Systems Covered:
Engine (including disassembly, assembly, troubleshooting), Fuel System (EFI), Ignition System, Transmission, Drive Train, Brakes, Suspension (front and rear), Electrical System (wiring diagrams, lighting, starting, charging), Chassis, Frame, Bodywork, Wheels, Tires, Controls, Lubrication, Maintenance, Diagnostics, Special Tools, Torque Specifications, Wear Limits, Performance Adjustments.
Electrical System Details:
Comprehensive wiring diagrams, starting system, charging system, lighting (headlamp, tail lamp, turn signals, brake lamp), instrumentation, horn, accessory circuits.
Chassis And Suspension:
Frame, front fork assembly, rear shock absorbers, wheel bearing maintenance, steering head bearing service.
Fuel System Details:
EFI system operation, fuel pump, injectors, throttle body, sensors, and diagnostics.
Engine Details:
In-depth coverage of Twin Cam 88B engine components, including top-end and bottom-end assemblies, lubrication system, and cooling system.
Bodywork And Trim:
Information on fenders, fuel tank, seat, handlebars, and other cosmetic and functional body components.
Procedures Included:
Detailed step-by-step procedures for removal, installation, disassembly, assembly, adjustment, inspection, testing, troubleshooting, and repair. Includes periodic maintenance schedules, fluid specifications, and tightening torques.
Troubleshooting Procedures:
Detailed diagnostic charts and troubleshooting guides for electrical issues, engine performance problems, transmission issues, and chassis-related problems.
Adjustment Procedures:
Precise instructions for clutch adjustment, brake adjustments, throttle cable adjustments, and other critical component settings.
Special Tool Reference:
References specific Harley-Davidson special tool numbers required for various repair and adjustment operations, with illustrations of tools in use.
Component Removal Installation:
Detailed procedures for removing and installing all major and minor components of the motorcycle.
Checks And Adjustments:
Procedures for checking and adjusting various parameters, including timing, fuel mixture, and mechanical clearances.
Assembly Disassembly:
Comprehensive guides for the disassembly and reassembly of all mechanical parts and systems.
Technical Depth:
Comprehensive and detailed, covering basic maintenance to advanced diagnostics and complete rebuilds. Explanations are simple and precise, suitable for both experienced mechanics and DIY enthusiasts.
Pictorial Diagrams:
Includes step-by-step explanations with detailed illustrations, exploded diagrams, drawings, and photos for all repair procedures.
Diagnostic Information:
Includes diagnostic information and flowcharts for identifying and resolving common vehicle problems.
Wear Limits:
Includes specified wear limits for critical engine and transmission components to ensure proper assembly and performance.
Pictorial Representation:
Illustrations are used to highlight fundamental principles and procedures, though they may not depict the exact motorcycle configuration in possession.
Oil Change Interval:
Refer to manual for specific mileage/time intervals. Typically every 5,000 miles or annually.
Major Service Intervals:
Refer to the manual for 10,000-mile, 20,000-mile, and other significant service intervals, including spark plug replacement, belt inspection, and brake fluid checks.
Periodic Maintenance Chart:
Availability of a periodic maintenance chart for consistent and timely servicing to maximize vehicle life.
Engine Oil Type:
Harley-Davidson SYN3 (or equivalent API SG, JASO FD approved SAE 20W50 motorcycle oil)
Primary Chain Case Oil:
Harley-Davidson Primary Chain Lubricant or equivalent SAE 80W-90 hypoid gear oil
Transmission Oil:
Harley-Davidson Formula + Transmission Lubricant or equivalent SAE 80W-90 hypoid gear oil
Fuel Type:
Unleaded gasoline, 91 octane (R+M)/2 or higher recommended
Known Issues:
Potential for cam bearing wear, oil leaks, and exhaust pipe discoloration. Refer to the manual for specific troubleshooting of these and other common issues.
Efi Troubleshooting:
Specific guidance on diagnosing and resolving issues related to the Electronic Fuel Injection system.
