Vehicle Segment:
Full-size touring motorcycle, popular for long-distance riding.
Key Competitors 2006:
Indian Chief, Honda Gold Wing, Kawasaki Vulcan Voyager, Yamaha Roadliner.
Touring Capabilities:
Designed for comfort and long-distance travel with fairing, saddlebags, and comfortable seating.
Styling:
Distinctive 'Sharknose' fairing and integrated saddlebags.
Comprehensive Coverage:
Full repair and maintenance procedures
Engine:
Detailed disassembly, assembly, inspection, and troubleshooting for the Twin Cam 96 engine.
Fuel System:
Fuel injection (EFI), fuel pump, fuel filter, fuel tank, and lines.
Ignition System:
Ignition module, coils, spark plugs, and wiring.
Transmission:
Six-speed Cruise Drive transmission: disassembly, assembly, lubrication, troubleshooting, and component replacement.
Clutch:
Clutch operation, adjustment, and service.
Drive System:
Belt drive system, primary drive, and final drive components.
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator), lighting, starting system (starter, solenoid), instrumentation, and accessories.
Brakes:
Hydraulic brake system: front and rear brake calipers, master cylinders, brake lines, brake pads, rotor inspection, and bleeding procedures.
Suspension:
Front fork (telescopic) and rear shock absorber system: disassembly, inspection, fluid changes, and adjustments.
Steering:
Handlebars, steering head bearings, and steering linkage service.
Frame And Body:
Frame inspection, body panel removal and installation, fairing, saddlebags, and seat service.
Wheels And Tires:
Wheel bearing inspection and replacement, tire mounting and balancing, and spoke tension adjustment (if applicable).
Exhaust System:
Exhaust pipe and muffler removal, installation, and inspection.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication points, and tune-ups.
Troubleshooting:
Diagnostic charts and procedures for identifying and resolving common and uncommon problems across all systems.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation.
Diagnostics:
Information on reading diagnostic codes (if applicable) and interpreting system behavior.
Level:
In-depth, suitable for professional technicians and experienced DIY mechanics.
Engine Type:
Air-cooled, 45-degree V-twin, Twin Cam 96
Displacement:
96 cubic inches (1584 cc)
Bore X Stroke:
3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)
Torque Figures:
Approximately 92.6 ft-lbs @ 3500 RPM (125.5 Nm)
Horsepower Figures:
Not officially stated by Harley-Davidson for this year, typically around 65-70 HP.
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded premium gasoline, minimum 91 octane
Oil Type:
Harley-Davidson recommends Screamin' Eagle Syn3 Full Synthetic Motorcycle Oil or equivalent SAE 20W-50.
Cooling Method:
Air-cooled
Transmission Type:
6-speed Cruise Drive, constant mesh
Primary Drive:
Plated, wet, multi-plate clutch, chain drive
Final Drive:
Belt drive, 25mm (2006 models)
Transmission Oil Type:
Harley-Davidson recommends Harley-Davidson Transmission Lubricant or Syn3 Synthetic Transmission Lubricant.
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months thereafter.
Engine Oil Grade:
SAE 20W-50
Primary Chain Case Fluid:
Harley-Davidson Primary Fluid or Syn3 Synthetic Motorcycle Oil
Transmission Fluid:
Harley-Davidson Transmission Lubricant or Syn3 Synthetic Transmission Lubricant
Cam Chain Tensioner:
Early Twin Cam models (pre-2007) had plastic cam chain tensioners that could wear out, leading to potential engine damage. This manual would cover inspection and replacement procedures.
Primary Drive Play:
Checking and adjusting primary drive chain tension is crucial.
Fuel Injector Issues:
Potential for clogging or sensor failures, addressed by system diagnostics.
Fork Seals:
Periodic inspection and replacement of fork seals due to normal wear and tear.
Brand Identity:
Iconic American motorcycle manufacturer known for its V-twin engines and cruiser/touring designs.
Road Glide Introduction:
Introduced in 1980 as the FLT Tour Glide.
Road Glide Name Change:
Renamed to Road Glide in 1998, featuring a frame-mounted fairing.
Twin Cam Introduction:
The Twin Cam 88 was introduced in 1999, with the Twin Cam 96 arriving for the 2007 model year. The 2006 model uses the Twin Cam 88B (balanced) or in some cases, the early Twin Cam 96 designation might be encountered for specific transitional production runs, though the standard for 2006 was largely the Twin Cam 88B.
Manufacturing Location:
York, Pennsylvania, USA and Milwaukee, Wisconsin, USA
