Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson owners and independent repair shops.
Competitors:
Other American V-twin cruisers of the era (e.g., Indian, custom choppers).
Model Identity:
Retro styling, comfortable riding position, iconic V-twin engine, advanced fuel injection for its time.
Manual Utility:
Essential for maintaining the longevity and performance of the FLSTNI.
Major Systems:
Engine, Fuel System, Ignition, Transmission, Clutch, Drive Train, Frame, Suspension, Wheels, Tires, Brakes, Electrical System, Lighting, Instruments, Controls, Bodywork, Fairings, Seats, Luggage
Estimated Pages:
Over 600 (typical for Harley service manuals of this era)
Type:
Service Repair Manual
Engine Overhaul:
Complete disassembly, inspection, and reassembly of the Twin Cam 88 engine.
Fuel System Diagnosis:
Fuel injection system troubleshooting, component testing (ECM, injectors, sensors), fuel pump, pressure regulator.
Ignition System:
Spark plug replacement, ignition coil testing, crank position sensor diagnosis, ignition module.
Transmission Service:
5-speed gearbox maintenance, clutch adjustment and replacement, primary drive system service.
Brake System:
Front and rear brake caliper service, master cylinder rebuild, brake fluid flush and bleeding procedures, ABS (if equipped).
Electrical Diagnostics:
Wiring diagrams, troubleshooting common electrical faults, battery maintenance, charging system diagnosis (stator, regulator/rectifier).
Suspension And Steering:
Front fork service (oil change, seal replacement), rear shock absorber replacement, steering head bearing adjustment.
Bodywork And Trim:
Fender removal and installation, fuel tank maintenance, seat mounting, fairing components.
Scheduled Maintenance:
Detailed procedures for oil changes, filter replacements, spark plug changes, and other routine services.
Troubleshooting Guides:
Systematic diagnostic steps for common and uncommon performance issues.
Component Replacement:
Step-by-step instructions for replacing major and minor components.
Torque Specifications:
All critical fastener torque values for engine, chassis, and bodywork.
Special Tool Requirements:
Identification and usage of specialized Harley-Davidson tools.
Depth:
Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds.
Diagnostic Capabilities:
In-depth electrical troubleshooting and fuel injection system diagnosis.
Engine Family:
Harley-Davidson Twin Cam 88
Engine Type:
Air-cooled, 45-degree V-twin
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Horsepower:
Approx. 65-70 HP (claimed, at crankshaft, varies with tuning)
Torque:
Approx. 80-86 ft-lbs (claimed, at crankshaft, varies with tuning)
Induction:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 89 octane recommended
Fuel Tank Capacity:
5.0 US gallons (18.9 L)
Transmission Type:
5-speed constant mesh, left-foot shift
Primary Drive:
Duplex chain, 34/46 ratio (1.35:1)
Final Drive:
Belt drive, 32/66 ratio (2.06:1)
Clutch Type:
Wet, multi-plate
Oil Capacity:
Primary Case: 2.8 US quarts (2.6 L) - Use Harley-Davidson Formula+ transmission and primary lubricant.
Safety Certifications:
Complies with applicable federal motor vehicle safety standards (FMVSS) for motorcycles.
Brakes:
Dual-action, front disc brake; Single-action, rear disc brake.
Lighting:
Halogen headlight, taillight, brake light, front and rear turn signals.
Instrumentation:
Analog speedometer, tachometer, fuel gauge, oil pressure gauge, and indicator lights. Often includes a clock and trip meter.
Audio System:
Optional factory or aftermarket radio/audio systems may be present, but not standard on all FLSTNI models.
ABS Availability:
Anti-lock Braking System (ABS) was an optional feature for this model year and specific trim.
Diagnostics Port:
On-board diagnostics (OBD-II equivalent for motorcycles) for engine management and fault codes, accessible via dealer diagnostic tools or compatible aftermarket scanners.
Engine Oil Change:
Every 2,500 miles (4,000 km) or 6 months, whichever comes first.
Primary Chain Tensioner Check:
Inspect at 1,000 miles (1,600 km), then every 5,000 miles (8,000 km) or annually.
Spark Plug Replacement:
Every 10,000 miles (16,000 km).
Brake Fluid Flush:
Every 2 years or as needed based on inspection.
Engine Oil:
Harley-Davidson 20W-50 Genuine Synthetic (or equivalent SAE 20W-50 motorcycle oil meeting Harley-Davidson performance requirements).
Transmission Primary Lube:
Harley-Davidson Formula+ Transmission and Primary Chain Lubricant.
Brake Fluid:
DOT 4 brake fluid.
Primary Chain Tensioner:
The automatic primary chain tensioner can wear prematurely; manual inspection and replacement as needed is crucial.
Cam Chain Tensioner Seals:
Early Twin Cam models (pre-2007) have non-hydraulic cam chain tensioners that can wear; refer to manual for inspection and potential upgrade advice.
Fuel Injector Clogging:
Can occur with poor fuel quality or infrequent use; periodic fuel system cleaner may help.
Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and distinct styling.
Softail Lineage:
The Softail line, introduced in the early 1980s, is characterized by its hidden rear suspension, mimicking the appearance of a rigid frame while providing modern comfort.
Flstni Development:
The FLSTNI Softail Deluxe debuted in 2005, building upon the Softail platform with retro styling cues, chrome accents, and the then-current Twin Cam 88 engine with fuel injection.
Production Period:
2005-2006 (as FLSTNI with Twin Cam 88 EFI)
