Target Audience:
Harley-Davidson Touring motorcycle owners seeking to perform maintenance and repairs themselves, as well as independent repair shops and professional dealerships.
Value Proposition:
Provides essential technical data and procedures that can save significant costs compared to dealership labor, while ensuring repairs are performed correctly to factory standards.
Diagnostic Focus:
Emphasis on troubleshooting and diagnostic procedures for identifying and resolving issues efficiently.
Visual Aids:
Includes detailed diagrams, schematics, and illustrations to aid understanding of complex procedures.
Specifications Accuracy:
Contains precise torque specifications, clearances, fluid capacities, and other critical technical data.
Primary Coverage:
Complete mechanical and electrical service, repair, and maintenance procedures.
Specific Models Included:
This manual covers all Harley-Davidson Touring models within the specified year range, including but not limited to Electra Glide, Road King, and Street Glide variants.
Estimated Pages:
Likely 800+ pages (typical for comprehensive workshop manuals of this era).
Type:
Workshop Service Repair Manual
Format:
Likely Digital (PDF or similar electronic format), potentially available in print.
Engine:
Detailed diagnostics, overhaul, tuning, and component replacement for Twin Cam 88, Twin Cam 96 engines (depending on model year and variant). Includes fuel injection systems (EFI), ignition systems, lubrication, cooling, and exhaust.
Transmission:
Comprehensive coverage of the 5-speed and 6-speed Cruise Drive transmissions, including clutch, gear sets, primary drive, final drive, and related components. Includes troubleshooting and overhaul procedures.
Electrical System:
Extensive detail on wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), ignition system, lighting, instrumentation, audio systems, and electronic control modules (ECM).
Chassis And Suspension:
Front fork (Telescopic, Springer forks for specific models), rear suspension (air-adjustable, emulsion shocks), steering, wheels, and tires. Includes bearing replacement, seal replacement, and alignment procedures.
Brakes:
Front and rear braking systems, including hydraulic components, calipers, master cylinders, brake lines, rotors, and ABS (if equipped). Includes bleeding procedures and pad/shoe replacement.
Fuel System:
Fuel tank, fuel pump, fuel injectors, fuel lines, and evaporative emissions control (EVAP) system for EFI models. Carburetor specifications and tuning for carbureted models.
Bodywork And Trim:
Fairings, saddlebags, tour-paks, fenders, seat removal, and general body panel maintenance. Includes graphical representations of component locations.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks/replacement, air filter cleaning/replacement, chain/belt adjustment (if applicable), brake fluid checks, and tire pressure adjustments.
Troubleshooting:
Systematic diagnostic guides for common performance issues, electrical faults, starting problems, and operational anomalies. Includes symptom-based troubleshooting charts.
Major Repairs And Overhauls:
Complete engine rebuilds, transmission disassembly and reassembly, suspension component overhauls, and brake system overhauls.
Electrical Diagnostics And Repair:
Wiring diagram interpretation, fault code reading (where applicable), component testing, and repair of electrical circuits.
Calibration And Adjustment:
Idle speed adjustment, throttle position sensor (TPS) calibration, and other necessary adjustments for optimal performance.
Depth Of Information:
Comprehensive, suitable for professional technicians and experienced DIY mechanics. Includes detailed specifications, torque values, and step-by-step instructions.
Engine Family:
Harley-Davidson Evolution (Evo) and Twin Cam engines.
Engine Variants Covered:
Twin Cam 88 (88 cubic inches, ~1450cc), Twin Cam 88B (counter-balanced), and early Twin Cam 96 (96 cubic inches, ~1584cc) engines, depending on model year.
Bore Stroke Twin Cam 88:
3.75 in x 4.00 in (95.25 mm x 101.6 mm)
Horsepower Twin Cam 88 Approx:
~70-75 HP (varies by model year and tune)
Torque Twin Cam 88 Approx:
~85-90 lb-ft (varies by model year and tune)
Fuel Delivery Systems:
Both Electronic Fuel Injection (EFI) with sequential port injection and Carbureted (Keihin CV carburetor) systems are covered.
Efi System Components:
Throttle body, fuel injectors, fuel pump, pressure regulator, oxygen sensors, MAP sensor, and ECM.
Recommended Fuel Octane:
Typically 91-93 octane (R+M)/2 unleaded gasoline.
Transmission Type Early:
5-speed manual, constant mesh.
Transmission Type Later:
6-speed Cruise Drive manual (introduced around 2007, but some earlier models may have received upgrades or the platform was transitioning).
Primary Drive:
Enclosed wet-type multi-plate clutch, chain drive to transmission.
Final Drive:
Belt drive (typically 1.125" width) or chain drive depending on specific model and year.
Transmission Fluid Type:
Harley-Davidson Formula+ Transmission Lubricant (or equivalent spec: SAE 50 gear oil).
Audio Systems:
Many Touring models of this era featured advanced (for the time) infotainment systems with AM/FM radio, cassette players, CD players, and CB radio/intercom functions, often with handlebar-mounted controls.
Speakers:
Integrated fairing speakers and/or saddlebag lid speakers.
Cruise Control:
Electronic cruise control was a common feature or option on Touring models.
Diagnostic Ports:
Features diagnostic connectors for accessing engine control module (ECM) data and fault codes using specialized Harley-Davidson diagnostic tools (e.g., Digital Technician).
First Service Mileage:
Typically 1,000 miles (1,600 km).
Subsequent Oil Change Interval:
Every 5,000 miles (8,000 km) or annually, whichever comes first, for engine oil and filter.
Transmission Fluid Change Interval:
Every 10,000 miles (16,000 km) or annually.
Primary Chain Case Fluid Change Interval:
Every 10,000 miles (16,000 km) or annually.
Spark Plug Replacement Interval:
Typically every 10,000 - 20,000 miles (16,000 - 32,000 km), depending on plug type.
Engine Oil Type:
Harley-Davidson Genuine Motor Oil (20W50 recommended for air-cooled engines) or equivalent API SG or higher rated synthetic/mineral oil.
Engine Oil Capacity:
Approx. 4 US quarts (3.8 liters) with filter change.
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid (check specific model for DOT 5 compatibility, though DOT 4 is more common).
Fork Oil Type:
Manufacturer-recommended fork oil (e.g., Harley-Davidson Type 'E' or equivalent, typically 5W or 10W).
Twin Cam 88 Cam Chain Tensioner:
Early Twin Cam 88 models are known for hydraulic cam chain tensioners that can wear and fail, potentially leading to noise or catastrophic engine damage if not addressed. Upgrade kits are available.
Primary Drive Bearing Issues:
Some models may experience wear in the primary drive bearings. Regular inspection and proper maintenance are crucial.
Rear Shock ABSorber Leaks:
Air-adjustable rear shocks on some models can develop leaks over time, affecting ride height and damping.
Electrical Connector Corrosion:
As with many motorcycles of this era, electrical connectors can be susceptible to corrosion, particularly in humid or coastal environments, leading to intermittent electrical issues.
