Systems Covered:
Engine (Top End, Cam Compartment, Bottom End, Oil Pump, Crankcase, Flywheels, Connecting Rods), Fuel System (Tank, Pump, Injectors, Evaporative Emissions), Cooling System (Operation, Testing, Repair), Drive (Primary Chaincase, Clutch, Transmission Sprocket, Drive Belt), Transmission (Assembly, Gears, Case), Electrical (Fuses, Relays, ECM, BCM, Ignition, Starter, Lighting, Sensors, Gauges, Infotainment, Wiring Harnesses), Chassis (Frame, Wheels, Tires, Brakes, Forks, Suspension, Steering, Handlebars, Fairings, Saddlebags, Tour-Pak, Footboards), Maintenance (Schedules, Fluids, Fasteners, Lubrication, Battery, Storage), Troubleshooting.
Electrical Systems:
Comprehensive electrical system coverage including fuses, relays, ECM, body control module, ignition, starter, all lighting types (headlamps, auxiliary, rear, fender tip, Tour-Pak, turn signals), ignition switch, accessory switches, various sensors (crankshaft position, engine temperature, coolant temperature, vehicle speed, wheel speed), neutral switch, oil pressure sender, stop lamp switches, horn, fairing power outlet, gauges, instruments, and the Boom Box Infotainment System.
Chassis Components:
Extensive coverage of chassis components including front and rear wheels, compensator, wheel lacing, runout, sealed bearings, tires, front and rear suspension, rear fork, handlebars, mirrors, seats, saddlebags, Tour-Pak, fairing lowers, engine guards, various fairing components (outer, inner, dash panel, instrument nacelle/bezel), storage compartments, air deflectors, fenders, rear fascia, rear frame, footboards, footrests, jiffy stand, and front engine mount.
Steering And Suspension:
Specific sections dedicated to steering head bearings (maintenance and adjustment) and rear suspension adjustments, crucial for handling and ride comfort.
Drive System:
Covers primary chaincase cover, drive components, primary chaincase housing, clutch (assist and slip), hydraulic clutch release bearing and pushrod, transmission sprocket, and drive belt maintenance and repair.
Cooling System Detailed:
Appendix B reiterates and expands upon the cooling system, providing further details on specifications, operation, testing, diagnostics, and repair, indicating its importance.
Procedures Included:
Complete overhaul, repair, replacement, inspection, adjustment, troubleshooting, and diagnostic procedures for all covered systems. Includes detailed steps for component removal and installation, torque specifications, service wear limits, and system operation explanations.
Brake System Procedures:
Detailed procedures for brake pads and discs inspection and replacement, brake fluid bleeding, front and rear brake master cylinder and caliper service, and ABS module maintenance.
Engine Rebuild Procedures:
Detailed procedures for engine removal and installation, top end service, cam compartment service, bottom end service, crankcase disassembly and repair, flywheel and connecting rod service, and oil pan repair.
Technical Depth:
Comprehensive. Covers everything from routine maintenance tasks and preventative care to in-depth engine rebuilds, transmission overhauls, and complex electrical system diagnostics. Includes Hi-Resolution illustrations, photos, and diagrams to aid in understanding and execution of procedures.
Illustrations And Diagrams:
Loaded with Hi-Resolution illustrations, instructions, photos, and diagrams that are critical for understanding complex procedures and component identification, significantly enhancing the manual's practical utility for repairs.
Wiring Diagrams:
Appendix A provides comprehensive wiring diagrams and connector information, essential for diagnosing and repairing electrical issues. Supports both 32-bit and 64-bit systems.
Troubleshooting Guides:
Dedicated troubleshooting sections for major systems like the engine, providing a structured approach to diagnosing and resolving common and uncommon issues.
Reference Appendices:
Includes valuable appendices for reference: Appendix A (Wiring), Appendix B (Cooling System), and Appendix C (Reference, including metric conversion, fluid conversion, torque conversion, and a glossary).
File Format Details:
PDF format compatible with all Windows and Mac computers (Windows 10, 8, 7, Vista 32/64, XP, ME, 98, NT, 2000), Tablets, and Phones. Supports 32-bit and 64-bit operating systems. Pages can be read and printed directly from the CD or copied to a hard drive.
Accessibility:
Cross-platform compatibility with Windows, Mac, Tablet, and Phone devices, ensuring broad accessibility for users regardless of their primary computing device.
Readability And Printing:
The PDF format allows for easy navigation, searching, and printing of specific pages or entire sections, enhancing the practical usability of the manual.
Print Quality:
High Resolution (as stated in product description), suitable for clear viewing of illustrations, photos, and diagrams. Facilitates accurate interpretation of technical information for repairs.
Binding Type:
N/A (Digital format - PDF)
Paper Type:
N/A (Digital format - PDF)
Engine Type:
Likely Twin-Cooled Milwaukee-Eight variants (e.g., 107 cubic inch) and Air-Cooled Twin Cam variations were still in production for some lower-end touring models or specific configurations. The manual covers engine disassembly and assembly procedures in detail.
Engine Performance Data:
Specific horsepower and torque figures are detailed within the manual's engine specifications section. The manual covers engine air flow, oil pump operation, and breathing systems, crucial for understanding performance characteristics.
Fuel System Components:
Covers fuel pressure tests, intake leak tests, air cleaner assembly, fuel tank, top plate, fuel filter, pressure regulator, level sender, twist grip sensor, induction module, MAP sensor, heated oxygen sensors, fuel injectors, and fuel pump. Also includes evaporative emissions control system diagnostics and repair.
Fuel Pressure Spec:
Provides specifications and procedures for fuel pressure testing, a critical diagnostic step for fuel injection systems.
Induction Module Service:
Covers service procedures for the induction module, a key component of the electronic fuel injection system.
Engine Operation Principles:
Explains fundamental engine operations such as engine air flow, oil pump operation, and breather operation, providing insight into how these systems function.
Engine Component Limits:
Includes service wear limits for critical engine components, allowing for accurate assessment of component condition during rebuilds.
Service Intervals General:
The manual contains a comprehensive Maintenance Schedule covering recommended intervals for fluid changes, filter replacements, inspections, and lubrication. Specific intervals for oil changes, primary lubricant, transmission lubricant, spark plugs, brake fluid, and cable lubrication are detailed.
Fluid Specifications:
Specifies required fluids for engine oil, primary chaincase, transmission, and hydraulic clutch. This includes recommended grades, specifications (e.g., Harley-Davidson proprietary fluids or equivalent), and capacities. Also details coolant specifications.
Brake Fluid Spec:
Specifies requirements for front and rear brake master cylinders and brake fluid lines, including fluid type and bleeding procedures.
Coolant Spec:
Details specifications, testing, diagnostics, and repair procedures for the cooling system, including coolant type and capacity, if applicable to the specific engine variants covered.
Common Issues Covered:
The troubleshooting section addresses common problems encountered with these models, such as starting issues, electrical gremlins, braking system quirks, and engine performance anomalies. While not listing 'known issues' like a recall bulletin, it provides the diagnostic path to resolve them.
Cable And Chassis Lubrication Schedule:
Includes guidelines for cable and chassis lubrication, essential for smooth operation of controls and suspension components.
Fastener Torque Values Coverage:
Provides Fastener Torque Values for various sections including General, Engine, Chassis, Fuel System, Cooling System, Drive, Transmission, and Electrical, ensuring correct assembly and preventing damage.
Battery Maintenance Procedures:
Covers battery maintenance procedures, critical for the electrical system's reliability.
Vehicle Storage Guidelines:
Includes guidelines for vehicle storage, important for maintaining the motorcycle's condition during periods of non-use.
