Engine:
Detailed diagnosis, disassembly, assembly, inspection, and repair of the Harley-Davidson Twin Cam 103 engine.
Fuel System:
EFI (Electronic Fuel Injection) system, fuel pump, injectors, fuel tank, lines, diagnostics.
Ignition System:
Ignition module, coil, spark plugs, wiring, diagnostics.
Exhaust System:
Exhaust pipes, mufflers, catalytic converters (if applicable), heat shields, mounting.
Transmission:
6-speed Cruise Drive transmission: disassembly, assembly, lubrication, troubleshooting, component replacement.
Clutch:
Clutch operation, adjustment, replacement, hydraulic system.
Drivetrain:
Primary drive, compensator sprocket, clutch shell, drive chain/belt, rear belt drive system maintenance and inspection.
Frame And Suspension:
Frame inspection, front forks (telescopic), rear shock absorbers, wheel bearings, steering head bearings.
Brakes:
Front and rear brake systems: hydraulic components, calipers, rotors, master cylinders, brake fluid service, ABS (Anti-lock Braking System) diagnostics.
Wheels And Tires:
Wheel types, tire maintenance, pressure, replacement, balancing.
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator), starting system (starter motor), lighting, instrumentation, accessory power.
Lighting System:
Headlight, taillight, turn signals, auxiliary lighting, bulb replacement, LED systems.
Instrumentation And Gauges:
Speedometer, tachometer, fuel gauge, voltage meter, indicator lights, troubleshooting.
Bodywork And Trim:
Fairing (Batwing style), saddlebags, fenders, fuel tank, seat, controls, removal, installation, and cosmetic repairs.
Infotainment System:
Boom! Box infotainment system, radio, speakers, connectivity (Bluetooth, USB), diagnostics.
Cruise Control:
Operation, troubleshooting, and repair of the electronic cruise control system.
Security System:
Smart Security System operation, fob programming, troubleshooting.
Scheduled Maintenance:
Detailed procedures for all scheduled maintenance intervals.
Troubleshooting:
Comprehensive diagnostic flowcharts and symptom-based troubleshooting guides for all systems.
Disassembly And Assembly:
Step-by-step instructions for component removal, repair, and reinstallation.
Component Testing:
Procedures for testing sensors, actuators, electrical components, and mechanical parts.
Wiring Diagrams:
Full-color, detailed wiring diagrams for all electrical systems.
Special Tools:
Identification and usage of specialized tools required for specific repairs.
Specifications And Tolerances:
Precise torque values, clearances, and measurement specifications for all components.
Fluid And Lubricant Replacement:
Instructions for changing engine oil, transmission oil, primary chaincase oil, and brake fluid.
Depth:
Comprehensive; covers everything from basic maintenance and fluid changes to complete engine and transmission rebuilds, advanced electrical diagnostics, and bodywork repair.
Initial Service:
First service typically at 1,000 miles (1600 km) or 6 months.
Subsequent Service:
Subsequent service intervals generally every 5,000 miles (8,000 km) or 12 months, whichever comes first. Refer to manual for specifics.
Engine Oil:
Harley-Davidson SYN3 (fully synthetic) or equivalent SAE 20W-50 motorcycle oil meeting Harley-Davidson specification.
Engine Oil Capacity:
Approx. 4 quarts (3.8 L) with filter change.
Transmission Oil:
Harley-Davidson Formula+ Transmission Lubricant or equivalent SAE 50 motorcycle transmission oil.
Primary Chaincase Oil:
Harley-Davidson Formula+ Transmission Lubricant or equivalent SAE 50 motorcycle transmission oil.
Brake Fluid:
DOT 4 Synthetic Brake Fluid (refer to manual for specific Harley-Davidson P/N).
Fork Oil:
Refer to manual for specific viscosity and type, typically a high-quality suspension fluid.
Cam Chain Tensioner:
Early Twin Cam models had issues with hydraulic cam chain tensioners. 2014-2017 models typically feature upgraded tensioners, but inspection is still recommended.
Compensator Nut:
Loose compensator sprocket lock nut can lead to primary drive noise and damage. Torque check and thread locker is crucial.
Harley Diagnostic Codes:
The manual provides extensive lists of diagnostic trouble codes (DTCs) for troubleshooting.