Harley Davidson Softail 2010 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Softail Year: 2010 Vehicle Type: Motorcycle Market Segment: Cruiser Codes Chassis Code: Softail Platform 👋 Introduction Market Position Positioning Statement: The 2010 Harley-Davidson...

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Softail

Year:

Vehicle Type:

Motorcycle

Market Segment:

Cruiser

Codes

Chassis Code:

Softail Platform

👋 Introduction

Market Position

Positioning Statement:

The 2010 Harley-Davidson Softail represents a significant era for the iconic American cruiser brand, blending classic styling with modern performance and technology.

Competitive Analysis

Key Competitors:

Competed against other large-displacement cruisers from brands like Indian Motorcycle, Victory Motorcycles, and some Japanese manufacturers offering similar styling cues.

Key Features

Design Philosophy:

Emphasizes the 'soft tail' look with hidden rear suspension, providing a rigid frame aesthetic while maintaining ride comfort.

Engine Options:

Primarily powered by Harley-Davidson's robust Twin Cam engine family, specifically the Twin Cam 96B and Twin Cam 103B variants, known for their distinctive V-twin character and torque delivery.

Heritage Appeal:

Continues the legacy of classic Harley-Davidson styling, making it a desirable choice for riders who appreciate tradition.

📋 Manual Details

Coverage Areas

Manual Scope:

All Softail models, engines, trims, and variants for the 2010 model year.

Page Count

Estimated Page Count:

Approximately 800-1200 pages (typical for comprehensive workshop manuals)

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine And Powertrain:

Detailed coverage of Twin Cam 96B and Twin Cam 103B engines, including disassembly, assembly, inspection, lubrication, cooling, fuel, ignition, and exhaust systems.

Transmission And Drivetrain:

Comprehensive information on the 6-speed Cruise Drive transmission, clutch, primary drive, final drive belt, and related components.

Suspension And Steering:

Front fork (e.g., 49mm Telescopic) and rear suspension (shock absorbers, swingarm) service, along with steering head bearing and handlebar assembly.

Brakes:

Front and rear brake systems, including hydraulic lines, master cylinders, calipers, rotors, and ABS (if equipped).

Electrical System:

Wiring diagrams, battery, charging system (alternator/stator, regulator/rectifier), starting system, lighting, ignition system, and electronic control modules (ECM).

Body And Frame:

Frame, body panels, fenders, fuel tank, seat, handlebars, mirrors, and cosmetic components.

Wheels And Tires:

Wheel bearing service, tire mounting and balancing, and specifications.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and changes, lubrication points, and scheduled inspections.

Engine Overhaul:

Complete engine teardown, inspection, measurement, and reassembly procedures for pistons, cylinders, crankshaft, camshafts, and valvetrain.

Transmission Repair:

Service and repair of the gearbox, clutch assembly, and primary drive.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, including symptom analysis, fault finding, and corrective actions.

Electrical Diagnostics:

Step-by-step troubleshooting for electrical faults using wiring diagrams and test procedures.

Component Replacement:

Detailed instructions for replacing specific parts such as brake pads, starter motor, alternator, fuel pump, and sensors.

Wheel Alignment And Balancing:

Procedures for proper wheel alignment and tire balancing.

Technical Depth

Diagnostic Tools:

Information on required special tools and diagnostic equipment (e.g., Harley-Davidson Diagnostic Tool - H-D-DTS).

Specifications And Tolerances:

Precise measurements, clearances, torque specifications, and tolerances for all mechanical and electrical components.

Rebuild Procedures:

Comprehensive instructions for engine and transmission rebuilds, including part specifications and critical clearances.

Wiring Diagrams:

Detailed, color-coded wiring diagrams for all electrical systems, facilitating easy tracing of circuits.

Troubleshooting Charts:

Flowchart-style troubleshooting guides for common problems.

📊 Manual Specifications

File Format

File Type:

Searchable:

Likely searchable text within the PDF for easy navigation.

Printable:

Designed to be printable for workshop use.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper Quality:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Harley-Davidson Twin Cam

Engine Variants:

Twin Cam 96B (96.7 cu in / 1584cc), Twin Cam 103B (103.1 cu in / 1690cc)

Configuration:

Air-cooled, 45-degree V-twin

Bore X Stroke 96B:

3.75 in x 4.38 in (95.25 mm x 111.25 mm)

Bore X Stroke 103B:

3.875 in x 4.38 in (98.4 mm x 111.25 mm)

Performance

Horsepower 96B:

Estimated 70-75 HP (figures vary by source and specific model)

Torque 96B:

Estimated 88-92 ft-lbs @ 3,000-3,500 RPM

Horsepower 103B:

Estimated 75-80 HP (figures vary by source and specific model)

Torque 103B:

Estimated 95-100 ft-lbs @ 3,000-3,500 RPM

Fuel System

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, 91 octane (R+M)/2 or higher recommended

Fuel Tank Capacity:

Typically 5.0 gallons (18.9 L)

🔧 Transmission

Standard

Transmission Type:

6-speed Cruise Drive, Constant Mesh

Optional

Optional Transmission:

N/A (6-speed was standard across Softail models)

Features

Clutch Type:

Hydraulically actuated, 9-plate, wet clutch

Primary Drive:

Plated, Heavy-Duty, Rubber-damped Chain

Final Drive:

Carbon fiber belt, 140-tooth, 14mm pitch

Transmission Fluid Capacity:

Approximately 2.6 quarts (2.5 L)

Transmission Fluid Specification:

Harley-Davidson Transmission Fluid (Part No. 99830-00)

📐 Dimensions

Exterior

Overall Length:

Varies by specific Softail model (e.g., Fat Boy Lo, Heritage Softail Classic, Night Train), typically 90-95 inches.

Wheelbase:

Varies by specific Softail model, typically 64.5 - 66.5 inches.

Weights

Dry Weight:

Varies by model, typically 600-700 lbs.

Gvwr:

Varies by model, typically around 1000-1100 lbs.

Ground Clearance:

Varies by model, typically 4-5 inches.

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles are not subject to the same crash testing protocols as automobiles)

Active Features

Optional on some models, standard on others. Refer to specific model for availability.

Braking System:

Hydraulic disc brakes front and rear.

Passive Features

Lighting:

Halogen headlamp, front and rear turn signals, brake light.

Tire Specifications:

Tubeless tires. Specific sizes vary by model (e.g., front 130/90B16, rear 150/80B16 for some models).

Wheel Bolt Pattern:

N/A (Wheels attach via axle and bearings)

💡 Technology Features

Infotainment

Audio System:

Optional or standard on some higher-trim models, typically featuring AM/FM radio and auxiliary input. Advanced infotainment systems were less common on base Softail models of this era.

Driver Assistance

Cruise Control:

Available on some models as an option or standard equipment.

Connectivity

Diagnostics Port:

Diagnostic port for connecting Harley-Davidson diagnostic tools for fault code retrieval and system analysis.

🔧 Maintenance

Service Intervals

First Service:

Typically at 1,000 miles (1,600 km) or 6 months, whichever comes first.

Subsequent Services:

Generally every 5,000 miles (8,000 km) or 12 months for routine checks and fluid changes. More specific intervals for components like spark plugs, belt tension, and brake fluid.

Fluid Specifications

Engine Oil Type:

Harley-Davidson V-Twin Synthetic (20W-50) or equivalent API CJ-4, JASO MA approved oil.

Engine Oil Capacity:

Approximately 4 quarts (3.8 L) with filter change.

Primary Chain Case Fluid:

Harley-Davidson Primary Formula SAE 50 (Part No. 99815-87A) or equivalent.

Primary Chain Case Fluid Capacity:

Approximately 1 quart (0.95 L)

Brake Fluid Type:

DOT 4 or DOT 5.1 (Check specific model for recommendations, DOT 5 silicone is not compatible with systems designed for DOT 4/5.1).

Fork Oil Type:

Varies by model and fork type, often a specific weight of fork oil (e.g., Harley-Davidson Type E or Type B).

Known Issues

Common Wear Items:

Clutch wear, belt wear, brake pad wear, and potential for oil leaks typical for high-mileage motorcycles.

Electrical Gremlins:

Intermittent electrical issues can sometimes arise due to vibration or corrosion, especially with aftermarket components.

Engine Temperature:

Air-cooled engines can run hot in heavy traffic, requiring proper maintenance of cooling fins and oil.

📚 Vehicle History

Brand Heritage

Heritage Statement:

Harley-Davidson, founded in 1903, is an American icon renowned for its V-twin motorcycles, freedom, and a distinct riding culture.

Model Evolution

Softail Introduction:

The Softail platform was introduced in 1984, designed to emulate the look of a hardtail frame with the comfort of hidden rear suspension.

2010 Generation:

The 2010 Softail lineup represented a mature iteration of the platform, benefiting from years of refinement and the introduction of the Twin Cam engine.

Production

Manufacturing Location:

Primarily manufactured in Milwaukee, Wisconsin, USA.

🏆 Awards & Recognition

Recognitions

Brand Awards:

Harley-Davidson has received numerous accolades for its engineering, design, and brand heritage over its long history.

Ratings

Customer Satisfaction:

Generally high customer satisfaction for the Softail line, appreciated for its classic styling and riding experience.

Certifications

Emissions Standards:

Meets applicable EPA and California Air Resources Board (CARB) emissions standards for motorcycles of its model year.