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Introduction
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Market Position
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Market Segment:
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Cruiser motorcycles, premium segment.
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Target Audience:
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Harley-Davidson Softail owners seeking to perform their own maintenance and repairs, custom builders, professional mechanics.
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Competitive Analysis
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Competitors 2006:
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Indian Motorcycles (Chief, Scout), Victory Motorcycles (Vegas, Kingpin), custom builders, other Harley-Davidson models.
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Key Features
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Manual Value Proposition:
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Provides in-depth technical knowledge to maintain and repair complex Harley-Davidson systems, potentially saving significant costs on dealership service.
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Coverage Scope:
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The inclusion of electrical diagnostics and a specific high-performance model supplement (FLSTFSE) makes this manual particularly valuable.
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Manual Coverage
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Systems Covered
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Engine:
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Engine overhaul, disassembly, assembly, tuning, lubrication, cooling system (air-cooled).
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Transmission:
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5-speed transmission (likely Cruise Drive), clutch, primary drive, gear shifting mechanisms, lubrication.
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Fuel System:
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Carburetion (Keihin CV on some models) or Fuel Injection (EFI - Electronic Fuel Injection) systems, fuel pump, fuel tank, fuel lines.
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Electrical System:
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Wiring diagrams, charging system (stator, regulator/rectifier), ignition system, starting system (starter motor, solenoid), lighting, instruments, gauges, switches, battery maintenance, fuses, relays.
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Brakes:
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Hydraulic brake systems (front and rear), calipers, master cylinders, brake lines, brake pads, rotor specifications, bleeding procedures.
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Suspension:
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Front fork (e.g., 49mm telescopic forks for FXST models), rear shock absorbers, suspension adjustments, fork seal replacement, shock absorber specifications.
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Chassis And Frame:
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Frame inspection, steering head bearing maintenance, swingarm service, wheel bearing replacement, lubrication points.
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Bodywork:
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Fenders, fuel tank removal/installation, seat service, fairings/windshields (if applicable), chrome component care.
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Diagnostics:
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Troubleshooting guides for common issues, diagnostic codes (for EFI models), electrical fault finding.
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Procedures Included
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Maintenance:
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Regular scheduled maintenance, oil changes, filter replacements, chain/belt adjustment (if applicable), tire pressure checks, brake pad inspection.
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Repair:
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Complete engine rebuild, transmission overhauls, suspension component replacement, brake system repairs, electrical component troubleshooting and replacement.
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Disassembly Assembly:
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Detailed step-by-step instructions for complete tear-down and reassembly of all major components.
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Troubleshooting:
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Systematic approaches to diagnosing and resolving mechanical and electrical problems.
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Torques:
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Specific torque specifications for critical fasteners throughout the motorcycle.
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Technical Depth
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Depth:
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Comprehensive from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics.
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Visual Aids:
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Includes pictures and part diagrams to illustrate procedures and component identification.
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Engine Specifications
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Primary Engine
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Engine Family:
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Harley-Davidson Twin Cam
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Displacement Standard:
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Approximately 1450cc (88 cubic inches) for FLST and FXST models. Note: FLSTFSE likely features a larger displacement like 117 cubic inches.
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Configuration:
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V-twin, air-cooled
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Bore X Stroke Standard:
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Approx. 3.75 in. x 4.00 in. (95.25 mm x 101.6 mm) for 1450cc.
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Compression Ratio Standard:
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Typically around 9.0:1 for the 1450cc Twin Cam.
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Performance
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Horsepower Standard:
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Estimated 65-70 HP at the crankshaft for the 1450cc Twin Cam.
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Torque Standard:
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Estimated 80-85 lb-ft at the crankshaft for the 1450cc Twin Cam.
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Peak Torque Rpm Standard:
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Typically around 3200 RPM for the 1450cc Twin Cam.
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Fuel System
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Fuel Delivery:
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Electronic Sequential Port Fuel Injection (ESPFI) or Keihin CV Carburetor, depending on specific sub-model and market.
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Ignition System:
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Distributorless Electronic Ignition (DS-ED) with coil-on-plug or dual-fire ignition.
