Engine Service:
Comprehensive procedures for engine disassembly, assembly, adjustment, and troubleshooting.
Transmission Service:
Detailed instructions for gearbox maintenance, repair, and adjustment.
Chassis And Suspension:
Covers fork, shock absorber, steering head, and frame service.
Braking System:
Includes procedures for brake caliper, master cylinder, lines, and ABS system (if equipped).
Electrical System:
Detailed wiring diagrams, troubleshooting for ignition, lighting, starting, charging, and accessory systems.
Fuel System:
Covers fuel injection system diagnostics, fuel pump, injectors, and fuel tank service.
Exhaust System:
Information on exhaust components and their service.
Wheels And Tires:
Specifications and procedures for wheel removal, installation, and tire maintenance.
Bodywork And Trim:
Guidance on removal and installation of body panels and trim.
Maintenance:
Periodic maintenance checks, adjustments, and fluid changes.
Troubleshooting:
Diagnostic procedures for common and uncommon issues with clear steps.
Disassembly And Assembly:
Step-by-step instructions for component removal and reinstallation.
Repair:
Detailed repair methodologies for all major vehicle systems.
Adjustments:
Specific procedures for various adjustments, including engine and chassis settings.
Depth:
Comprehensive from basic maintenance to complete engine rebuilds and electrical diagnostics.
Pictorial Guidance:
Detailed illustrations, exploded diagrams, drawings, and photos for all procedures.
Special Tools:
References to specific Harley-Davidson special service tools required for certain operations.
Torque Specifications:
Inclusion of critical torque values for fastener tightening during assembly and repair.
Wear Limits:
Specification of wear limits for various components to ensure proper function and longevity.
Braking:
Disc brakes front and rear, ABS optional or standard depending on market.
Lighting:
Headlight, taillight, brake light, turn signals, and marker lights.
Initial Service:
Typically at 1,000 miles (1600 km) for oil change, primary chain adjustment, and general inspection. Refer to manual for specifics.
Subsequent Service:
Scheduled maintenance typically every 5,000 miles (8,000 km) or annually. Refer to manual for exact intervals.
Engine Oil:
Specific Harley-Davidson proprietary blend or approved equivalent (e.g., SAE 20W-50). Refer to manual for exact specifications and part numbers.
Primary Chain Case Oil:
Specific Harley-Davidson primary fluid or approved equivalent. Refer to manual for specifications.
Transmission Oil:
Specific Harley-Davidson transmission fluid or approved equivalent. Refer to manual for specifications.
Brake Fluid:
DOT 4 approved brake fluid.
Common Issues:
Potential issues can include clutch cable adjustment needs, exhaust leaks, and minor electrical gremlins. The manual addresses these comprehensively.
