Major Systems:
Maintenance, Chassis, Engine, Fuel System, Starter, Drive, Transmission, Electrical, Fuel Injection, TSM & TSSM, Starting & Charging, Instruments, Engine Management (Carbureted & EFI), Wiring
Specific Engine Components:
Cylinder heads, pistons, connecting rods, crankshaft, camshafts, valve train, oil pump, cooling system (air-cooled, but includes oil cooler if equipped)
Specific Fuel System Components:
Carburetor (Mikuni BST or Keihin CV depending on model variation), fuel injection throttle body, injectors, fuel pump, fuel pressure regulator, fuel lines
Specific Transmission Components:
Gear sets, shift drum, shift forks, mainshaft, countershaft, clutch components, primary drive components
Specific Electrical Components:
Ignition system, charging system (stator, regulator/rectifier), starter motor, battery, lights, instruments, switches, relays, fuses, security system (TSM/TSSM)
Chassis Components:
Frame, front forks (including Springer front end for FXSTS), rear suspension (shock absorbers, swingarm), wheels, hubs, steering head, brakes (calipers, rotors, master cylinders), controls (handlebars, levers, foot controls).
Bodywork:
Fenders, fuel tank, seat, side covers, fairings (if applicable), lighting components.
Repair Procedures:
Complete tear down and rebuild, overhaul, troubleshooting, repair, maintenance, refurbishment, restoration
Diagnostic Procedures:
Troubleshooting charts, symptom-based diagnostics, error code interpretation (if applicable to the system), wiring diagrams for fault finding
Maintenance Procedures:
Oil changes, filter replacements, spark plug replacement, air filter service, brake fluid flush, chain adjustment, tire pressure checks, battery maintenance, clutch and throttle cable adjustments
Rebuild Procedures:
Engine top-end and bottom-end rebuilds, transmission overhaul, brake caliper overhaul, fork seal replacement, wheel bearing replacement
Installation Procedures:
Installation of accessories, replacement of major components, timing adjustments
Depth:
Comprehensive; includes pictures, part diagrams, torque specs, maintenance schedules, troubleshooting guides, electrical schematics
Detail Level:
Includes detailed step-by-step instructions with supporting visuals, torque specifications for all critical fasteners, component tolerances, and diagnostic flowcharts.
Wiring Diagrams:
Detailed electrical schematics with component locations and wire colors are included for comprehensive electrical diagnostics.
Typical Interval:
5,000-10,000 miles (detailed schedule in manual)
Specific Tasks:
Spark plug replacement (typically every 10,000 miles), belt inspection/replacement (drive belt), brake pad inspection.
Engine Oil:
Typically 20W50 Harley-Davidson motorcycle oil or equivalent (check manual for specific grade and capacity)
Primary Chain Case Oil:
Harley-Davidson primary chain case lubricant or equivalent
Transmission Oil:
Harley-Davidson transmission lubricant or equivalent
Coolant:
N/A (Air-cooled engines)
Common Topics In Manual:
Carburetor tuning (CV carb), EFI system diagnostics, starter clutch wear, primary chain adjustment, clutch adjustment, suspension maintenance, electrical component troubleshooting (TSM/TSSM issues).
Specific Electrical Troubleshooting:
TSM/TSSM (Turn Signal Modulator/Smart Security System) diagnostics, ignition coil testing, crank position sensor issues, starting system circuit failures.
Common Engine Topics:
Tappet adjustments, cam support plate inspection, primary drive chain tension, clutch disc wear.