetrain:
Clutch operation, primary drive, transmission gears, shifting mechanisms, final drive belt maintenance and replacement.
Brakes:
Front and rear brake system maintenance, caliper service, hydraulic lines, brake fluid specifications, bleeding procedures.
Suspension Steering:
Front fork service (air assist and standard), rear shock absorber replacement and adjustment, steering head bearing maintenance.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting, starter motor, ignition switch, fuse box.
Frame Bodywork:
Frame inspection, fairing removal and installation, saddlebag service, body panel repair and alignment.
Wheels Tires:
Wheel bearing service, tire pressure recommendations, tire replacement, wheel balancing.
Diagnostics Troubleshooting:
Diagnostic procedures for common issues, fault code interpretation (for EFI models), systematic troubleshooting guides.
Routine Maintenance:
Oil changes, filter replacement, spark plug replacement, drive belt adjustment, brake pad inspection.
Major Repairs:
Engine rebuilds, transmission overhauls, fork seal replacement, electrical system diagnostics and repair.
Component Rebuilds:
Carburetor overhaul, starter motor repair, generator/stator testing and replacement.
Installations:
Accessory installation guidance (where applicable), aftermarket part integration.
Depth:
Comprehensive; covers from basic user maintenance to full engine and transmission rebuilds, including diagnostic procedures.
Detail Level:
Detailed step-by-step instructions, torque specifications, clearances, diagnostic flowcharts, and component identification diagrams.
Engine Type:
Harley-Davidson Evolution (V-Twin) Big Twin
Displacement:
Commonly 1450cc (88 cubic inches) for this era.
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Compression Ratio:
Approximately 9.0:1
Cooling System:
Air-cooled
Valve Train:
OHV (Overhead Valve), 2 valves per cylinder
Horsepower Est:
Approximately 65-70 HP (varies by model and tuning)
Torque Est:
Approximately 85-90 lb-ft @ 3000-3500 RPM (varies by model and tuning)
Carburetor:
Keihin CV (Constant Velocity) 40mm
Fuel Injection:
Sequential Electronic Fuel Injection (ESPFI) on some models (e.g., FLHTCUI).
Type:
5-speed Manual Constant Mesh
Primary Drive:
Multi-plate wet clutch, chain drive to transmission
Gear Ratios:
Specific ratios provided within the manual for each gear. (Example: 1st Gear: 9.01:1, 2nd Gear: 6.07:1, 3rd Gear: 4.51:1, 4th Gear: 3.74:1, 5th Gear: 3.10:1 - *approximate, check manual for exact*)
Transmission Fluid Type:
Harley-Davidson SYN3 or equivalent (check manual for specific API GL-4 or GL-5 requirements).
Crash Test Data:
Motorcycles typically do not undergo standardized crash testing in the same manner as automobiles. Manual focuses on rider safety features and maintenance of safety systems.
Braking System:
Dual disc front brakes, single disc rear brake with hydraulic actuation. ABS was an option on some high-end touring models (e.g., FLHTCUI).
Lighting:
Halogen headlamp, dual rear taillamps/brake lights, turn signals.
Audio System:
Many touring models featured integrated AM/FM radio, CB radio, and intercom systems, often with handlebar-mounted controls. Some models had cassette players.
Display:
Analog gauges for speedometer, tachometer, oil pressure, voltage, and fuel level. Some models had digital readouts for odometer and trip meters.
Cruise Control:
Electronic cruise control was available on many 2000 Touring models, offering rider convenience on highways.
Diagnostic Ports:
EFI models utilize a diagnostic connector for engine diagnostics (requires specific Harley-Davidson diagnostic tools).
Initial Service:
Typically at 1,000 miles (1,600 km) for break-in service (oil change, filter, primary chain adjustment, inspection).
Regular Service:
Every 5,000 miles (8,000 km) or annually for oil changes, primary and transmission fluid checks, drive belt inspection.
Major Service:
As recommended by the manual, typically involving spark plug replacement, air filter service, brake fluid flush, and more in-depth inspections.
Engine Oil:
Harley-Davidson SYN3 (20W-50) or equivalent V-twin specific motorcycle oil meeting Harley-Davidson specifications. Capacity: approx. 4 quarts (3.8 L).
Primary Chain Case Fluid:
Harley-Davidson Primary Chaincase Lubricant or equivalent. Capacity: approx. 1 quart (0.95 L).
Transmission Fluid:
Harley-Davidson SYN3 or equivalent (see transmission section for GL rating). Capacity: approx. 1 quart (0.95 L).
Brake Fluid:
DOT 4 (check specific manual recommendation for front and rear systems).
Oil Leaks:
Common potential for leaks from primary cover, transmission, and engine case gaskets due to age and vibration. Manual covers gasket replacement procedures.
Carburetor Issues:
CV carburetor can require adjustments or rebuilds due to wear or clogging. Manual provides detailed carburetor service.
Electrical Connections:
Corrosion or loose connections in wiring harnesses, especially on older models, can cause intermittent issues. Manual includes wiring diagrams.
Clutch Slippage:
Can occur with high mileage or improper adjustment. Manual details clutch adjustment and replacement.
Founding:
Harley-Davidson Motor Company founded in 1903 in Milwaukee, Wisconsin.
Touring Lineage:
The Touring line evolved from earlier FL series motorcycles, emphasizing comfort, luggage capacity, and long-distance riding. The 2000 models represent a mature iteration of the Evolution Big Twin platform.
Engine Development:
The Evolution engine, introduced in 1984 for the Softail and Dyna lines, was adopted by the Touring line, offering improved reliability and performance over the Shovelhead and previous Big Twin engines.
Manufacturing Location:
United States (primarily York, Pennsylvania and Milwaukee, Wisconsin)
