Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson owners, independent repair shops, and motorcycle enthusiasts seeking detailed service information.
Competitors:
Other manufacturers' service manuals, aftermarket repair guides.
Manual Value:
Essential for accurate maintenance, troubleshooting, and repairs, saving on dealership service costs.
Brand Strength:
Leverages Harley-Davidson's reputation for quality and rider community support.
Primary Coverage:
Maintenance and Repair Procedures
Diagnostic Coverage:
Troubleshooting and Diagnostics
Component Coverage:
Engine, Transmission, Chassis, Electrical Systems, Bodywork, Suspension, Brakes, Fuel System, Exhaust System, Controls
Estimated Page Count:
Approximately 600-800 pages (typical for a comprehensive Harley-Davidson service manual)
Type:
Service and Repair Manual
Engine:
Detailed procedures for Twin Cam 96B engine, including disassembly, inspection, assembly, timing, and tuning.
Transmission:
Coverage of the 6-speed Cruise Drive transmission, including removal, installation, clutch service, and internal component repair.
Electrical:
Comprehensive electrical schematics, wiring diagrams, component testing, diagnostic codes, ignition system, lighting, and charging system.
Brakes:
Front and rear brake system service, including hydraulic system bleeding, caliper and rotor replacement, and ABS (if applicable).
Suspension:
Front fork (49mm telescopic) and rear shock absorber service, including fluid changes, seal replacement, and adjustments.
Fuel System:
Fuel injection system (ESPFI), fuel pump, injectors, throttle body, and fuel tank service.
Exhaust System:
Exhaust system inspection, component replacement, and emissions-related information.
Chassis And Frame:
Frame inspection, steering head bearing service, and general chassis maintenance.
Bodywork:
Fender, tank, seat, fairing, and other body component removal, installation, and repair.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, chain/belt adjustment, tire pressure checks.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and complex issues.
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly.
Component Replacement:
Detailed guidance on replacing wear items and failed components.
Calibration And Adjustment:
Procedures for clutch adjustment, throttle cable adjustment, and other calibrations.
Depth:
Comprehensive, covering basic owner maintenance through to complete engine and transmission rebuilds.
Diagnostic Capability:
Includes information on diagnostic trouble codes (DTCs) and methods for reading them.
Service Data:
Torque specifications, clearances, fluid capacities, and other critical data.
Engine Type:
Air-cooled, Twin Cam 96B V-Twin
Displacement:
96 cubic inches (1584 cc)
Bore X Stroke:
3.75 in. x 4.48 in. (95.25 mm x 113.74 mm)
Valve Train:
Pushrod-actuated, overhead valves with hydraulic valve lifters
Cooling System:
Air-cooled
Horsepower Estimate:
Approx. 75-80 HP (at crank)
Torque Estimate:
Approx. 96 ft-lbs (at crank)
Induction System:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, 91 octane (R+M)/2 minimum
Fuel Tank Capacity:
5.0 gallons (18.9 L)
Type:
6-speed Cruise Drive
Clutch:
Clutch: Multiplate, wet
Primary Drive:
Primary drive: Chain, 34/46 ratio
Final Drive:
Final drive: Belt, 32/66 ratio
Gear Ratios:
1st: 9.315, 2nd: 6.650, 3rd: 4.945, 4th: 3.874, 5th: 3.317, 6th: 2.790
Transmission Fluid:
Harley-Davidson Transmission Fluid (or equivalent) - Capacity: 2.8 US qt (2.6 L)
Crash Test Ratings:
Not applicable to motorcycles in the same way as automobiles; focus is on structural integrity and rider protection.
Braking System:
Dual front disc brakes, single rear disc brake. ABS (Anti-lock Braking System) was an optional feature on some 2013 models.
Lighting:
Halogen headlamp, LED tail lamp and brake lamp, incandescent turn signals.
Frame Construction:
Steel double-cradle frame for rigidity and stability.
Rider Ergonomics:
Low seat height and forward controls designed for rider comfort and control.
Audio System:
Optional factory-installed audio system with AM/FM/Weatherband and auxiliary input for aftermarket or factory accessory integration.
ABS:
Optional Anti-lock Braking System (ABS) available on some configurations.
Diagnostic Port:
Diagnostic connector for accessing engine control module (ECM) data and diagnostic trouble codes.
Dashboard Features:
Analog speedometer, tachometer, fuel gauge, and indicator lamps. Digital odometer and trip meter.
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months thereafter
Specific Checks:
Include checking primary chain tension, belt tension, spark plugs, air filter, brakes, tires, and all fluid levels.
Engine Oil:
Harley-Davidson SYN3 (20W50 Synthetic) or equivalent
Engine Oil Capacity:
Approx. 3.0 US qt (2.8 L) with filter change
Transmission Fluid:
Harley-Davidson Transmission Fluid or Harley-Davidson Formula + (SAE 50)
Primary Chain Case Fluid:
Harley-Davidson primary chain case oil or Harley-Davidson Formula + (SAE 50)
Common Concerns:
Clutch lever play adjustment, primary chain tension, some electrical connections, occasional fuel injector issues. Manual provides solutions.
Oil Filter Example:
Harley-Davidson oil filter: 63796-77B (common to many Twin Cam models)
Heritage:
Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903, known for its V-twin engines and cruiser styling.
Dyna Lineage:
The Dyna platform, introduced in 1991, featured a rubber-mounted engine for reduced vibration, distinguishing it from the rigid-mounted Big Twin models. The Low Rider (FXDL) is a classic cruiser variant known for its comfortable riding position.
Manufacturing Location:
United States (e.g., York, Pennsylvania or Milwaukee, Wisconsin assembly plants)
