Market Segment:
Full-size, luxury touring motorcycle.
Key Competitors:
Indian Chief, Honda Gold Wing, BMW R1200RT (in different segments but direct touring competitors).
Distinctive Features:
Classic styling, comfortable touring ergonomics, large displacement V-twin engine, ample luggage capacity, air-adjustable suspension.
Typical Owner:
Experienced riders prioritizing comfort, long-distance touring capability, and iconic American cruiser styling.
Systems Covered:
Engine, Transmission, Drivetrain, Fuel System, Electrical System, Chassis, Suspension, Brakes, Bodywork, Instrumentation, Diagnostics, Troubleshooting, Maintenance
Estimated Page Count:
800+
Manual Type:
Factory Service Manual / Workshop Manual
Format:
PDF (Digital Download)
Engine Mechanical:
Detailed procedures for engine disassembly, inspection, assembly, and troubleshooting for the Twin Cam 103 Engine.
Fuel System:
EFI system diagnosis, fuel pump, injectors, throttle body service, and emission controls.
Electrical System:
Comprehensive wiring diagrams, component testing, diagnostic procedures, lighting, ignition, charging system, and accessories.
Transmission Drivetrain:
6-speed Cruise Drive transmission service, clutch, primary drive, and final drive belt inspection and adjustment.
Chassis Suspension:
Frame inspection, front fork service (including air-assisted), rear shock absorber replacement, and wheel bearing maintenance.
Brake System:
Front and rear brake caliper service, master cylinder overhaul, brake fluid flush and bleeding procedures, ABS system diagnostics.
Bodywork Fittings:
Fairing removal and installation, fuel tank, fenders, saddlebags, seat assembly, and trim components.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, brake fluid checks, tire pressure, chain/belt adjustment.
Diagnostic Procedures:
Step-by-step troubleshooting guides for common and uncommon issues, including DTC (Diagnostic Trouble Code) interpretation.
Repair Procedures:
Detailed instructions for component repair, replacement, and reassembly for all major motorcycle systems.
Electrical Diagnostics:
Tests for sensors, actuators, switches, and control modules. Includes troubleshooting for CAN bus systems.
Engine Rebuild:
Complete instructions for engine disassembly, cylinder head service, piston/ring replacement, and crankshaft/rod inspection.
Depth Of Coverage:
Comprehensive, covering everything from basic scheduled maintenance to full engine and transmission overhauls. Suitable for professional technicians and advanced DIY enthusiasts.
Engine Type:
Air-cooled, Twin Cam 103ci (1690cc) V-twin
Bore X Stroke:
3.875 in x 4.38 in (98.4 mm x 111.3 mm)
Peak Horsepower Est:
Approx. 78 HP @ 5010 RPM
Peak Torque Est:
Approx. 105 lb-ft @ 3500 RPM
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Premium Unleaded Gasoline
Ignition System:
High-performance electronic sequential infotainment.
Audio System:
Standard AM/FM/WB stereo with CB and Intercom functionality, SiriusXM Satellite Radio capability, 5.25-inch weather band speakers.
Display:
Analog gauges with a digital display for odometer, trip, gear, fuel, and diagnostics.
Cruise Control:
Standard Electronic Cruise Control.
Usb Port:
Optional accessory.
Bluetooth:
Optional accessory for audio streaming.
Initial Service Mileage:
1,000 miles (1,600 km)
Engine Oil Change Interval:
Every 5,000 miles (8,000 km) or annually.
Transmission Oil Change Interval:
Every 10,000 miles (16,000 km)
Primary Chain Case Oil Change Interval:
Every 10,000 miles (16,000 km)
Engine Oil Spec:
Harley-Davidson 20W-50 Synthetic (e.g., Harley-Davidson Genuine Motor Oil SAE 20W-50)
Transmission Fluid Spec:
Harley-Davidson Formula + Transmission and Primary Chain Case Lube (or equivalent)
Common Wear Items:
Clutch plates, brake pads, drive belt, fork seals, wheel bearings.
Potential Issues:
Rear brake piston seizure (requiring caliper service), minor electrical gremlins if not properly maintained, exhaust system corrosion on older models.
Spark Plug Type:
Harley-Davidson OEM or equivalent (e.g., NGK)
Tire Pressure Front:
36 PSI (248 kPa)
Tire Pressure Rear:
40 PSI (276 kPa)
