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Manual Coverage
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Systems Covered
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Engine:
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1550cc Twin Cam 96B (Engine disassembly, assembly, inspection, diagnosis, tuning, lubrication systems, cooling systems if applicable).
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Fuel System:
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Fuel injection (EFI), throttle body, fuel pump, fuel lines, fuel tank maintenance, diagnostic procedures for fuel delivery.
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Ignition System:
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Ignition module, coil, spark plugs, wiring, troubleshooting of ignition faults.
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Transmission:
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6-speed Cruise Drive transmission (disassembly, assembly, inspection, lubrication, clutch operation, troubleshooting).
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Clutch:
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Primary drive system, clutch assembly, clutch cable/hydraulic actuation, adjustment, service.
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Frame And Suspension:
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Frame inspection, front fork (telescopic, cartridge/dual damping types), rear shock absorbers, swingarm, wheel bearings, steering head bearings.
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Brakes:
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Front and rear brake systems (calipers, rotors, master cylinders, brake lines, ABS if equipped), bleeding procedures, pad replacement, service.
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Electrical System:
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Battery, charging system (alternator, regulator), starting system (starter motor, solenoid), lighting, instrumentation, horn, wiring diagrams, fuses, relays.
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Diagnostics:
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Diagnostic trouble codes (DTCs) for EFI and other electronic systems, use of Harley-Davidson diagnostic tools (e.g., Digital Technician Lite/Pro).
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Bodywork:
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Fenders, fuel tank, seat, fairings (if applicable), controls, mounting hardware, cosmetic repairs.
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Wheels And Tires:
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Wheel removal and installation, tire balancing, tire pressure recommendations, rim specifications.
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Procedures Included
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Scheduled Maintenance:
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Oil changes, filter replacements, spark plug replacement, drive belt inspection and adjustment, brake fluid flush, general inspection checklists.
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Troubleshooting:
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Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides.
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Repair Procedures:
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Detailed step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.
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Technical Specifications:
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Torque specifications for all fasteners, clearances, tolerances, electrical specifications.
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Wiring Diagrams:
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Comprehensive electrical schematics for all systems, facilitating diagnosis and repair.
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Technical Depth
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Depth:
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Comprehensive (covering routine maintenance to full engine and transmission rebuilds, advanced electrical diagnostics).
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Engine Specifications
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Primary Engine
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Engine Type:
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Air-cooled, Twin Cam 96B V-twin
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Displacement:
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1584 cc (96 cubic inches)
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Bore X Stroke:
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3.75 in x 4.38 in (95.25 mm x 111.25 mm)
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Compression Ratio:
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8.9:1
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Valve Train:
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Overhead valve (OHV), 2 valves per cylinder, pushrod actuated.
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Timing Drive:
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Chain drive camshafts.
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Performance
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Horsepower:
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Approx. 65-70 HP (at crank, estimated for the era)
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Torque:
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Approx. 85-90 lb-ft (at crank, estimated for the era)
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Fuel System
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Fuel Delivery:
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Electronic Sequential Port Fuel Injection (ESPFI)
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Fuel Type:
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Unleaded gasoline, minimum 91 octane (Octane rating may vary by region/manufacturer recommendation).
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Lubrication System
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Oil Type:
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Harley-Davidson 20W-50 SYN3 (or approved equivalent motorcycle specific oil).
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Oil Capacity:
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Approx. 4.0 US quarts (3.8 liters) with filter change.
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Oil Filter Part Number
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Oil Filter:
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Harley-Davidson 63731-37B (or equivalent).
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Dimensions
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Exterior
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Wheelbase:
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Approx. 64.5 - 65.7 inches (model dependent)
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Length:
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Approx. 92.1 - 93.4 inches (model dependent)
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Seat Height Laden:
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Approx. 24.5 - 25.0 inches (model dependent)
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Weights
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Dry Weight:
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Approx. 650 - 680 lbs (model dependent)
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Gross Vehicle Weight Rating Gvwr:
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Approx. 1050 lbs
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Fuel Capacity
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Fuel Tank Capacity:
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Approx. 5.0 US gallons (18.9 L)
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Tires
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Front Tire Size:
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e.g., 90/90-21 (FXSTC), 130/90B16 (FLSTF/FLSTN)
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Rear Tire Size:
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e.g., 180/55B17 (FXSTC), 150/80B16 (FLSTF/FLSTN)
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Wheels
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Wheelbase Type:
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Cast aluminum or Chrome laced, model dependent.
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Bolt Pattern:
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Not applicable for hub-mounted wheels.
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Maintenance
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Service Intervals
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First Service:
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Typically at 1,000 miles (1,600 km) for initial break-in service (oil change, filter change, belt tension check, etc.).
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Subsequent Oil Changes:
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Every 5,000 miles (8,000 km) or annually, whichever comes first.
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Spark Plug Replacement:
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Every 10,000 miles (16,000 km).
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Drive Belt Inspection:
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Every 5,000 miles (8,000 km) for tension and condition.
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Brake Fluid Flush:
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Every 2 years (or as per manual recommendation, often more frequent depending on use).
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Fluid Specifications
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Engine Oil:
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Harley-Davidson 20W-50 SYN3 Motorcycle Oil (or equivalent API CI-4 or higher rated synthetic motorcycle oil).
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Transmission Oil:
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Harley-Davidson SYN3 (or SAE 75W-90 Gear Lubricant).
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Primary Chain Case Oil:
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Harley-Davidson primary fluid or SAE 20W-50 motorcycle oil.
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Brake Fluid:
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DOT 4 hydraulic brake fluid.
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Known Issues
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Cam Chain Tensioners:
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Early Twin Cam models (prior to 2007) had issues with hydraulic cam chain tensioners wearing prematurely. The 2007 models generally use improved tensioners, but inspection is still advised. Retrofitting upgraded components is a common modification.
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Crank Position Sensor:
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Potential for failure leading to starting or running issues.
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Regulator Rectifier:
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Can be a point of failure in charging systems; diagnostic checks are important.
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Fuel Pump In Tank:
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Early EFI systems could experience issues with the fuel pump module.
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Idle Control Module:
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Can cause rough idling or stalling.
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Vehicle History
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Brand Heritage
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Founding:
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Founded in 1903 in Milwaukee, Wisconsin, USA.
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Iconic Models:
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Known for V-twin engines, cruiser styling, and its distinctive sound and heritage.
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Model Evolution
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Softail Introduction:
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The Softail platform, featuring a hidden rear suspension that mimics the look of a hardtail frame, was introduced in 1983.
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Twin Cam Introduction:
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The Twin Cam 88 engine was introduced in 1999, with the Twin Cam 96 (1584cc) arriving for the 2007 model year, offering increased displacement and refinement.
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Production
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Manufacturing Location:
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Primarily manufactured in York, Pennsylvania, and Milwaukee, Wisconsin, USA.
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Model Year Introduction:
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2007 marked a significant update with the introduction of the 96 cubic inch Twin Cam engine across the Softail lineup.
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