Engine Mechanical:
Engine assembly, disassembly, internal components, cylinder heads, pistons, crankshaft, camshafts, valve train, oil pump, lubrication system.
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors (EFI models), carburetor (if applicable), throttle body, fuel pressure regulator.
Ignition System:
Ignition module, ignition coils, spark plugs, wiring, sensors (crank position, etc.).
Exhaust System:
Exhaust pipes, mufflers, catalytic converter (if equipped), gaskets, mounting hardware.
Transmission Drivetrain:
Clutch assembly, primary drive, transmission gears, shift mechanism, final drive belt, wheel sprockets.
Brakes:
Brake calipers, master cylinders, brake lines, brake pads, brake discs, hydraulic fluid, parking brake system (if applicable).
Suspension Steering:
Front forks (telescopic, cartridge type), rear shock absorbers, swingarm, steering head bearings, fork seals, fork oil.
Wheels Tires:
Wheel bearings, wheel balancing, tire mounting and dismounting, tire pressures.
Electrical System General:
Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlight, taillight, signals), horn, fuses, relays, wiring harnesses.
Instrumentation Controls:
Speedometer, tachometer, indicator lights, handlebar controls (switches, levers), throttle control, clutch control.
Bodywork Chassis:
Frame, fenders, fuel tank, seat, handlebars, footpegs, fairings (if equipped), body panels, mounting hardware.
Diagnostics Troubleshooting:
Diagnostic trouble codes (DTCs), common fault finding procedures, electrical system schematics, symptom-based troubleshooting.
Routine Maintenance:
Oil changes, filter replacements, spark plug inspection/replacement, chain adjustment (if applicable), brake fluid flush, tire pressure checks, lubrication points.
Engine Repair:
Top-end rebuilds, bottom-end overhauls, component replacement (pistons, rings, bearings), timing adjustments.
Transmission Service:
Clutch adjustment and replacement, transmission gear inspection, bearing replacement, primary chain tensioner service.
Brake System Service:
Brake pad replacement, caliper service, master cylinder bleeding, brake line replacement, fluid flushing.
Suspension Fork Service:
Fork seal replacement, fork oil change, fork spring replacement, shock absorber replacement.
Electrical Troubleshooting:
Wiring harness inspection, connector repair, component testing (stator, regulator, starter), fuse and relay diagnosis.
Fuel Injection System Service:
Fuel injector cleaning/replacement, throttle body cleaning, fuel pressure testing, sensor diagnostics.
Wheel Tire Service:
Wheel bearing replacement, tire installation, balancing procedures.
Frame Chassis Inspection:
Frame integrity checks, steering head bearing adjustment/replacement.
Depth Level:
Comprehensive, covering from basic maintenance to complete engine and transmission overhauls, including detailed electrical diagnostics.
Diagnostic Tools:
Includes procedures for using diagnostic tools (e.g., Harley-Davidson Digital Technician or similar diagnostic interfaces for EFI models).
Torque Specifications:
Detailed torque values for all critical fasteners and components.
Schematics:
Extensive electrical wiring diagrams for all systems and model variations.
Special Tools:
Lists and describes the use of specialized tools required for specific repair procedures.
Initial Service Miles:
1000 miles (1600 km).
Subsequent Service Miles:
Every 5,000 miles (8,000 km) or annually, whichever comes first.
Oil Change Interval Miles:
Every 5,000 miles (8,000 km) or annually.
Drive Belt Inspection Interval Miles:
Inspect at 5,000 mile intervals, adjust tension as needed.
Fork Oil Viscosity:
Harley-Davidson Genuine Motorcycle Fork Oil (Type E, 15W) or equivalent, capacity varies by model.
Brake Fluid Type:
DOT 4, or DOT 5.1 for models with ABS (verify per manual).
Cam Chain Tensioner:
Early models (pre-2007) had hydraulic tensioners that could wear out and cause noise; 2006 is on the cusp, so this is a potential area of inspection.
Primary Chain Tensioner:
The automatic primary chain tensioner can wear, leading to noise and potential chain slack. Manual adjustment or replacement may be needed.
Wheel Bearings:
Can require replacement due to mileage and environmental factors.
Regulator Rectifier:
As with many motorcycles of this era, regulator/rectifier units can be a point of failure, affecting charging system performance.