Systems Covered:
Engine (Twin Cam 103, fuel injection), Transmission (6-speed Cruise Drive), Drivetrain (clutch, primary drive, final drive), Chassis, Suspension (front fork, rear shocks), Brakes (ABS, hydraulic), Electrical System (wiring diagrams, ignition, lighting, starting, charging), Fuel System (tank, pump, injectors), Exhaust System, Cooling System (oil cooling), Frame, Bodywork (fairings, fenders, saddlebags), Instrumentation, Controls
Chassis And Frame:
Frame, swingarm, fork, shocks, steering head, wheel bearings.
Braking System:
Front and rear hydraulic disc brakes, ABS system components, master cylinders, calipers, lines, bleeding procedures.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), ignition system (ECU, ignition module, coils, spark plugs), lighting (headlamp, tail lamp, turn signals, running lights), instrumentation, horn, wiring diagrams for all circuits.
Fuel And Exhaust:
Fuel tank, fuel pump, fuel lines, injectors, throttle body, exhaust system, mufflers.
Bodywork And Trim:
Fenders, fairing, windshield, saddlebags, seat, grips, mirrors, trim pieces, mounting hardware.
Procedures Included:
Routine maintenance, diagnostics, troubleshooting, component repair, assembly/disassembly, electrical troubleshooting, wiring harness repair, fluid changes, brake bleeding, suspension adjustments, engine overhaul, transmission rebuild, component installation/replacement
Routine Maintenance:
Oil and filter changes, primary and transmission fluid changes, brake fluid flush, tire pressure checks, belt tension adjustment, lubrication points, air filter replacement.
Engine Repair:
Top-end rebuild (cylinders, pistons, heads), valve adjustments, camshaft installation, oil pump service, timing procedures, fuel system diagnostics and repair.
Transmission And Drivetrain Repair:
Clutch service and replacement, transmission disassembly and reassembly, gear inspection, drive belt replacement, pulley service.
Electrical Diagnostics:
Troubleshooting wiring faults, component testing (sensors, actuators), diagnosing charging and starting issues, using diagnostic codes.
Suspension And Brakes:
Fork seal replacement, fork oil change, shock absorber replacement, brake pad replacement, caliper overhaul, brake system bleeding.
Technical Depth:
Comprehensive; covers everything from basic maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and specifications.
Diagnostic Procedures:
Detailed step-by-step diagnostic flowcharts and troubleshooting trees for common and complex issues.
Torque Specifications:
Comprehensive list of torque specifications for all critical fasteners and components.
Special Tools:
Identification and usage instructions for specialized tools required for specific repairs.
First Service Interval:
1,000 miles (1,600 km) or 6 months
Subsequent Service Intervals:
Every 5,000 miles (8,000 km) or 12 months thereafter for most checks and fluid changes.
Major Engine Service Interval:
Refer to manual for detailed engine overhaul or component-specific intervals.
Brake Fluid Type:
DOT 4 (for ABS and non-ABS systems)
Primary Chain Case Fluid:
Harley-Davidson Primary Chain Lubricant or SYN3 (check manual for specific grade)
Fork Oil Type:
Harley-Davidson Type E (or equivalent 10W fork oil), check manual for specific viscosity for model year.
Common Wear Items:
Clutch plates, brake pads, tires, drive belt, spark plugs, battery terminals, wheel bearings.
Potential Issues 2013 Twin Cam:
While generally robust, potential areas for inspection include primary compensator, cam chain tensioners (though hydraulic tensioners were introduced earlier, manual checks are still important), and fuel injector o-rings. The manual will detail checks and potential fixes.
Diagnostic Tools:
Harley-Davidson Digital Technician (HD-DT) or similar diagnostic scan tools are often required for advanced troubleshooting and code reading.