Target Audience:
Harley-Davidson owners, independent repair shops, and professional motorcycle technicians.
Value Proposition:
Provides authorized-level repair and maintenance information, enabling significant cost savings compared to dealership service. Essential for owners who perform their own maintenance.
Comprehensiveness:
Covers all aspects of motorcycle service and repair, ensuring accuracy and completeness for a wide range of tasks.
Official Guidance:
Based on factory service procedures, ensuring correct methods and specifications are followed for optimal performance and longevity.
Engine:
Twin Cam 88B and Twin Cam 96B V-Twin engines, including disassembly, assembly, inspection, and diagnosis.
Fuel System:
Fuel injection (EFI) system, including sensors, actuators, fuel pump, injectors, and diagnostic procedures. Carbureted models may have separate sections or be covered if applicable to specific sub-models.
Transmission:
5-speed constant mesh transmission, including clutch, primary drive, gear inspection, lubrication, and repair procedures.
Electrical System:
Ignition system, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instrumentation, and accessory wiring. Includes wiring diagrams.
Brakes:
Hydraulic disc brake systems (front and rear), including caliper service, master cylinder overhaul, brake fluid replacement, and bleeding procedures. ABS system diagnostics if applicable.
Suspension:
Front fork (including cartridge types) and rear shock absorber service, inspection, fluid replacement, and spring adjustments. Wheel bearing service.
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat service, fuel tank mounting, and fairing/saddlebag components.
Wheels And Tires:
Wheel removal, installation, spoke tensioning (if applicable), tire mounting and balancing, and recommended tire pressures.
Exhaust System:
Exhaust pipe and muffler inspection, gasket replacement, and mounting hardware.
Cooling System:
Engine oil cooling system, including oil filter replacement and oil level checks.
Maintenance:
Routine maintenance tasks such as oil changes, filter replacements, spark plug service, battery checks, and lubrication points.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides for common electrical, engine, and mechanical issues.
Repair:
Step-by-step instructions for disassembling, repairing, and reassembling major vehicle components and systems.
Diagnostics:
Detailed diagnostic procedures for engine control modules (ECM), sensors, and actuators. Use of Harley-Davidson diagnostic tools (e.g., Digital Technician) may be referenced.
Specifications:
Torque specifications, clearance measurements, timing procedures, and other critical technical data.
Depth:
Comprehensive, covering everything from basic maintenance to major component overhaul and advanced diagnostics. Geared towards professional mechanics and experienced DIY enthusiasts.
Engine Variants:
Twin Cam 88B (96 cu. in./1584cc), Twin Cam 96B (102 cu. in./1670cc) for some 2007 models.
Configuration:
Air-cooled, 45-degree V-twin
Bore Stroke:
Twin Cam 88B: 3.75 in. x 4.38 in. (95.25 mm x 111.25 mm); Twin Cam 96B: 3.75 in. x 4.50 in. (95.25 mm x 114.3 mm)
Compression Ratio:
Typically 9.2:1 for Twin Cam 88B, 9.0:1 for Twin Cam 96B
Valve Train:
Overhead valve (OHV), 2 valves per cylinder
Horsepower:
Approx. 60-70 HP (Varies by specific model and tune)
Torque:
Approx. 85-95 lb-ft (Varies by specific model and tune)
Injection Type:
Electronic Sequential Port Fuel Injection (ESPFI) is standard. Some earlier or special edition models might have carburetion.
Fuel Requirement:
87-91 Octane Unleaded Gasoline
Ignition System:
Electronic Ignition with knock sensor
Wheelbase:
Approx. 64.5 - 65.5 inches (1638 - 1664 mm), depending on specific Softail model (e.g., Fat Boy, Heritage Softail Classic).
Length:
Approx. 90-95 inches (2286-2413 mm)
Seat Height:
Approx. 26-27 inches (660-686 mm)
Dry Weight:
Approx. 650-700 lbs (295-318 kg), depending on specific model.
