Target Audience:
Owners of 2007-2008 Harley-Davidson Softail motorcycles seeking to perform their own maintenance, diagnostics, and repairs.
Value Proposition:
Provides detailed, accurate, and official information typically found in dealership-bound service manuals, saving owners significant costs associated with professional servicing.
Key Manual Features:
Includes detailed exploded views, torque specifications, diagnostic procedures, wiring diagrams, and troubleshooting guides.
Engine Mechanical:
Engine assembly, disassembly, inspection, overhaul, tuning, lubrication, cooling (air-cooled), timing.
Fuel System:
Fuel injection (EFI - Electronic Fuel Injection) system diagnostics and repair, throttle body, fuel pump, injectors, sensors (MAP, IAT, O2), fuel lines, fuel filter.
Ignition System:
Ignition module, spark plugs, ignition coils, wiring, troubleshooting ignition faults.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox (5-speed Cruise Drive), primary drive, final drive belt inspection and tensioning, lubrication.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlight, taillight, signals), horn, fuses, relays, wiring diagrams, diagnostic codes (DTCs).
Brakes:
Front and rear brake systems (hydraulic disc), brake calipers, master cylinders, brake lines, brake fluid specifications and bleeding procedures, rotor inspection.
Suspension Steering:
Front fork (telescopic) overhaul and oil replacement, rear shock absorber removal and installation, steering head bearing adjustment and replacement.
Wheels Tires:
Wheel bearing inspection and replacement, tire pressure specifications, wheel balancing.
Frame Bodywork:
Frame inspection, body panel removal and installation, seat, fenders, fuel tank, handlebar replacement.
Exhaust System:
Exhaust system inspection, gasket replacement, muffler mounting.
Routine Maintenance:
Oil changes, filter replacement, spark plug replacement, air filter cleaning/replacement, belt tension checks, brake fluid checks, battery maintenance.
Diagnostic Troubleshooting:
Step-by-step diagnostic flowcharts for common and uncommon issues, symptom-based troubleshooting, reading diagnostic trouble codes (DTCs).
Component Overhaul Rebuild:
Detailed procedures for engine teardown and rebuild, transmission disassembly and reassembly, brake caliper rebuilds, fork servicing.
Wiring Diagrams:
Complete, high-resolution wiring schematics for all electrical systems, color-coded and with component identification.
Adjustment Calibration:
Clutch cable adjustment, throttle cable adjustment, steering head bearing adjustment, idle speed adjustment.
Special Tools Procedures:
Identification of required special tools and specific procedures for their use (e.g., flywheels, bearing pullers).
Depth Of Coverage:
Comprehensive, from basic owner maintenance to in-depth mechanical and electrical diagnostics and repair, suitable for both home mechanics and professional technicians.
โ๏ธ Engine Specifications
Engine Family:
Harley-Davidson Twin Cam 96โข (1584cc)
Engine Type:
Air-cooled, 45-degree V-twin, 4-stroke
Bore X Stroke:
3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)
Displacement:
96 cu. in. (1584 cc)
Valve Train:
Overhead valve, pushrod-actuated, two valves per cylinder
Torque Rating Approx:
92 ft-lbs @ 3500 RPM (typical for Twin Cam 96)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Premium Unleaded Gasoline, 91 octane or higher recommended
Fuel Tank Capacity:
Approximately 5.0 gallons (18.9 L)
Overall Length:
Varies by model (e.g., Fat Boy ~96.2 in., Heritage Softail ~98.5 in.)
Wheelbase:
Varies by model (e.g., Fat Boy ~64.5 in., Heritage Softail Classic ~65.7 in.)
Ground Clearance:
Varies by model (typically 4.5-5.5 inches)
Dry Weight:
Varies by model (e.g., Fat Boy ~675 lbs, Heritage Softail Classic ~700 lbs)
Gross Vehicle Weight Rating:
Typically around 1160-1200 lbs
First Service:
1,000 miles (1,600 km) or 6 months, whichever comes first (includes engine oil change, primary chain tension adjustment, inspect all systems).
Subsequent Oil Change:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first.
Transmission Oil Change:
Every 10,000 miles (16,000 km) or 24 months.
Primary Chain Tension Check:
Every 1,000 miles (1,600 km) and every 5,000 miles (8,000 km) thereafter.
Engine Oil Type:
Harley-Davidson SYN3ยฎ Synthetic (or equivalent SAE 20W-50 V-Twin specific motorcycle oil with API CI-4 or higher specification)
Engine Oil Capacity:
3.5 US quarts (3.3 L) with filter change
Brake Fluid Type:
DOT 4 hydraulic brake fluid (non-silicone based)
Cam Chain Tensioners:
Early Twin Cam engines (prior to Twin Cam 96 with hydraulic tensioners) could experience wear on spring-loaded cam chain tensioners. The Twin Cam 96, however, uses hydraulic tensioners which are generally more robust. However, proper oil maintenance is still critical.
Regulator Rectifier Failure:
A common issue across many Harley-Davidson models of this era, leading to charging system failures. Diagnosis and replacement procedures are detailed in the manual.
Idle Control Issues:
Potential issues with the Idle Air Control (IAC) motor on EFI systems, leading to rough idle or stalling. The manual covers diagnostics for this.
Brand Legacy:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer known for its V-twin engines, cruiser styling, and extensive customization culture.
Softail Platform Introduction:
The Softail platform, distinguished by its hidden rear suspension designed to mimic the look of a hardtail frame, was first introduced in 1983.
Twin Cam Era:
The 2007-2008 models represent the early to mid-life cycle of the Twin Cam 88ยฎ engine's successor, the Twin Cam 96โข (1584cc), which offered increased displacement and torque.
Manufacturing Location:
Primarily manufactured in York, Pennsylvania, USA, and Milwaukee, Wisconsin, USA.