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Fuel Type:
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Unleaded gasoline, minimum 87 octane.
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Transmission
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Standard
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Type:
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5-speed Constant Mesh, Cruise Drive
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Clutch Type:
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Wet, multi-plate, 9-plate diaphragm spring.
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Primary Drive:
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Plated chain, hydraulic tensioner, compensator sprocket.
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Final Drive:
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Belt drive, 136-tooth belt, 65-tooth rear pulley, 32-tooth front pulley (typical).
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Features
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Gear Ratios Typical:
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1st: 9.896, 2nd: 6.470, 3rd: 4.774, 4th: 3.874, 5th: 3.151
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Transmission Fluid Type:
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Harley-Davidson Syn 3 Transmission Oil or equivalent SAE 85W-140 Hypoid gear lubricant.
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Safety Features
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Ratings
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Crash Test Ratings:
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N/A (Motorcycle safety is typically assessed through regulatory standards and industry practices, not standardized crash test ratings like automobiles).
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Active Features
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Braking System:
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Hydraulic disc brakes front and rear, dual-piston calipers standard.
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Tire Specifications Front Typical:
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Bias-ply or Radial, e.g., MT90B16 or 100/90-19.
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Tire Specifications Rear Typical:
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Bias-ply or Radial, e.g., MU85B16 or 150/80B16.
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Passive Features
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Lighting:
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Halogen headlamp, incandescent tail and turn signals.
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Frame Construction:
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Steel, backbone type.
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Technology Features
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Infotainment
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Audio System:
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Some higher-spec models or optional equipment may include an audio system; the manual would cover its basic operation and troubleshooting.
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Gauges And Instruments:
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Analog speedometer, tachometer (optional), fuel gauge, oil pressure indicator, and warning lights. Manual details their function and troubleshooting.
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Driver Assistance
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ABS:
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Anti-lock Braking System (ABS) was an optional feature on many Harley-Davidson models by 2006. The manual would detail its components and servicing if equipped.
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Connectivity
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Cruise Control:
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Optional electronic cruise control may be available; procedures for its operation and diagnosis would be included.
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Diagnostics
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Diagnostic Tool Interface:
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EFI models likely support basic diagnostics via a diagnostic port and a dealer tool (e.g., H-D Dealer Diagnostic Tool). The manual will guide owners on interpreting codes.
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Maintenance
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Service Intervals
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First Service:
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Typically around 1,000 miles (1,600 km) for initial break-in service (oil change, filter, primary chain check).
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Regular Service Interval:
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Typically every 5,000 miles (8,000 km) or annually, whichever comes first, for oil changes and general inspection.
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Major Service Intervals:
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Includes transmission and primary drive service, often recommended around 10,000-20,000 miles, with detailed procedures in the manual.
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Fluid Specifications
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Engine Oil Type:
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Harley-Davidson 20W-50 Performance Oil or equivalent API CI-4 or higher rated synthetic motorcycle oil.
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Engine Oil Capacity:
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Approximately 4 quarts (3.8 L) with filter change.
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Primary Chain Case Oil Type:
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Harley-Davidson Formula+ Transmission and Primary Chaincase Lubricant or equivalent SAE 85W-140 Hypoid gear lubricant.
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Primary Chain Case Oil Capacity:
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Approximately 1 quart (0.95 L).
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Brake Fluid Type:
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DOT 5 Silicone-based brake fluid is typically specified by Harley-Davidson for this era. **Important: Verify specific model requirements as DOT 4 might be used on some newer models.**
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Known Issues
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Twin Cam Tensioners:
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Early Twin Cam models are known for cam chain tensioner wear, which can lead to catastrophic engine failure. The manual will detail inspection and replacement procedures for these.
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Primary Drive Issues:
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Potential for hydraulic tensioner failure or primary bearing wear. Manual covers inspection and replacement.
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Electrical Connections:
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Corrosion or loose connections can cause intermittent electrical faults. The electrical diagnostic section is crucial here.
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Fuel Injector Issues:
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EFI models can experience clogged injectors or issues with the fuel pump, covered in the diagnostic section.
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