harley davidson

HARLEY-DAVIDSON UNIVERSITY

TECHNICAL FORUM 2007 MODEL YEAR

HARLEY-DAVIDSON UNIVERSITY

TECHNICAL FORUM 2007 MODEL YEAR

ALL MODELS

H-D 07

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2007 MODEL YEAR TECHNICAL FORUM ALL MODELS

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NEW Smart Security System Option

• Hands/button-freesecuritykeyfob

• Systemarmsitselfwithinfivesecondsofturningignition“off,”anddisarmswhenignitionisturnedonormotorcycleismovedwithfobpresent

• Securitysystemis“transparent”tothecustomer

• Attemptstomovethemotorcyclewithfobontheseatorwithin4in.fromantennacouldactivatethesystem

• Harley-Davidson®SmartSecuritySystemimpacts:

• PDIprocess • ServiceWritersandSales • Transportation

ofmotorcycle • Servicingofmotorcycle • Customerexpectations• Storagemodeeliminated;

currentdrawdropsfrom3.2mAto.7mA

• P&Asirenupgradessystemwithchirpdisablefeature

• HDImotorcycles,excludingJapan,featureOEsiren-equippedsecuritysystems

Important Service Note:Fobrequiresserial#assignmentwithDT,andPIN#mustbeenteredbeforefobassignment.

2

ALL MODELS 2007 MODEL YEAR TECHNICAL FORUM

NEW Speedometers, Tachometers and Indicators (except VRSC™)

• Similarfeaturesasthe2006VRSC™models

• Clockfunction

• 6thGearindicatorforBigTwinmotorcycles

• Dualtripmeters

• Retrofitgauges(suffixchange)

• P&Atachometeroutputsignalon4in.speedometer

• Lowerstandbycurrent

• UKdual-facespeedometerschangeto130mph(200km/h)

2

Clock Function

• DisplayedonLCD(odometerwindow)

• Selectedwithtripswitchbutton(pressrelease)

• Setwithtripswitchbutton(presshold/pressrelease)

• 12/24-Hourselectable

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Reduced-Effort Clutch Cable

• 2006Dyna™design

• Newclutchcable

• Reduced-effortclutchlever:

• 8%ReductionforSportster®models

• 10%ReductionforSoftail®models

• 7%ReductionforTouringmodels

NEW LED Indicators (except VRSC™)

• Easier-to-readLEDindicatorsreplaceincandescentbulbs

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Clutch Interlock Switch

• Clutchinterlockswitchfunctionsasan“or”functionwiththeneutralswitch

• Switchverifiesifthemotorcycleisinneutralandifnot,theclutchlevermustbedisengaged(pulledin)beforemotorcyclewillstart

• Excellentfeaturefornewriders

Electronic Sequential Port Fuel Injection (E.S.P.F.I.)

• Similardesignwasincorporatedforthe2006Dyna™models

• O2feedbacksystemeliminatestheneedforcatalysts(exceptVRSC™models)

• HDImotorcyclesareequippedwithO2sensorfeedback

• Systemadjuststoprovideoptimalair/fuelmixture

• SomeCVOmotorcyclesrequirecatalyst


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NEW Molex® Connectors (except Buell®)

• Molex®connectorsaresmallerthanDeutsch®connectors

• Molex®connectorsareinternallysealedfrommoisture

• VRSC™modelsfeatureMolex®connectorsexclusively

• Connectorisonlyservicedfromthematedside

MolexisaregisteredtrademarkofMolexProductsCompany.

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Final Drive Belt

• 1in.wideX7Nbelt

• Secondgenerationcarbonfiber

• Thickerfabricforincreasedtoothstrengthandwearresistance

• Touringmodelsreceivea137Tbelt

• H-DJapanTouringmodelsreceivea136Tbelt

Important Service Note:

Newbelttensionspecificationsforallmodels.

Tooth JacketThickerfabricfor

increasedtoothstrengthandwearresistance

Polyurethane BodySamematerial

aspreviousbelts

Tensile CordSecondgeneration

carbonfiber

BIG TWIN eNGINes

H-D 07

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2007 MODeL YeAR TeCHNICAL FORUM BIG TWIN

NeW Twin Cam 96™ engine Powertrain specifications

• Displacement:96cu.in.1584ccupfrom88in.1450cc

• Achievedbystrokeincreaseto4.375in.(111.13)

• TouringAlphaengineshaveincreasedtorqueto93ft.lbs.(126NM)@3500rpm

• Softail®Betaengineshaveincreasedtorqueto90ft.lbs.(122NM)@2750rpm

• Dyna™Alphaengineshaveincreasedtorqueto92ft.lbs.(125NM)@3000rpm

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2

BIG TWIN

2

Twin Cam 96™ Connecting Rods and Pistons

• Lighterpistonsandconnectingrodsforlowerreciprocatingweight

• Shorterwristpin

25-Degree Injectors

• 2006runningchangeto25-degreefuelinjectors(P/NH-D-27709-06A)

2007 MODeL YeAR TeCHNICAL FORUM

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• TwinCam96™Alphaengine/transmissiongasket

Twin Cam 96™ Components Follow 2006 Dyna™ Powertrain

• Compensatorassembly/alternators

• FourspringpackdesignfordomesticandHDImodels

• Compensatorspringpacknowweldedtorotor

2007 MODeL YeAR TeCHNICAL FORUMBIG TWIN 2007 MODeL YeAR TeCHNICAL FORUM

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Twin Cam 96™ Components Follow 2006 Dyna™ Powertrain (cont.)

