Engine:
Yes, complete overhaul, diagnostics, tuning, and component replacement.
Transmission:
Yes, including clutch, gearbox, primary drive, and final drive.
Electrical System:
Yes, comprehensive wiring diagrams, diagnostics for all electronic modules, lighting, ignition, starting, charging, and infotainment.
Chassis And Frame:
Yes, suspension, steering, wheels, tires, brakes, and frame inspection/repair.
Bodywork And Fairings:
Yes, disassembly, installation, and cosmetic repair of fairings, fenders, saddlebags, and related components.
Fuel System:
Yes, including fuel injection, injectors, fuel pump, and fuel lines.
Exhaust System:
Yes, diagnosis, repair, and component replacement.
Brake System:
Yes, including ABS, hydraulic systems, brake pads, rotors, and bleeding procedures.
Cooling System:
N/A (Air-cooled engine)
Diagnostic Troubleshooting:
Yes, detailed symptom-based troubleshooting guides and diagnostic procedures.
Maintenance Procedures:
Yes, routine checks, adjustments, and scheduled services.
Parts Replacement:
Yes, step-by-step instructions for major component replacement.
Special Tools:
Yes, identification and usage of specialized tools required for specific procedures.
Estimated Pages:
700-900 (typical for a comprehensive CVO service manual)
Type:
Service and Repair Manual
Engine Mechanical:
Cylinder head assembly, valve train, piston and connecting rod, crankshaft and flywheel, oil pump, timing and primary drive system.
Fuel And Ignition:
Electronic sequential port fuel injection (ESPFI), throttle body, idle air control, ignition system, spark plugs, sensors (MAP, IAT, TPS, O2).
Drivetrain:
Clutch operation and adjustment, transmission gear inspection and repair, final drive belt inspection and adjustment, wheel bearing service.
Electrical Components:
Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), ignition switch, main circuit breaker, fuses, relays.
Lighting And Signals:
Headlight, taillight, brake lights, turn signals, hazard lights, instrument illumination, auxiliary lighting (if equipped).
Instrumentation And Gauges:
Speedometer, tachometer, fuel gauge, voltage meter, indicator lights, diagnostic trouble codes (DTCs).
Infotainment System:
Boom! Box infotainment system, speakers, radio, navigation, Bluetooth connectivity, and associated wiring.
Braking System:
Front and rear disc brakes, hydraulic lines, master cylinders, calipers, ABS modulator, brake fluid flush and bleeding.
Suspension:
Front forks (telescopic), rear shock absorbers, fork oil change, seal replacement, rear shock adjustment and replacement.
Steering:
Handlebar assembly, steering stem bearings, steering damper (if equipped), troubleshooting steering looseness or stiffness.
Wheels And Tires:
Wheel bearing replacement, tire inspection, tire pressure recommendations, wheel balancing.
Chassis And Frame:
Frame inspection, alignment checks, and fastener torque specifications.
Scheduled Maintenance:
Oil changes, filter replacements, spark plug replacement, belt inspections, brake fluid flushes, primary chain tensioner checks.
Engine Rebuild:
Complete disassembly, cleaning, inspection, measurement, and reassembly of engine components.
Transmission Overhaul:
Gearbox disassembly, inspection of gears, bearings, and shift forks, reassembly and adjustment.
Electrical Diagnostics:
Using diagnostic tools to read DTCs, troubleshooting open circuits, short circuits, and faulty sensors.
Fuel System Diagnostics:
Testing fuel pressure, injector pulse width, and throttle position sensor calibration.
Suspension Service:
Fork seal replacement, rear shock absorber adjustment and replacement, wheel bearing replacement.
Brake System Maintenance:
Brake pad replacement, caliper service, rotor replacement, brake fluid flush and bleeding (including ABS systems).
Bodywork And Fairing Removal:
Step-by-step instructions for safely removing and reinstalling all body panels, fairings, and luggage components.
Troubleshooting Guides:
Systematic approaches to diagnosing and resolving common and uncommon issues.
Wiring Diagrams:
Detailed, color-coded wiring diagrams for all electrical systems.
Torque Specifications:
Precise torque values for all critical fasteners and components.
Performance Tuning:
Guidance on engine tuning and adjustments for optimal performance (may require specific diagnostic tools).
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics).
โ๏ธ Engine Specifications
Engine Type:
Air-cooled, Twin Cam 110โข (110 cubic inch)
Engine Displacement:
1783 cc (110 cubic inches)
Bore X Stroke:
4.000 in. x 4.380 in. (101.6 mm x 111.3 mm)
Valve Train:
Pushrod actuated, overhead valves, two valves per cylinder
Horsepower Rated:
Approx. 95-100 hp @ 5000 rpm (subject to specific CVO tuning and dynamometer readings)
Torque Rated:
Approx. 110-115 ft-lbs @ 3500 rpm (subject to specific CVO tuning and dynamometer readings)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI) with individual spark plugs and injectors per cylinder.
Fuel Type:
Premium unleaded gasoline, minimum 91 octane
Oil Type:
Harley-Davidson Genuine SYN3ยฎ Synthetic Motor Oil or equivalent API SG or higher, JASO FD certified SAE 20W-50.
Oil Capacity:
Approx. 4 quarts (3.8 L) with filter change.
Ignition Type:
Electronic, with ignition module and crank position sensor.
First Service:
1,000 miles (1,600 km) or 3 months, whichever comes first. Includes oil and filter change, primary chain tensioner check, clutch and brake lever adjustment, and general inspection.
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first. Includes oil and filter change, inspection of brake system, drive belt, tires, and all critical fasteners.
Spark Plug Replacement:
Recommended every 10,000 miles (16,000 km).
Brake Fluid Flush:
Recommended every 2 years or 24,000 miles (38,000 km).
Primary Chain Tensioner:
Check at 1,000 miles and every 10,000 miles. Automatic hydraulic tensioner typically does not require adjustment unless noise is present.
Engine Oil:
Harley-Davidson Genuine SYN3ยฎ SAE 20W-50 Synthetic Motor Oil or equivalent.
Transmission Oil:
Harley-Davidson Genuine Formula + SAE 50 Transmission and Primary Chain Case Oil or equivalent.
Brake Fluid:
DOT 4 compatible fluid.
Fork Oil:
Harley-Davidson Genuine Fork Oil Type 1 (10W) or equivalent.
Twin Cam 110 Issues:
Potential for primary chain tensioner wear over time (manual covers inspection and replacement), oil leaks from seals, and occasional issues with early electronic components.
Infotainment System:
Some early Boom! Box systems could experience software glitches or connectivity issues, which are typically addressed by firmware updates or diagnostic procedures outlined in the manual.
Paint And Finish:
CVO models feature intricate paint jobs that require careful handling during maintenance and repair to avoid damage.
Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines, cruising motorcycles, and rich history of customization and performance.
Road Glide Evolution:
The Road Glide platform, characterized by its frame-mounted fairing for reduced steering feedback, has evolved significantly since its introduction. The CVO (Custom Vehicle Operations) division takes this platform to its highest expression with exclusive features and performance enhancements.
Twin Cam Evolution:
The Twin Cam engine family, introduced in 1999, became Harley-Davidson's primary engine platform. The Twin Cam 110โข variant, exclusive to CVO models, represents an enlarged and higher-performing iteration.
Cvs Philosophy:
CVO models are produced in limited quantities with unique components, paint schemes, and engine configurations, making them highly sought after by collectors and enthusiasts.
Manufacturing Location:
Typically assembled at Harley-Davidson's York, Pennsylvania, or Kansas City, Missouri, manufacturing facilities.