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Manual Coverage
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Systems Covered
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Electrical Diagnostics:
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Comprehensive electrical system diagnosis and troubleshooting, including wiring diagrams and component testing.
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Engine Overhaul:
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Complete engine tear-down, rebuild procedures, including cylinder head, piston, crankshaft, and camshaft servicing.
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Transmission And Drivetrain:
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Service and repair of the transmission, clutch, primary drive, and final drive systems.
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Suspension And Steering:
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Fork servicing, rear shock absorber replacement, and steering head bearing maintenance.
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Braking System:
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Brake caliper, rotor, master cylinder, and hydraulic system service.
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Fuel System:
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Fuel injection system (EFI) diagnostics, fuel pump, injectors, and throttle body service.
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Cooling System:
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Engine cooling system maintenance and repair (where applicable for specific models).
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Exhaust System:
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Exhaust component replacement and gasket service.
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Bodywork And Trim:
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Fairing, saddlebag, and cosmetic component removal and installation.
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Procedures Included
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Maintenance:
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Routine maintenance tasks, including oil changes, filter replacements, and lubrication schedules.
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Troubleshooting:
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Systematic approach to diagnosing and resolving common and uncommon faults.
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Repair:
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Detailed, step-by-step repair procedures for all major vehicle components.
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Rebuild:
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Complete engine and component rebuild instructions.
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Diagnostics:
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In-depth diagnostic procedures for electrical and mechanical systems.
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Technical Depth
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Depth:
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Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts.
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Illustrations:
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Illustrated with clear, high-quality images and detailed part diagrams.
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Technical Data:
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Includes essential torque specifications, clearances, and fluid capacities.
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Engine Specifications
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Primary Engine
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Engine Type:
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Air-cooled, Twin Cam 88 V-Twin
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Displacement:
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1450cc (88 cubic inches)
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Bore X Stroke:
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3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
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Compression Ratio:
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8.8:1
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Performance
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Horsepower:
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Approximately 65-70 HP (estimate, varies by model and tuning)
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Torque:
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Approximately 75-80 lb-ft (estimate, varies by model and tuning)
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Fuel System
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Injection Type:
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Electronic Sequential Port Fuel Injection (ESPFI) for EFI models.
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Fuel Type:
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Unleaded gasoline, minimum 91 octane recommended.
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Ignition System
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Type:
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High-performance, electronic ignition with knock sensor.
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Lubrication System
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Oil Type:
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Harley-Davidson SYN3 Synthetic Motorcycle Oil (SAE 20W-50) or equivalent.
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Transmission
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Standard
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Transmission Type:
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5-speed constant mesh, helical gear
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Clutch Type:
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Wet, multi-plate, diaphragm spring
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Features
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Primary Drive:
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Plated, heavy-duty, 36-tooth, 1.375-inch pitch, chain drive.
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Final Drive:
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Carbon fiber belt, 25mm width, 140-tooth count.
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Fluid Specifications
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Transmission Oil Type:
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Harley-Davidson Genuine Transmission Fluid or Formula+ (GL-4 rated, SAE 75W-90).
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Dimensions
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Exterior
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Length:
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Approx. 96.5 in. (2450 mm) - varies by model
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Width:
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Approx. 37.0 in. (940 mm) - varies by model
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Height:
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Approx. 54.5 in. (1385 mm) - varies by model
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Weights
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Dry Weight:
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Approx. 700-800 lbs (317-363 kg) - varies by model
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Gross Vehicle Weight Rating Gvwr:
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Approx. 1200 lbs (544 kg) - varies by model
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Fuel Capacity:
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5.0 US gallons (18.9 L)
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Wheels And Tires
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Front Tire Size:
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MT90B16 (varies slightly by model)
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Rear Tire Size:
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130/90B16 (varies slightly by model)
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Wheel Type:
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Cast aluminum or laced, depending on model and trim.
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Safety Features
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Ratings
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Safety Standards:
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Designed to meet or exceed applicable federal motorcycle safety standards.
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Active Features
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Braking System:
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Dual 32mm, 4-piston, fixed front caliper with dual 11.5 in. (292mm) discs; 32mm, 4-piston, floating rear caliper with 11.5 in. (292mm) disc.
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Lighting:
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Halogen headlight, LED tail light, front and rear turn signals.
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Passive Features
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Chassis Construction:
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Steel, triple-cradle frame for stability and rigidity.
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Anti Lock Braking System ABS:
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Optional on some models.
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Maintenance
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Service Intervals
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Engine Oil Change:
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Every 5,000 miles (8,000 km) or 6 months, whichever comes first.
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Primary Chain Tensioner Inspection:
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Inspect at 10,000 miles (16,000 km), replace if necessary (especially with the early spring-loaded design).
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Spark Plug Replacement:
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Inspect every 10,000 miles (16,000 km), replace as needed.
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Drive Belt Inspection:
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Inspect tension and condition every 10,000 miles (16,000 km).
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Fluid Specifications
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Engine Oil Capacity:
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4.0 US quarts (3.8 L) with filter change.
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Brake Fluid Type:
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DOT 4 synthetic brake fluid.
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Coolant Type:
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N/A (Air-cooled engine)
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Known Issues
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Primary Chain Tensioner:
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Early models utilized a spring-loaded tensioner which could wear prematurely; upgrade to the hydraulic tensioner is a common modification.
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Cam Chain Tensioners:
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Internal cam chain tensioners can also wear; inspection and potential upgrade to the hydraulic tensioner is recommended.
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Crankshaft Runout:
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While generally robust, checking crankshaft runout during engine rebuilds is crucial for long-term reliability.
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Vehicle History
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Brand Heritage
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Legacy:
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Harley-Davidson boasts over a century of motorcycle manufacturing, synonymous with American freedom and craftsmanship.
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Model Evolution
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Touring Lineage:
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The FLHT/FLHR platforms have evolved from the early Electra Glide models, consistently refining comfort and performance for touring riders.
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Twin Cam 88 Introduction:
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The Twin Cam 88 engine, introduced in 1999, represented a significant technological advancement for Harley-Davidson, offering increased power and reliability.
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Production
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Manufacturing Location:
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York, Pennsylvania, USA and Milwaukee, Wisconsin, USA.
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