Category:
Heavyweight Touring Motorcycle
Target Audience:
Long-distance touring riders, customizers, and owners seeking in-depth maintenance and repair knowledge
Positioning:
Flagship touring model offering premium features and comfort for extended journeys, competing with other premium touring motorcycles from brands like Indian and Honda (Gold Wing).
Touring Amenities:
Integrated fairing with windshield, saddlebags, Tour-Pak luggage, comfortable seating for rider and passenger, advanced sound system, cruise control.
Performance Highlights:
Torquey V-Twin engine, stable chassis, smooth power delivery for highway cruising.
General Coverage:
Complete Service and Repair
Specific Coverage:
Engine, Transmission, Chassis, Electrical, Fuel System, Ignition, Suspension, Brakes, Bodywork, Maintenance, Troubleshooting
Type:
Workshop Service Repair Manual
Primary Language:
English
Digital Format:
Downloadable PDF
Engine Systems:
Twin Cam 96 V-Twin, Fuel Injection (EFI), Ignition System, Lubrication System, Cooling System (Oil), Exhaust System
Powertrain Systems:
Transmission (6-speed Cruise Drive), Clutch, Drive Belt System
Chassis Systems:
Frame, Suspension (Front & Rear), Steering, Wheels, Tires, Brakes (Front & Rear Disc), Swingarm
Electrical Systems:
Battery, Charging System (Alternator, Regulator), Starting System, Lighting System (Headlights, Taillights, Signals), Instruments and Gauges, Audio System, Cruise Control, Security System (Smart Security System), Wiring Diagrams, ECM/ECU Diagnostics
Fuel And Emission Systems:
Fuel Tank, Fuel Pump, Fuel Filter, Fuel Injectors, Emission Controls (Catalytic Converters)
Body Components:
Fairing, Saddlebags, Tour-Pak, Seat, Handlebars, Controls, Windshield
Maintenance Procedures:
Oil Change, Filter Replacement, Air Filter Service, Spark Plug Replacement, Brake Pad Replacement, Belt Tension Adjustment, Battery Maintenance
Repair Procedures:
Engine Overhaul, Transmission Rebuild, Clutch Replacement, Suspension Component Repair, Brake System Bleeding and Repair, Electrical Component Diagnosis and Replacement
Troubleshooting Guides:
Diagnostic flowcharts for common issues, error code interpretation, electrical system fault finding
Assembly Disassembly:
Detailed step-by-step instructions for component removal and installation
Depth Level:
Comprehensive; from basic maintenance to full engine and transmission rebuilds, including electrical diagnostics
Diagnostic Capability:
Covers common issues, fault codes, and diagnostic procedures for electronic systems
Engine Type:
Harley-Davidson Twin Cam 96 V-Twin
Displacement:
96 cubic inches (1584cc)
Bore X Stroke:
3.75 in x 4.38 in (95.25 mm x 111.25 mm)
Cooling System:
Air-cooled with oil cooler
Valvetrain:
Overhead valves (OHV), 2 valves per cylinder
Ignition Type:
Electronic Sequential Port Fuel Injection (ESPFI)
Horsepower Estimate:
Approximately 75-80 HP (at crankshaft, depending on dyno and specific model year tuning)
Torque Estimate:
Approximately 90-95 ft-lbs (at crankshaft, depending on dyno and specific model year tuning)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded Gasoline, 91 octane or higher recommended
Fuel Tank Capacity:
6.0 gallons (22.7 L)
Transmission Type:
6-speed Cruise Drive
Gear Ratios:
1st: 9.593, 2nd: 6.650, 3rd: 4.943, 4th: 3.895, 5th: 3.307, 6th: 2.790
Clutch Type:
Hydraulically actuated, 9-plate, wet clutch
Final Drive:
Carbon fiber reinforced belt, 1.25 in wide
Transmission Fluid Type:
Harley-Davidson Formula Plus Lubricant (or equivalent recommended by Harley-Davidson)
Transmission Fluid Capacity:
Approximately 2.8 quarts (2.65 L)
Overall Length:
Approx. 101.0 inches (2565 mm)
Overall Width:
Approx. 38.0 inches (965 mm)
Overall Height:
Approx. 53.5 inches (1359 mm)
Wheelbase:
Approx. 63.5 inches (1613 mm)
Ground Clearance:
Approx. 5.0 inches (127 mm)
Dry Weight:
Approx. 850 lbs (386 kg)
Gvwr (Gross Vehicle Weight Rating):
Approx. 1360 lbs (617 kg)
Payload Capacity:
Approx. 510 lbs (231 kg)
Saddlebag Capacity:
Approx. 2.0 cu ft (56 L) each
Tour Pak Capacity:
Approx. 2.2 cu ft (62 L)
Crash Test Ratings:
Motorcycles are not typically subjected to standardized crash test ratings like automobiles. Safety relies on design and rider skill.
