Engine Service:
Complete overhaul, tuning, diagnostics, component repair (cylinders, pistons, crankshaft, camshaft, valve train).
Fuel System:
Fuel injection (EFI) system, throttle body, fuel pump, injectors, fuel lines, fuel tank.
Transmission Service:
Primary drive, transmission assembly, clutch, shift mechanism, lubrication.
Electrical System:
Ignition system, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instrumentation, sensors, wiring diagrams.
Chassis And Suspension:
Frame, swingarm, front forks (telescopic), rear shock absorbers, wheel bearings, steering head bearings.
Braking System:
Front and rear brake calipers, master cylinders, brake lines, rotors, pads, hydraulic system maintenance.
Wheel And Tire Service:
Wheel removal/installation, tire mounting/balancing, spoke tensioning (if applicable).
Bodywork And Trim:
Fenders, fuel tank, seat, saddlebags, windshield, trim pieces, mounting hardware.
Scheduled Maintenance:
Oil changes, filter replacements, spark plug service, drive belt inspection/adjustment, brake fluid flush, fork oil change.
Troubleshooting:
Diagnostic procedures for common faults, error code interpretation, symptom-based repair guidance.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, electrical system repairs.
Performance Tuning:
EFI tuning, exhaust system installation guidance, camshaft recommendations (general).
Special Tools:
Identification and use of specialized Harley-Davidson tools required for specific procedures.
Diagnostic Capabilities:
Detailed diagnostic flowcharts and procedures for identifying and resolving issues.
Rebuild Specifications:
Torque specifications, clearances, measurements, and assembly procedures for all major components.
Wiring Diagrams:
Comprehensive, color-coded electrical wiring diagrams for all systems.
Engine Type:
Air-cooled, Twin Cam 103B V-twin
Displacement:
1690 cc (103 cubic inches)
Bore X Stroke:
3.875 in. x 4.380 in. (98.4 mm x 111.3 mm)
Torque:
101 ft-lbs (137 Nm) @ 3,500 RPM (approximate)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane
Ignition Type:
Electronic, high-performance ignition module
Engine Oil Change:
Every 5,000 miles (8,000 km) or annually.
Primary Chaincase Oil Change:
Every 10,000 miles (16,000 km).
Transmission Oil Change:
Every 20,000 miles (32,000 km).
Drive Belt Tension Check:
Every 10,000 miles (16,000 km).
Engine Oil Type:
Synthetic SAE 20W-50 (e.g., Harley-Davidson SYN3 or equivalent API CI-4)
Engine Oil Capacity:
3.5 US quarts (3.3 L) with filter change.
Brake Fluid Type:
DOT 4 (for ABS systems), DOT 5.1 recommended for non-ABS.
Common Complaints:
Oil leaks (e.g., primary cover, cam cover), clutch drag, fuel line expansion (recall applicable).
Diagnostic Notes:
Monitor for engine pinging or knocking under load, which may indicate lean fuel mixture or timing issues.
