Engine System:
Complete engine disassembly, assembly, troubleshooting, tuning, and diagnostics for the Twin Cam 96 V-Twin engine.
Fuel System:
Fuel injection system (EFI), throttle body, fuel pump, fuel injectors, fuel lines, and evaporative emissions control system.
Transmission System:
6-speed Cruise Drive transmission: disassembly, assembly, gear inspection, clutch service, and shift mechanism.
Drivetrain System:
Primary drive, clutch assembly, final drive belt inspection and adjustment, rear sprocket.
Brake System:
Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake pads, rotors, bleeding procedures.
Suspension System:
Front fork (telescopic), rear shock absorbers (Softail hidden suspension), fork oil changes, shock absorber replacement.
Electrical System:
Battery, charging system (stator, regulator/rectifier), ignition system, lighting (headlight, taillight, turn signals), starter, horn, instrument cluster, wiring diagrams.
Chassis System:
Frame inspection, steering head bearings, swingarm, wheel bearings, front and rear wheel service.
Bodywork And Trim:
Fenders, fuel tank removal and installation, seat, handlebars, mirrors, fairings (if applicable), chrome trim.
Cooling System:
Air-cooled engine, but includes any related oil cooling systems or heat management components.
Exhaust System:
Exhaust pipes, mufflers, catalytic converter (if equipped), exhaust gaskets, mounting hardware.
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, brake fluid flush, spark plug replacement, drive belt tensioning.
Troubleshooting Guides:
Diagnostic flowcharts for common issues, electrical system troubleshooting, engine performance problems.
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair of all major motorcycle systems.
Overhaul Instructions:
Detailed instructions for engine, transmission, and fork overhauls, including part specifications and tolerances.
Wiring Diagrams:
Comprehensive, color-coded electrical system wiring diagrams for accurate diagnostics and repairs.
Special Tools:
Identification of required Harley-Davidson specific tools for various repair and maintenance procedures.
Depth:
Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds.
Engine Oil Change:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first.
Primary Chain Case Oil Change:
Every 10,000 miles (16,000 km) or 24 months.
Transmission Oil Change:
Every 10,000 miles (16,000 km) or 24 months.
Drive Belt Inspection:
Inspect tension and condition every 5,000 miles (8,000 km).
Brake Fluid Flush:
Every 24 months, regardless of mileage.
Spark Plug Replacement:
Every 10,000 miles (16,000 km).
Engine Oil:
Harley-Davidson SYN3 Synthetic (SAE 20W50) or equivalent API CG-4 or higher rated motorcycle oil.
Primary Chain Case Oil:
Harley-Davidson primary fluid or SAE 20W50 motorcycle oil (ensure it's wet clutch compatible).
Transmission Oil:
Harley-Davidson transmission oil (e.g., Formula+ or Syn-3) or SAE 85W-140 gear oil.
Brake Fluid:
DOT 4 brake fluid.
Fork Oil:
Harley-Davidson front fork oil (e.g., Type E, SAE 10W) - consult manual for exact type and quantity.
Common Wear Items:
Clutch wear, drive belt wear, front fork seals, wheel bearings, brake pads.
Engine Performance Notes:
Twin Cam 96 can be sensitive to air intake and exhaust modifications; proper tuning is crucial for optimal performance and longevity.
Electrical System Notes:
Intermittent issues can arise from wiring harness connections, especially in high-vibration environments; regular inspection recommended.
Brand History:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its cruiser and touring motorcycles.
Softail Lineage:
The Softail platform, introduced in 1984, features a rear suspension system designed to mimic the appearance of a hardtail frame, providing a classic look with modern suspension comfort.
Flstn Design:
The FLSTN Deluxe model is characterized by its retro styling, often featuring a tear-drop shaped fuel tank, full fenders, whitewall tires, and extensive chrome detailing, evoking classic Harley-Davidson designs from the 1940s and 1950s.
Manufacturing Location:
United States