Braking System:
Linked, power-assisted, 4-piston front and rear calipers, 320mm front and rear floating rotors.
Cruise Control:
Standard electronic cruise control system.
Lighting:
Halogen headlight, LED taillight, front and rear amber turn signals, auxiliary running lights on fairing.
Security System:
Standard Harley-Davidson Smart Security System with hands-free fob.
Chassis Stability:
Designed for stable handling at highway speeds.
Audio System:
Harley-Davidson's Advanced Audio System with AM/FM/WB tuner, CD player (in some configurations), and auxiliary input for MP3 players or smartphones.
Speakers:
Fairing-mounted speakers, and often rear speakers integrated into the Tour-Pak or fairing lowers, depending on trim.
Cruise Control:
Electronic cruise control for reduced rider fatigue on long journeys.
Braking Enhancements:
Linked, power-assisted braking system for improved stopping power and feel.
Device Integration:
Auxiliary audio input for connecting external audio devices.
Diagnostics Interface:
The manual provides insights into the bike's Electronic Control Module (ECM) and diagnostic port for reading fault codes.
First Service:
1,000 miles (1,600 km) or 6 months (whichever comes first) - includes engine oil and filter change, primary chain tension adjustment, inspection of brakes, tires, and other critical components.
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months (whichever comes first) - includes engine oil and filter change, primary chain tension adjustment, inspection of brakes, tires, etc. Specific items like spark plugs, air filters, and brake fluid have longer intervals specified in the manual.
Engine Oil:
Harley-Davidson Full Synthetic 20W-50 motorcycle oil (e.g., SYN3) or a high-quality equivalent API CI-4 rated 20W-50 diesel engine oil. Capacity: 4 quarts (3.8 L) for crankcase oil.
Transmission Oil:
Harley-Davidson Formula Plus Lubricant or an equivalent 75W-90 synthetic gear oil (API GL-5). Capacity: 2.8 quarts (2.65 L).
Primary Chain Case Oil:
Harley-Davidson Formula Plus Lubricant or an equivalent 20W-50 motorcycle oil. Capacity: 2.8 pints (1.3 L).
Brake Fluid:
DOT 4 brake fluid
Cam Chain Tensioners:
Early Twin Cam engines (pre-2007) were known for hydraulic cam chain tensioner wear. Models from 2007 onwards utilize improved tensioners, but inspection and potential replacement with upgraded components are still relevant.
Regulator Rectifier:
Some Harley-Davidson models of this era experienced premature failure of the regulator/rectifier, affecting charging system performance. This manual will detail testing and replacement.
Exhaust Leaks:
Exhaust gaskets can sometimes leak, particularly at the cylinder head. Proper torque and gasket replacement are covered.
Idle Speed Control:
Issues with the idle air control (IAC) motor or throttle body can lead to rough idling or stalling. The manual will cover diagnostics.
Brand Origin:
Founded in Milwaukee, Wisconsin, in 1903, Harley-Davidson is an iconic American motorcycle manufacturer known for its V-twin engines and cruiser/touring motorcycles.
Touring Lineage:
The Ultra Classic Glide is a descendant of Harley-Davidson's long line of touring motorcycles, evolving from the original Electra Glide models introduced in the 1960s.
Twin Cam Introduction:
The Twin Cam engine platform, introduced in 1999, represented a significant upgrade in performance and reliability for Harley-Davidson's V-twin motorcycles. The Twin Cam 96 variant, used in these years, offered increased displacement and torque.
Manufacturing Location:
Primarily manufactured at Harley-Davidson's York, Pennsylvania, and Milwaukee, Wisconsin facilities.
Market Reputation:
Consistently recognized as a benchmark in the luxury touring motorcycle segment for comfort, features, and long-distance capability.
Industry Awards:
While specific awards may vary by year, the Ultra Classic Glide platform has frequently been lauded by motorcycle publications for its comprehensive touring amenities and V-twin performance.
Emission Compliance:
Compliant with EPA and California Air Resources Board (CARB) emission standards for the respective model years.