Market Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson owners and independent repair shops seeking detailed technical information.
Value Proposition:
Provides authoritative, in-depth repair and maintenance guidance for the specific model and year, crucial for preserving value and ensuring optimal performance.
Key Features:
Comprehensive coverage, detailed diagrams, troubleshooting flowcharts, torque specifications, and maintenance schedules.
Systems Covered:
Engine, Transmission, Drivetrain, Chassis, Electrical System, Fuel System, Ignition System, Braking System, Suspension, Wheels and Tires, Bodywork, Controls, Diagnostics, Troubleshooting, Maintenance, Repair Procedures.
Page Count:
Estimated 500+ pages (typical for complete workshop manuals of this era)
Manual Type:
Complete Workshop Service Repair Manual
Engine Mechanical:
Detailed procedures for engine disassembly, assembly, inspection, and component replacement (e.g., pistons, rings, cylinders, crankshaft, camshafts, valvetrain).
Fuel System:
Fuel injection system (EFI), throttle body, injectors, fuel pump, fuel pressure regulator, fuel lines, and related components.
Ignition System:
Ignition coils, spark plugs, ignition module, and diagnostic procedures for ignition-related issues.
Transmission Drivetrain:
Primary drive, transmission case, gears, clutch, shift mechanism, and final drive belt inspection and replacement.
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator), starting system (starter motor), lighting, ignition, instrumentation, and accessory circuits.
Braking System:
Front and rear brake systems, master cylinders, calipers, brake pads, rotors, brake lines, and bleeding procedures.
Suspension Steering:
Front fork (e.g., telescopic, internal components), rear shock absorbers, swingarm, steering head bearings, and related adjustments.
Wheels Tires:
Wheel bearing inspection and replacement, tire pressure recommendations, and wheel balancing.
Chassis Frame:
Frame inspection, swingarm, and related chassis components.
Bodywork Fittings:
Fender, fuel tank, seat, handlebars, controls, and minor body panel removal and installation.
Maintenance Routine:
Scheduled maintenance, oil changes, filter replacements, chain/belt adjustment, lubrication points, and general inspection.
Troubleshooting Diagnostics:
Systematic diagnostic procedures for identifying and resolving common and complex issues, including fault codes where applicable.
Repair Rebuild:
Step-by-step instructions for component removal, repair, reassembly, and installation for all major systems.
Technical Specifications:
Torque specifications for all fasteners, fluid capacities, electrical specifications, and dimensional data.
Depth Of Coverage:
Comprehensive, covering everything from basic rider maintenance to complete engine and transmission overhauls. Suitable for both DIY enthusiasts and professional mechanics.
Engine Type:
Air-cooled, Twin Cam 96, V-twin
Displacement:
96 cubic inches (1584 cc)
Bore X Stroke:
3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)
Valve Train:
Overhead valves (OHV), 2 valves per cylinder
Horsepower:
Estimated 70-75 HP (at crank, varies with specific tuning)
Torque:
Estimated 90-96 ft-lbs (at crank, varies with specific tuning)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane
Oil Capacity:
Approximately 4 quarts (3.8 liters) with filter change
Oil Type:
Harley-Davidson SYN3 (or equivalent SAE 20W-50 synthetic motorcycle oil)
Transmission Type:
6-speed constant mesh, helical gears
Clutch Type:
Wet, multi-plate, hydraulically actuated
Primary Drive:
Duplex chain, 34/46 ratio
Final Drive:
Belt drive, 32/65 ratio
Gear Ratios:
1st: 9.31, 2nd: 6.72, 3rd: 4.74, 4th: 3.75, 5th: 3.23, 6th: 2.79 (typical for Twin Cam 6-speed)
Transmission Fluid Type:
Harley-Davidson Formula+ (or equivalent primary chaincase lubricant)
Transmission Fluid Capacity:
Approximately 3.0 US quarts (2.8 liters)
Safety Features Standard:
Dual disc front brakes, single disc rear brake, strong frame construction.
Braking System Details:
Front: 4-piston calipers, dual 292mm discs. Rear: 2-piston calipers, single 292mm disc.
Tire Specifications:
Front: MT90B16 72H. Rear: 150/80B16 77H (typical)
Lighting:
Halogen headlamp, LED tail/stop lamp, amber turn signals.
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Services:
Every 5,000 miles (8,000 km) or 12 months thereafter (engine oil & filter, belt check, etc.)
Engine Oil:
SAE 20W-50 Motorcycle Oil (Harley-Davidson SYN3 recommended)
Primary Chaincase Fluid:
Harley-Davidson Formula+ or equivalent SAE 85W-140 gear oil
Transmission Fluid:
Harley-Davidson Formula+ or equivalent SAE 85W-140 gear oil
Brake Fluid:
DOT 4 (typically)
Common Wear Items:
Clutch cable, belt drive, wheel bearings, fork seals, brake pads, battery.
Electrical Gremlins:
Can sometimes occur with aging wiring or connectors, particularly related to lighting and ignition.
Engine Performance Tuning:
While the Twin Cam 96 is reliable, many owners opt for performance upgrades; the manual provides base specifications for these tasks.
Brand Origins:
Founded in Milwaukee, Wisconsin, in 1903, Harley-Davidson is an iconic American motorcycle manufacturer known for its V-twin engines and distinctive styling.
Dyna Series:
The Dyna platform was introduced in 1991, characterized by its traditional styling, rubber-mounted engines for reduced vibration, and a right-side drive system. The Street Bob (FXDB) variant emphasizes a minimalist, stripped-down aesthetic.
Manufacturing Location:
United States (various plants, e.g., York, PA; Kansas City, MO)
