Engine:
Complete Engine Overhaul, Tuning, and Troubleshooting
Transmission:
Clutch, Gearbox, Primary Drive, Final Drive Maintenance and Repair
Fuel System:
Carburetor (Keihin CV) Disassembly, Cleaning, Adjustment, and Troubleshooting
Ignition System:
Ignition Module, Spark Plugs, Wiring Diagnostics
Electrical System:
Wiring Diagrams, Battery, Charging System, Lighting, Starters, Instruments
Brakes:
Hydraulic Brake System, Caliper Rebuild, Fluid Replacement, Bleeding Procedures
Suspension:
Front Fork (Greasable, Non-adjustable) and Rear Shock Absorber Service and Adjustment
Frame And Bodywork:
Frame Inspection, Sheet Metal Repair, Fairing Removal and Installation
Exhaust System:
Exhaust pipe and muffler removal, installation, and common repair procedures
Clutch And Brake Controls:
Lever replacement, cable adjustment, hydraulic line maintenance
Lighting And Signals:
Bulb replacement, circuit diagnostics, switch gear maintenance
Maintenance:
Regular Scheduled Maintenance, Oil Changes, Filter Replacements, Lubrication
Troubleshooting:
Diagnostic Flowcharts, Symptom-Based Troubleshooting Guides
Repair:
Step-by-Step Repair Instructions for all Major Components
Rebuilds:
Engine Rebuilds, Transmission Rebuilds, Carburetor Rebuilds
Wheel And Tire Service:
Wheel bearing replacement, tire mounting and balancing
Diagnostic Charts:
Systematic troubleshooting flowcharts for common performance and electrical issues.
Level Of Detail:
Comprehensive Rebuild and Diagnostic Procedures
Wiring Diagrams:
Detailed, factory-quality electrical schematics
Torque Specifications:
Comprehensive list of all critical torque specifications for assembly and disassembly.
Engine Type:
Air-cooled, Twin Cam 88
Displacement:
1449 cc (88 cubic inches)
Bore X Stroke:
3.75 in x 4.00 in (95.25 mm x 101.6 mm)
Horsepower:
Approx. 60-65 HP (Stock)
Torque:
Approx. 70-75 ft-lbs (Stock)
Carburetor:
Keihin CV (Constant Velocity) 40mm
Fuel Type:
Unleaded Premium Gasoline (91 Octane Recommended)
Oil Type:
Harley-Davidson SYN3 (or equivalent V-Twin specific motorcycle oil meeting API CI-4)
Oil Capacity:
3.0 US quarts (2.8 Liters) with filter change
Type:
5-speed manual constant mesh
Primary Drive:
Duplex chain
Clutch:
Wet, multi-plate, diaphragm spring
Transmission Oil Type:
Harley-Davidson Formula + (or equivalent manual transmission lubricant)
Transmission Oil Capacity:
24 US fluid ounces (0.71 Liters)
Engine Oil Change:
Every 5,000 miles (8,000 km) or 6 months
Primary Chain Tensioner:
Inspect every 5,000 miles (8,000 km), replace if necessary (hydraulic tensioner common failure point)
Spark Plugs:
Replace every 10,000 miles (16,000 km)
Transmission Oil Change:
Every 10,000 miles (16,000 km) or 12 months
Belt Drive Tension:
Adjust as needed, typically every 5,000 miles (8,000 km)
Engine Oil Viscosity:
20W-50 (Harley-Davidson recommended)
Brake Fluid:
DOT 4 Hydraulic Fluid
Primary Chain Tensioner:
Hydraulic tensioner can wear out prematurely, leading to chain slap and potential damage. Upgrade to an aftermarket manual tensioner is common.
Carburetor Idle Stability:
Keihin CV carburetor may require periodic adjustment for stable idle and smooth throttle response.
Rear Wheel Alignment:
Proper rear wheel alignment is crucial for belt drive longevity and stable handling. Requires careful adjustment.