Gross Vehicle Weight Rating:
Typically around 1160 lbs (526 kg)
Cargo Capacity:
Primarily dependent on accessory saddlebags and luggage racks.
Crash Test Data:
Motorcycle crash testing data is not standardized in the same way as automobiles. Focus is on handling and braking performance.
Braking:
Dual-piston front and rear hydraulic disc brakes. Anti-lock Braking System (ABS) was an optional or standard feature on certain 2006/2007 Softail models (e.g., FLHTCI, FLHTCUI, etc., though these are touring models. Softail ABS availability might be model-specific).
Lighting:
Halogen headlamp, LED tail/brake lamp, front and rear turn signals.
Instrumentation:
Speedometer, tachometer (on some models), fuel gauge, oil pressure indicator, engine diagnostics indicator (CEL).
Oil Change:
Typically every 2,500 - 5,000 miles or 6-12 months, whichever comes first. Specific interval depends on oil type and riding conditions.
Primary Chain Tensioner Inspection:
Inspect every 5,000 - 10,000 miles, as automatic tensioners can wear out.
Spark Plugs:
Replace every 10,000 - 15,000 miles.
Brake Fluid:
Flush and replace every 2 years, regardless of mileage.
Engine Oil:
Harley-Davidson SYN3 Full Synthetic Motorcycle Oil (SAE 20W-50) is recommended. Equivalent high-quality motorcycle-specific synthetic oil can be used.
Transmission Oil:
Harley-Davidson SYN3 Full Synthetic Motorcycle Oil or Formula Plus (SAE 50W) is recommended. Some owners use dedicated transmission fluids like Red Line ShockProof Gear Oil.
Primary Chain Case Oil:
Harley-Davidson Formula + or equivalent primary lubricant (typically 20W-50 motorcycle oil or a specific primary lubricant).
Brake Fluid:
DOT 4 Brake Fluid
Fork Oil:
Harley-Davidson Type E (5W) or Type B (10W) fork oil, or equivalent. Specific weight depends on model and preference.
Engine Oil Capacity:
Approx. 4 US quarts (3.8 L) with filter change.
Transmission Oil Capacity:
Approx. 2.8 US quarts (2.6 L)
Primary Chain Case Capacity:
Approx. 1.1 US quarts (1.0 L)
Primary Chain Tensioner:
The automatic primary chain tensioner (plastic shoe) is known to wear out, leading to chain slap and potential damage if not replaced. Upgraded hydraulic tensioners are a common aftermarket solution.
Cam Chain Tensioners:
Older Twin Cam engines (pre-2007) used cam chain tensioners that could wear. While the 2006/2007 models might have improved versions, inspection is still recommended. Later models used a single hydraulic tensioner.
Crank Position Sensor:
Failure of the crank position sensor can cause starting issues or the engine to stall.
Fuel Pump Reliability:
Some early EFI systems experienced issues with fuel pump reliability, though improvements were made over time.
Motorcycle Icon:
Harley-Davidson is synonymous with American cruiser motorcycles, known for their V-twin engines, distinctive styling, and rich cultural heritage.
Softail Introduction:
The Softail platform was introduced in 1983, featuring a hidden rear suspension designed to mimic the look of a rigid frame while providing rider comfort. The styling and engineering have evolved significantly over the years.
2006 2007 Era:
This period saw the transition and widespread adoption of the Twin Cam 88B and the introduction of the larger Twin Cam 96B engine, representing a significant upgrade in performance and refinement.
Manufacturing Location:
Harley-Davidson motorcycles are primarily manufactured in the United States (e.g., Milwaukee, Wisconsin; York, Pennsylvania).
Brand Acclaim:
Harley-Davidson motorcycles consistently receive acclaim for their iconic styling, V-twin sound, and heritage, appealing to a loyal customer base.
Customer Satisfaction:
Generally high customer satisfaction ratings among owners, particularly for styling and ownership experience, though mechanical reliability can vary.
Technical Accuracy:
This manual aims to adhere to the technical standards and procedures set by Harley-Davidson, providing certified accuracy for repair work.
