Engine Mechanical:
Engine disassembly, assembly, inspection, timing, valve adjustments, cylinder head service, piston and connecting rod service, crankshaft service.
Fuel System:
Fuel injection system (EFI), throttle body, fuel pump, fuel injectors, fuel lines, fuel tank servicing.
Ignition System:
Ignition module, spark plugs, ignition coils, troubleshooting ignition faults.
Transmission:
Primary drive, transmission case, gears, bearings, clutch, shifter mechanism, transmission fluid service.
Drivetrain:
Final drive belt, belt tensioning, pulleys, wheel bearings.
Brakes:
Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake pads, brake fluid flush and bleeding, ABS system (if equipped).
Suspension:
Front fork service (oil change, seal replacement), rear shock absorbers, swingarm, wheel alignment.
Electrical System:
Battery, charging system (alternator, regulator), starter motor, lighting (headlights, taillights, turn signals), horn, fuses, relays.
Instrumentation:
Speedometer, tachometer, fuel gauge, indicator lights, diagnostics (fault codes).
Chassis And Frame:
Frame inspection, steering head bearings, jiffy stand, footboards, handlebars.
Bodywork And Trim:
Fairing, saddlebags, fenders, seat removal and installation, graphics.
Diagnostics:
Troubleshooting procedures, diagnostic trouble codes (DTCs), using diagnostic tools (e.g., Digital Technician).
Wiring Diagrams:
Comprehensive electrical schematics and wiring diagrams with component identification.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, brake fluid changes, battery checks, tire pressure checks, lubrication points.
Repair:
Step-by-step instructions for all major and minor repairs to all systems.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and uncommon issues.
Rebuilds:
Complete engine and transmission rebuild instructions.
Disassembly Assembly:
Detailed procedures for taking apart and reassembling all components and systems.
Component Replacement:
Instructions for replacing wear items such as brake pads, clutch plates, bearings, and seals.
Adjustments:
Valve clearance adjustments, clutch cable adjustments, idle speed adjustments.
Depth Level:
Comprehensive, suitable for professional technicians and experienced DIY mechanics.
Diagnostic Capabilities:
Advanced diagnostic strategies and troubleshooting flowcharts for complex issues.
Rebuild Detail:
Detailed specifications for machining, tolerances, and assembly procedures for engine and transmission overhauls.
Engine Type:
Air-cooled, Twin Cam 96B
Displacement:
96 cu. in. (1584 cc)
Bore X Stroke:
3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)
Valve Train:
Overhead valves (OHV), 4 valves per cylinder (2 intake, 2 exhaust)
Timing:
Hydraulic lifters, single camshaft
Horsepower Est:
~75-80 HP (at crankshaft, estimated)
Torque Est:
~88-92 ft-lbs @ 3500 RPM (at crankshaft, estimated)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Premium unleaded gasoline, minimum 91 octane (R+M)/2
Engine Oil Capacity:
4.0 US qt. (3.8 L) with filter change
Engine Oil Type:
Harley-Davidson® 20W-50 Genuine Motor Oil or equivalent meeting Harley-Davidson® Specification (H-D 360 or SYN3)
First Service:
1000 miles (1600 km) or 6 months, whichever comes first (engine oil, primary chain case oil, inspect, lubricate).
Subsequent Service:
Every 5000 miles (8000 km) or 12 months (engine oil, primary chain case oil, inspect, lubricate).
Transmission Fluid Change:
Every 10,000 miles (16,000 km) or 24 months.
Brake Fluid Change:
Every 24 months, regardless of mileage.
Spark Plug Replacement:
Every 10,000 miles (16,000 km) or as needed.
Drive Belt Inspection:
Inspect at every service interval for wear and tension.
Primary Chain Case Oil Type:
Harley-Davidson® Genuine Formula™ Primary Chain Case Lubricant or Formula™ Plus.
Brake Fluid Type:
DOT 4 (Harley-Davidson® Premium Motorcycle Brake Fluid)
Primary Chain Case Oil Capacity:
2.8 US qt. (2.65 L)
Common Wear Items:
Clutch plates, drive belt, wheel bearings, front fork seals, brake pads.
Electrical Gremlins:
Occasional issues with the charging system (regulator/stator), faulty sensors, or connection corrosion, often detailed in diagnostic sections.
Engine Vibrations:
Normal for V-twin engines, but excessive vibrations can indicate an imbalance or mounting issue, covered in troubleshooting.
Special Tools:
Includes lists of essential and specialized Harley-Davidson tools for specific procedures (e.g., fork seal drivers, bearing pullers).