Market Segment:
Premium Full-Size Touring Motorcycles
Key Competitors:
Indian Roadmaster, Honda Gold Wing, BMW R 1250 RT, Kawasaki Vulcan Voyager
Vehicle Philosophy:
Designed for long-distance comfort, rider and passenger amenities, and substantial luggage capacity.
Manual Value Proposition:
Comprehensive DIY resource for maintaining and repairing Harley-Davidson Touring motorcycles, enabling cost savings and self-sufficiency.
Engine Systems:
Fuel System (EFI), Ignition System, Engine Mechanical (Disassembly/Assembly), Lubrication System, Cooling System (Oil Cooling)
Transmission Systems:
Clutch System, Primary Drive, Transmission Assembly (5-Speed Cruise Drive), Final Drive (Belt Drive)
Electrical Systems:
Battery, Charging System (Alternator/Regulator), Starting System, Lighting System (Headlight, Taillight, Signals), Ignition System, Instrumentation, Diagnostics (ECU/ECM Codes), Audio System, Cruise Control, Security System (H-D Smart Security)
Chassis Systems:
Frame, Front Suspension (Forks, Triple Clamps), Rear Suspension (Shocks, Swingarm), Brakes (Front and Rear Calipers, Master Cylinders, ABS Systems), Wheels and Tires, Steering System (Handlebars, Headset)
Bodywork And Trim:
Fairings (Batwing, King/Queen), Saddlebags, Tour-Pak, Fenders, Fuel Tank, Seats, Fairing Lowers, Windshield, Body Panels
Routine Maintenance:
Oil Changes, Filter Replacements, Spark Plug Service, Air Filter Cleaning/Replacement, Brake Pad Inspection/Replacement, Tire Pressure Checks, Chain/Belt Adjustment (where applicable)
Diagnostic Procedures:
Troubleshooting charts based on symptoms, DTC (Diagnostic Trouble Code) retrieval and interpretation, Component testing procedures
Repair Procedures:
Engine rebuild, Transmission overhaul, Suspension servicing, Brake caliper rebuild, Electrical component replacement, Body panel repair and replacement
Disassembly Assembly:
Complete step-by-step instructions for disassembling and reassembling all major vehicle components and systems.
Diagnostic Capabilities:
Advanced diagnostics, including wiring diagrams, circuit testing, sensor analysis, and ECU relearn procedures.
Rebuild Specifications:
Detailed specifications for engine and transmission component clearances, torque values, and assembly sequences for full rebuilds.
Special Tool Requirements:
Identification and usage instructions for specialized Harley-Davidson tools required for specific repair and maintenance tasks.
Engine Family:
Twin Cam 96 (1584cc)
Engine Configuration:
45-degree V-Twin
Bore X Stroke:
3.75 in x 4.38 in (95.25 mm x 111.25 mm)
Displacement:
96 cu in (1584 cc)
Horsepower Est:
~70-75 HP (Varies by specific model and tune)
Torque Est:
~90-95 lb-ft @ 3200 RPM (Varies by specific model and tune)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded Gasoline, 91 Octane (or higher recommended)
Oil Type:
Harley-Davidson SYN3 Synthetic (or equivalent SAE 20W50)
Oil Capacity:
Approximately 4 US quarts (3.8 L) with filter change
Transmission Type:
6-Speed Cruise Drive (for 2007-2008, 5-speed was standard on some models, 6-speed became standard later in the generation)
Transmission Options:
N/A (Primarily a single transmission type per model/year)
Primary Drive:
Multi-plate Wet Clutch, Primary Chain Drive
Transmission Fluid Type:
Harley-Davidson Formula + (or equivalent SAE 50)
Transmission Fluid Capacity:
Approximately 2.5 US quarts (2.4 L)
Overall Length:
Varies by specific model (e.g., Road King, Electra Glide Classic, Street Glide)
Wheelbase:
Approximately 63.5 - 64.5 inches (1613 - 1638 mm)
Seat Height:
Approximately 27.3 - 29.5 inches (693 - 750 mm) (laden)
Dry Weight:
Approximately 700 - 800 lbs (317 - 363 kg)
Gross Vehicle Weight Rating:
Approximately 1300 - 1400 lbs (590 - 635 kg)
Saddlebag Capacity:
Integrated hard saddlebags, approximately 2.2 cu ft total capacity
Tour Pak Capacity:
Optional, adds significant cargo volume
Safety Certifications:
Not typically rated by NCAP or similar automotive crash test agencies.
ABS:
Available or standard on many models (Anti-lock Braking System)
Cruise Control:
Standard on most Touring models for highway comfort.
Security:
H-D Smart Security System with keyless fob and siren (optional/standard depending on trim).
Lighting:
Halogen headlight, LED taillight and brake lights, front and rear turn signals.
Frame Construction:
Steel, cradle frame designed for stability and load carrying.
Audio System:
Factory-installed AM/FM/WB stereo with CD player or CB/Intercom (model dependent), handlebar-mounted controls.
Display:
Analog gauges with LCD information screen.
Cruise Control:
Electronic cruise control standard on most models.
ABS:
Optional or standard Anti-lock Braking System for enhanced control.
Diagnostic Interface:
OBD-II compliant for diagnostic code retrieval with appropriate tools.
Accessory Integration:
Pre-wired for various Harley-Davidson accessories like heated grips, auxiliary lighting, and CB radios.
First Service Mileage:
1,000 miles (1,600 km)
Subsequent Service Interval:
Every 5,000 miles (8,000 km) or annually, whichever comes first.
Engine Oil Change Interval:
Every 5,000 miles (8,000 km) or annually.
Primary Chain Case Fluid:
Harley-Davidson Formula + (or equivalent SAE 50)
Brake Fluid:
DOT 4 (refer to manual for specific caliper requirements)
Coolant Type:
N/A (Air-cooled engine, oil is the primary cooling medium)
Common Wear Items:
Clutch plates, wheel bearings, brake pads, front fork seals, battery.
Potential Reliability Concerns:
Cam chain tensioner wear (early Twin Cam), starter drive issues, electrical connector corrosion.
Performance Enhancements:
Tuning for exhaust and air intake modifications, potential for increased heat in stop-and-go traffic.
Brand Founding:
1903, Milwaukee, Wisconsin
Motorcycle Pioneers:
One of the oldest motorcycle manufacturers globally.
Touring Lineage:
Evolution of iconic Harley-Davidson models like the Electra Glide, Road King, and Low Rider.
Twin Cam Introduction:
Twin Cam engine family introduced in 1999, providing increased power and reliability over previous Evolution engines.
Manufacturing Location:
York, Pennsylvania, USA and Milwaukee, Wisconsin, USA (Assembly)
