Motorcycle Segment:
Cruiser, touring-capable
Competitors 2006:
Indian Chief, Victory Kingpin, other large-displacement V-twin cruisers from Japanese manufacturers (e.g., Yamaha Road Star, Kawasaki Vulcan 2000).
Distinctive Characteristics:
Detachable windscreen, large saddlebags, classic styling, comfortable rider and passenger seating, powerful V-twin engine.
Manual Value Proposition:
Provides factory-accurate repair and maintenance procedures, ensuring correct servicing for optimal performance and longevity. Essential for DIY enthusiasts and professional mechanics.
Primary Coverage:
Full Service, Repair, Troubleshooting, Diagnostics, Electrical Systems, Engine, Transmission, Chassis, Bodywork
Estimated Page Count:
Approx. 500-700 pages (typical for this era's factory manuals)
Type:
Factory Service Repair Workshop Manual
Format:
Downloadable (Digital)
Engine Mechanical:
Engine disassembly, assembly, tuning, lubrication, cooling, ignition system, fuel delivery (carbureted), exhaust system
Transmission Drivetrain:
Clutch, gearbox, primary drive, final drive, belt/chain maintenance, lubrication
Electrical System:
Wiring diagrams, lighting, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), ignition system components, sensors, diagnostic codes
Chassis Suspension:
Frame, front fork (telescopic), rear suspension (shocks), steering head bearings, wheel bearings, swingarm
Braking System:
Front and rear brake systems (hydraulic disc), brake caliper service, master cylinder service, fluid bleeding, rotor and pad replacement
Fuel System:
Fuel tank, fuel lines, fuel filter, carburetor (likely Keihin CV40 for this model), choke operation
Bodywork Cosmetics:
Fenders, fuel tank, seat assembly, fairing (if applicable), saddlebags, chrome components, trim
Preventive Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication, adjustments, inspections
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems, symptom analysis
Repair Rebuild:
Detailed step-by-step instructions for disassembly, component replacement, and reassembly of all major systems
Diagnostics:
Diagnostic trouble codes (DTCs), sensor testing, electrical system checks
Depth:
Comprehensive: Covers everything from basic fluid changes to complete engine and transmission overhauls, including detailed electrical troubleshooting.
Engine Family:
Harley-Davidson Twin Cam 88
Engine Type:
Air-cooled, 45-degree V-twin
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Valve Train:
Pushrod-actuated overhead valves with two valves per cylinder
Horsepower Est:
Approx. 65-70 HP (at crankshaft, manufacturer estimate)
Torque Est:
Approx. 85-90 ft-lbs (at crankshaft, manufacturer estimate)
Fuel Delivery:
Carbureted (likely Keihin CV40, requires manual confirmation)
Fuel Type:
Unleaded gasoline, 91 octane (AKI) or higher recommended
Oil System:
Dry sump, oil tank separate from crankcase
Oil Capacity:
Approx. 4 quarts (3.8 liters) with filter change
Recommended Oil:
Harley-Davidson SYN3 (SAE 20W50) or equivalent motorcycle-specific oil meeting HD-4A or HD-4B specifications
Transmission Type:
5-speed constant mesh, manual
Optional Transmissions:
N/A for this model year and configuration
Primary Drive:
Duplex chain
Transmission Oil Type:
Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant (or equivalent)
Transmission Oil Capacity:
Approx. 1 quart (0.95 liters)
Overall Length:
Approx. 94.5 inches (2400 mm)
Seat Height Laden:
Approx. 27.3 inches (693 mm)
Ground Clearance:
Approx. 5.2 inches (132 mm)
Dry Weight:
Approx. 690 lbs (313 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 1160 lbs (526 kg)
Saddlebag Capacity:
Lockable, hard-shell saddlebags with significant storage volume.
Safety Certifications:
Meets or exceeds all relevant federal motor vehicle safety standards (FMVSS) for motorcycles.
Braking System Type:
Dual-action, front and rear hydraulic disc brakes.
Front Brake:
Dual 4-piston calipers, 11.5 in. (292 mm) floating rotors
Rear Brake:
4-piston caliper, 11.5 in. (292 mm) rotor
Lighting:
Halogen headlight, taillight, brake light, front and rear turn signals, passing lamps (often included).
Rearview Mirrors:
Standard chrome handlebar-mounted mirrors.
Audio System:
Optional AM/FM radio with cassette player and/or CD player, often integrated into the handlebar fairing/dashboard.
Speakers:
Fairing-mounted speakers (if equipped with audio system).
Cruise Control:
Often an optional accessory for this model, not standard equipment.
Diagnostic Interface:
CAN bus system, requires specific diagnostic tools (e.g., Harley-Davidson Digital Technician) for advanced diagnostics.
First Service:
1000 miles (1600 km) or 6 months, whichever comes first.
Subsequent Service:
Every 5000 miles (8000 km) or 12 months for most items (oil change, inspections), with more detailed checks at higher mileage intervals.
Engine Oil Viscosity:
SAE 20W50 (Harley-Davidson SYN3 or equivalent)
Transmission Primary Oil:
Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant
Brake Fluid:
DOT 4 (for hydraulic brake systems)
Common Wear Items:
Clutch plates, primary chain tensioner (hydraulic update available for earlier models), wheel bearings, fork seals, exhaust gaskets.
Electrical Considerations:
Stator/regulator failure is a known issue on some Twin Cam models; ensure proper voltage regulation.
Carburetor Tuning:
CV40 carburetor may require periodic adjustments for optimal performance, especially with aftermarket exhaust or air cleaner modifications.
Oil Filter Part Number Example:
Harley-Davidson OEM 63731-35A (or equivalent aftermarket)
Heritage Statement:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines, distinctive styling, and strong rider community.
Road King Introduction:
The Road King line was introduced in 1994, embodying a retro-styled touring motorcycle that harks back to the classic '60s era FLH models.
Twin Cam Introduction:
The Twin Cam engine platform debuted in 1999, replacing the Evolution engine, offering increased displacement and torque.
Manufacturing Location:
USA (primarily York, Pennsylvania and Milwaukee, Wisconsin)
Production Period For Tc88:
1999-2006 (Twin Cam 88)
