Motorcycle Segment:
Cruiser motorcycle, known for its custom styling and touring capability.
Target Audience:
Harley-Davidson owners seeking to perform their own maintenance, repairs, and customization.
Competitors 2007:
Primarily other Harley-Davidson models, custom choppers, and other American V-twin cruisers from brands like Indian, Victory.
Model Features:
Softail chassis with hidden rear suspension, Twin Cam 96B engine, custom styling, forward controls, distinctive fuel tank and fender designs.
Manual Value Proposition:
Empowers owners with the knowledge to maintain their investment, save on service costs, and perform more advanced tasks.
Engine Mechanical:
Engine assembly, disassembly, inspection, repair, and overhaul of Twin Cam 96B engine.
Fuel System:
Fuel injection system (EFI), throttle body, injectors, fuel pump, fuel filter, pressure regulator.
Ignition System:
Ignition module, coils, spark plugs, wiring, timing.
Transmission:
6-speed Cruise Drive transmission service, disassembly, repair, fluid specifications.
Clutch:
Clutch assembly, primary drive, clutch plates, hydraulic clutch system.
Drivetrain:
Final drive belt, sprockets, bearings, tensioners.
Chassis Suspension:
Softail frame, swingarm, front forks (including cartridge service), rear shock absorbers, bushings.
Brakes:
Front and rear brake systems, calipers, master cylinders, brake lines, pads, rotors, bleeding procedures.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter, lighting, ignition switch, fuses, relays.
Instrumentation Controls:
Speedometer, tachometer, indicator lights, handlebar controls, throttle cables, clutch cable.
Body Frame:
Fuel tank, fenders, seat, saddlebags, fairings, frame components, mounting hardware.
Wheels Tires:
Wheel bearings, tire mounting, balancing, wheel alignment.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), wiring diagrams, diagnostic tool usage (e.g., Harley-Davidson Digital Technician).
Preventative Maintenance:
Oil changes, filter replacements, lubrication, chain/belt adjustment, brake inspection, fluid checks.
Troubleshooting Guides:
Step-by-step diagnostic procedures for common and uncommon faults.
Repair Procedures:
Detailed, illustrated instructions for component removal, installation, and repair.
Overhaul Procedures:
Complete engine and transmission rebuild instructions with specifications.
Wiring Diagrams:
Full electrical system wiring schematics for all circuits.
Tightening Torques:
Precise torque specifications for all critical fasteners.
Special Tools:
Identification and usage of specialized Harley-Davidson tools required for specific procedures.
Depth Level:
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds and advanced diagnostics.
Diagnostic Capability:
Detailed diagnostics for EFI system, CAN bus communication, and sensor readings.
Engine Family:
Harley-Davidson Twin Cam 96B
Engine Type:
Air-cooled, 45-degree V-twin
Displacement:
96 cubic inches (1584 cc)
Bore X Stroke:
3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)
Compression Ratio:
8.9:1 (typical)
Valve Train:
Overhead valves (OHV), 2 valves per cylinder, pushrod actuated.
Horsepower:
Approximately 70-75 HP (estimated, unconfirmed by specific model rating)
Torque:
Approximately 80-85 ft-lbs @ 3000 RPM (estimated, unconfirmed by specific model rating)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
91 octane or higher unleaded gasoline
Oil Type Engine:
Harley-Davidson SAE 20W50 Genuine Motor Oil or equivalent motorcycle-specific oil
Oil Capacity Engine:
3.9 US qt (3.7 L) with filter change
First Service:
1000 miles (1600 km) or 6 months (whichever comes first)
Subsequent Service:
Every 5000 miles (8000 km) or 12 months
Belt Tension Check:
Check at every service interval, adjust as needed.
Spark Plug Replacement:
Typically every 10,000-20,000 miles, refer to manual for exact spec.
Brake Fluid Type:
DOT 4 (as specified by Harley-Davidson)
Primary Chaincase Fluid:
Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant (or equivalent)
Common Wear Items:
Clutch plates, brake pads, wheel bearings, drive belt, fork seals.
Efi System:
Occasional issues with throttle position sensors, idle air control (IAC) if equipped, or fuel injectors. Manual provides diagnostic steps.
Softail Suspension:
Rear shock absorber performance can degrade over time; front fork seals can leak. Manual covers servicing.
