Engine Mechanical:
Engine disassembly, assembly, inspection, diagnosis, timing, valve adjustments, piston/ring replacement, cylinder head service, crankcase service
Fuel System:
Fuel injection system (EFI), throttle body, injectors, fuel pump, fuel pressure regulator, fuel tank, fuel lines, fuel filter replacement
Ignition System:
Ignition coils, spark plugs, ignition module, crank position sensor, troubleshooting ignition faults
Exhaust System:
Exhaust pipes, mufflers, catalytic converter (if applicable), exhaust gasket replacement
Transmission:
Clutch system, primary drive, transmission case, gear sets, shift drum, shift forks, mainshaft, countershaft, final drive belt maintenance, clutch service
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlight, taillight, turn signals), wiring diagrams, fuses, relays, diagnostic connectors (e.g., J1850 VCM)
Brakes:
Front and rear brake calipers, master cylinders, brake lines, brake pads, brake discs, bleeding procedures, brake fluid specifications
Suspension:
Front fork (telescopic, possibly with adjustable preload/rebound), rear shock absorbers, swingarm, fork oil replacement, shock absorber service, bearing maintenance
Steering:
Handlebars, steering stem bearings, triple clamps, troubleshooting steering play
Wheels And Tires:
Wheel bearing replacement, tire mounting/balancing, spoke tensioning (if applicable), wheel alignment
Frame And Bodywork:
Frame inspection, body panel removal/installation, seat, fenders, fuel tank removal/installation, fairings (if applicable)
Routine Maintenance:
Oil changes, filter replacement, spark plug inspection/replacement, air filter cleaning/replacement, drive belt inspection/tensioning, chain adjustment (if applicable), lubrication points
Troubleshooting:
Diagnostic procedures for common malfunctions, electrical system fault finding, engine performance issues, braking system problems
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly
Diagnostics:
Fault code retrieval and interpretation (where applicable via diagnostic port), electrical circuit testing
Overhaul:
Detailed instructions for complete engine and transmission overhauls
Depth:
Comprehensive, covering basic maintenance to complete engine rebuilds and advanced electrical diagnostics.
Engine Family:
Harley-Davidson Evolution (Big Twin)
Displacement:
103 cubic inches (approx. 1690cc)
Configuration:
Air-cooled, 45-degree V-twin
Bore X Stroke:
3.875 in. x 4.38 in. (98.4 mm x 111.3 mm)
Compression Ratio:
9.6:1 (typical for 103)
Valve Train:
OHV, 2 valves per cylinder
Horsepower:
Estimated 70-80 HP (varies with tuning)
Torque:
Approx. 90-100 lb-ft @ 3000-3500 RPM (varies with tuning)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended
Engine Oil Type:
Harley-Davidson SYN3 (fully synthetic) or equivalent SAE 20W-50 motorcycle oil meeting HD-MS-01.3 specification
Engine Oil Capacity:
4.0 US quarts (3.8 Liters) with filter change
Type:
6-speed Cruise Drive Transmission
Gear Ratios:
1st: 9.312, 2nd: 6.650, 3rd: 4.943, 4th: 4.315, 5th: 3.779, 6th: 3.224
Primary Drive:
Plated chain, 34/46 ratio
Final Drive:
Belt drive, 32/66 ratio
Transmission Oil Type:
Harley-Davidson Formula+ transmission lubricant or equivalent SAE 85W-140 gear oil meeting HD-8825-A specification
Transmission Oil Capacity:
2.8 US quarts (2.6 Liters)
First Service:
1,000 miles (1,600 km) or 3 months
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months
Drive Belt Inspection:
Every 5,000 miles (8,000 km), adjust tension as needed.
Spark Plug Replacement:
Recommended every 10,000-15,000 miles (16,000-24,000 km)
Brake Fluid Flush:
Recommended every 2 years or as per manufacturer's schedule
Brake Fluid Type:
DOT 4 (refer to manual for specific Harley-Davidson P/N if available)
Fork Oil Type:
Harley-Davidson Formula Fork Oil Light (or equivalent SAE 5W)
Fork Oil Capacity:
Approx. 11.5-12.0 US fl oz (340-355 ml) per fork leg (verify in manual)
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, drive belt, brake pads.
Potential Electrical:
Voltage regulator/rectifier failures, wiring harness chafing in certain areas.
Engine Vibration:
While characteristic, excessive vibration may indicate internal issues or worn mounts.
Suspension Performance:
Stock suspension can be considered basic; upgrades are common for improved handling.
Founder:
William S. Harley, Arthur Davidson, Walter Davidson, William A. Davidson
Dyna Platform Introduction:
Introduced in 1991, known for its rubber-mounted engine, offering a smoother ride than earlier rigid-mount frames.
Low Rider Concept:
Low seat height, forward controls, and swept-back handlebars for a relaxed cruiser stance, a concept originating in the late 1970s.
Manufacturing Location:
United States (primarily Milwaukee, Wisconsin, and York, Pennsylvania)
Engine Updates Era:
Transitioned to Twin Cam 96 and later Twin Cam 103 engines in the Dyna platform, offering increased displacement and power.