Positioning:
Flagship touring motorcycle, designed for long-distance comfort and premium features
Competitors 2006:
Honda Gold Wing, Indian Roadmaster, Kawasaki Vulcan Nomad
Touring Capabilities:
Spacious fairing, ample luggage capacity (saddlebags and tour-pak), comfortable rider and passenger seating
Engine Type:
Fuel-injected, air-cooled V-Twin
Infotainment:
Integrated audio system with CB radio and passenger intercom
Comfort Features:
Cruise control, adjustable rider backrest, fairing lowers
Engine:
Full overhaul, diagnostics, component testing, specifications
Transmission:
Service, repair, troubleshooting, fluid specifications
Fuel System:
Fuel injection system, fuel pump, injectors, diagnostics
Electrical System:
Wiring diagrams, component testing, charging system, ignition system, lighting, accessories
Braking System:
Hydraulic system, ABS (if equipped), brake pad replacement, caliper service
Suspension System:
Front and rear suspension, fork service, shock absorber replacement
Frame And Bodywork:
Chassis, body panel removal, fairing service, seat service
Clutch:
Service, adjustment, replacement
Cooling System:
Not applicable for this air-cooled model
Exhaust System:
Component inspection and replacement
Wheels And Tires:
Tire inspection, replacement, wheel bearing service
Instrumentation And Controls:
Gauge cluster, handlebar controls, switches
Lighting And Accessories:
Headlight, taillight, turn signals, audio system, cruise control
Scheduled Maintenance:
Detailed intervals and procedures for all service items
Troubleshooting:
Diagnostic charts, common problems and solutions
Engine Rebuild:
Complete disassembly, inspection, and reassembly procedures
Transmission Repair:
Gearbox disassembly, repair, and assembly
Electrical Diagnostics:
Wiring harness testing, component resistance checks, voltage testing
Brake Bleeding:
Step-by-step instructions for hydraulic brake bleeding
Fork Service:
Oil change, seal replacement, component inspection
Wheel Bearing Replacement:
Proper procedures for wheel bearing removal and installation
Fuel System Cleaning:
Injector cleaning and system flush procedures
Battery Service:
Inspection, charging, and replacement
Tire Mounting And Balancing:
Guidelines for proper tire installation and balancing
Depth:
Comprehensive (from basic maintenance to complete engine/transmission rebuilds)
Diagnostics:
Advanced diagnostic procedures and troubleshooting trees
Specifications:
Detailed torque specifications, clearances, tolerances
Wiring Diagrams:
High-quality, detailed electrical schematics
Special Tools:
Identification and usage of required special tools
Engine Type:
Twin Cam 96 V-Twin
Displacement:
1584 cc (96 cubic inches)
Bore X Stroke:
3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)
Valvetrain:
Overhead valve (OHV), 8 valves total (2 per cylinder)
Cooling System:
Air-cooled
Horsepower:
Approx. 68 HP @ 5200 RPM (manufacturer estimate, not always explicitly stated)
Torque:
Approx. 92 ft-lbs @ 3500 RPM (manufacturer estimate)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Premium Unleaded Gasoline
Fuel Capacity:
5.0 gallons (18.9 L)
Crash Test Ratings:
N/A (Motorcycle specific, not rated by NHTSA)
Braking:
Full-length disc brakes, front and rear, linked braking system (optional for some Harley models, but common on touring)
ABS:
Anti-lock Braking System (ABS) available as an option or standard on some variants
Lighting:
Halogen headlight, LED taillight, auxiliary passing lamps, front and rear turn signals
Fairing:
Large front fairing for wind and weather protection
Cruise Control:
Electronic cruise control for reduced fatigue on long rides
Initial Service:
1000 miles (1600 km) or 6 months
Subsequent Service:
Every 5000 miles (8000 km) or 12 months thereafter
Engine Oil Change:
Every 5000 miles (8000 km) or 12 months
Transmission Oil Change:
Every 10000 miles (16000 km) or 24 months
Primary Chain Case Oil Change:
Every 10000 miles (16000 km) or 24 months
Spark Plug Replacement:
Every 10000 miles (16000 km)
Air Filter Cleaning/Replacement:
Inspect every 5000 miles (8000 km), clean/replace as needed
Engine Oil Type:
Harley-Davidson recommended SAE 20W-50 (e.g., Harley-Davidson Full Synthetic or Syn3)
Engine Oil Capacity:
3.5 quarts (3.3 L) with filter change
Transmission Oil Type:
Harley-Davidson Formula + Transmission Lubricant (or equivalent SAE 80W-90 GL-5)
Transmission Oil Capacity:
28-32 fl. oz. (828-946 ml)
Primary Chain Case Oil Type:
Harley-Davidson Formula + Transmission Lubricant (or equivalent SAE 80W-90 GL-5)
Primary Chain Case Oil Capacity:
20-24 fl. oz. (591-710 ml)
Brake Fluid Type:
DOT 4 Hydraulic Fluid
Known Issues 2006 Tc96:
Potential for oil leaks, compensator sprocket wear (early models), stator failure, starter clutch issues. Manual covers diagnostics and repair for these.