Engine:
Detailed disassembly, assembly, inspection, and repair of the Twin Cam 96B engine.
Transmission:
Service and repair procedures for the 6-speed Cruise Drive transmission.
Fuel System:
Fuel injection system diagnostics, components, and servicing.
Electrical System:
Wiring diagrams, component testing, troubleshooting for lighting, ignition, starting, and charging systems.
Brakes:
Front and rear brake system servicing, bleeding, component replacement, and hydraulic systems.
Suspension:
Front fork (Springer front end) and rear shock absorber servicing, adjustments, and component replacement.
Chassis:
Frame, swingarm, steering head, and related components inspection and service.
Bodywork:
Fender removal/installation, fuel tank servicing, seat adjustments, and related trim.
Wheels And Tires:
Wheel bearing service, tire replacement, and spoke tension checks.
Controls:
Handlebar, levers, cables, and foot controls adjustment and service.
Clutch System:
Service and adjustment procedures for the clutch assembly.
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication points, and inspection procedures.
Troubleshooting:
Comprehensive diagnostic flowcharts and symptom-based troubleshooting for various systems.
Repair:
Step-by-step instructions for component removal, disassembly, repair, assembly, and installation.
Adjustments:
Precise instructions for adjusting clutch, throttle, primary chain, and other critical components.
Diagnostics:
Methods for diagnosing engine performance issues, electrical faults, and mechanical problems.
Wiring Diagrams:
Complete electrical system wiring diagrams are provided for accurate diagnosis and repair.
Depth:
Comprehensive 'bumper-to-bumper' coverage, suitable for both professional mechanics and experienced DIY enthusiasts.
Pictorials:
Detailed illustrations, exploded diagrams, drawings, and photographs guide through repair procedures.
Special Tools:
References to required special service tools with associated illustrations for their use.
Wear Limits:
Inclusion of wear limits and allowable tolerances for critical components.
Torque Specifications:
Explicit torque values for fasteners during assembly and installation.
Schematics:
Inclusion of schematics and diagrams to clarify complex procedures.
Illustrations:
Illustrations include exploded views, sectional views, and application photos of special tools.
Quality:
High-resolution PDF with printable pages.
Searchability:
Likely searchable text within the PDF document.
Printability:
All pages are printable.
Binding:
Digital Download (PDF format), not a physical binding.
Paper:
N/A (Digital format)
Software:
Adobe Reader required for viewing.
Compatibility:
Compatible with Windows, Mac, and Linux operating systems.
Audio System:
Optional accessory audio systems were available, but not standard integrated infotainment in the same way as modern vehicles.
Assistance Features:
Limited driver assistance features, focus is on the riding experience and mechanical function.
Connectivity Features:
No integrated Bluetooth or smartphone connectivity; focus is on core motorcycle function.
Gauges:
Analog speedometer, tachometer (optional), fuel gauge, and indicator lights.
First Service:
Typically at 1,000 miles (1,600 km).
Subsequent Service:
Generally every 5,000 miles (8,000 km) or 6 months, whichever comes first (refer to manual for specifics).
Engine Oil Type:
Harley-Davidson Genuine Motor Oil (or approved equivalent meeting Harley-Davidson specifications, e.g., SAE 20W50).
Primary Chain Case Oil:
Harley-Davidson Genuine Primary Chain Case Lubricant (or approved equivalent).
Transmission Oil:
Harley-Davidson Genuine Formula+ Transmission and Primary Chaincase Lubricant (or approved equivalent).
Brake Fluid:
DOT 4 brake fluid (check manual for specific type and manufacturer recommendations).
Primary Chain Tensioner:
Early Twin Cam models, including some 2009 models, may have had issues with the hydraulic tensioner. Later models (post-2009) often featured upgraded or aftermarket solutions.
Idle Control Module:
Some riders have reported issues with the idle air control module affecting idle stability.
Fuel Level Sensor:
Occasional reports of fuel level sensor inaccuracies.
Brand Legacy:
Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903.
Softail Platform:
The Softail platform, known for its hidden rear suspension, debuted in 1984.
Cross Bones Introduction:
The Cross Bones model was introduced to offer a retro, customized aesthetic with a Springer front end, reminiscent of earlier Harley-Davidson models.
Production Period:
The FLSTSB Softail Cross Bones was produced from 2008 to 2011.