• Enginecaseswithintegraloilfilteradapter

• ExternaloillineshavebeeneliminatedforDyna™andTouringBigTwinengines

• Softail®enginescontinuewithexternaloillines

5


5


• Camplatechanges

• Primaryhydrauliccamchaintensioner

• Camplatechanges

• Secondaryhydrauliccamchaintensioner


66


• Camplatechanges

• Camplateusesparentmaterialbearings

• Crankshaftassemblyandcases

• Innercambearings


77

• Oilpumpassembly

• 10%Moreflowand23%scavengingcapacityimprovement

• O-ringbetweenoilpumpandcamsupportplatehasbeeneliminated

• 10/11Lobegerotorset


• Assembledcams

2007 MODeL YeAR TeCHNICAL FORUMBIG TWIN

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• Flywheelsprocketshaftsplinesmatch2006Dyna™models


• Dyna™-stylerollercamchains

• AllBigTwinmodelsfeaturehydraulicchaintensionersandnewcamchains

2007 MODeL YeAR TeCHNICAL FORUM

9


9

• 5thand6thgearsareintegraloncountershaft

• Sixof12gearsareindividuallyserviceable

• Christmastreegearlayoutonshafts

• VRSC™-styledogringshifting

• XL/XB-styleshifterdesign


• 6-SpeedCruiseDrive™transmission

• 6thGearisdirectdrive1:1

• Lowercruisingrpmin6thgearisachievedwithnewprimaryratio

• 2nd,3rd,4thand6tharehelicalgears

• 1stand5tharespurgears

• 1st,2nd,3rdand4thgearsareintegralonmainshaft

2007 MODeL YeAR TeCHNICAL FORUMBIG TWIN

�0


• 6thMaindrivegear

• Quad-ringreplacedbyO-ringonnewmaindrivegear

• Needlebearingsfor6thgearmainshaft

• Needlebearingssecuredbyretainingrings

• Double-rowoutputbearing

• Sprocketspacerincorporatedintobearing

• Primarydrivesystem

• Driveratiois1.35:1

• Dyna™clutchshell

• Starterringgearmovedtoinboardonclutchhub

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• Automaticmechanicalprimarychaintensioner

• Newinnerprimaryhousings

• Innerprimarymustberemovedtoservicerotorandstator


�2


• Primarygasket/fasteners

• Primarychaininspectioncoverhasbeenremoved

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6th Gear Indicator

• Lampactivatesduringmotorcycleoperationin6thgear

• Vehiclespeedandenginerpmdeterminelightactivation;notaswitch

Charging system

• Softail®andDyna™modelsfeatureanew40-ampalternator


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NeW One-Piece Horn Cover

• Foreaseofassembly

Oe exhaust

• Improvedsoundquality

�5


�5

HDI Only – Active Intake

• Solenoidcontrolstheopeningandclosingofbaffleintheaircleanerbackingplatetoreduceintakenoise

• H-DJapanmotorcyclesdonotfeatureactiveintake

• Solenoidattachedtobacksideofaircleanerbackingplate


�6

HDI Active exhaust (except Japan)

• Actuatorclosesvalveintheexhaustsystemduringhigherengineloads

• Optimizespowerwhilemeetingnoiseregulations

• Compositecablemountandcablearesoldasakit


Nevermovetheactuatorbyhand(orwithatool).

Actuatorcannotbedroppedoritwillneedreplacement.

Activeexhaustsystemsaretobe“replaceonly”serviceitems,norepairs.


�7�7

Twin Cam 96B™ Balanced engine

• New1584ccTwinCam96B™balancedengine

• 6-SpeedCruiseDrive™transmissionispartofthispowertrain

Twin Cam 96B™ Balancers

• Newbalancerisfirstpressedintobearing

• Anewtoolshownheretopressassembly

H-D 07

VRSC™ family

2007 mODEl yEaR TECHNiCal fORUm VRSC™

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Two-Piece Rear Caliper assembly

• New brake lines

• Two-piece assembly is easier to service

• VRSCR rear caliper unchanged

�Important�Service�Note:

Rotor does not need to be removed during tire changes.

NEw Brake Pads on VRSC™ models

• New brake pad material

• Reduced brake noise

• Reduced rotor wear

• Brake pads retrofit to 2006 models

Old

New

2

VRSC™

NEw fuel Sending Unit for all VRSC™ models

• Ultrasonic sending unit reads fuel levels via sound waves that reflect off the fuel level

• Fuel lines/connectors are easier to service

• Fuel line routing

• Does not retrofit

NEw fuel Tank on VRSCa, VRSCD, VRSCDX and VRSCX models

• Five-gallon fuel tank for new frame

• Does not retrofit

2007 mODEl yEaR TECHNiCal fORUm


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VRSCDX Night Rod™ Special

• Black-finished cam covers, alternator and clutch covers

• Blacked-out triple trees and fork lowers

• Black slotted wheels with Orange pin stripe

• Smoked turn signal lenses

• Forward controls

• 240 mm rear tire

• Wide rear fender

• New rear axle

• Lowered rear shocks

• Lowest ride height (25.2 in.) to date


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VRSC™

frame Change

• New seat pan assembly

• VRSCA/VRSCD frame accommodates new five-gallon fuel tank

• Ignition switch moved to right front side

• Passenger footpegs relocated to frame


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2�0 mm Rear Tire Standard on New VRSCDX, VRSCX and VRSCaw models

• Night Rod™ Special VRSCDX

• VRSCAW is a Wide version of the VRSCA from prior model years

• High-powered VRSCX

• Wide rear fenders

• New license plate bracket and inner fender

• Wide swingarm

NEw Coolant Tank

• Coolant tank relocated

• VRSCR coolant tank remains unchanged


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VRSC™

• 1250 cc engine

• Limited production of 1,400 units

• Laced front wheel

VRSCX Unique Styling

• New paint scheme incorporates the “#1” logo

• Based on the Screamin’ Eagle®/Vance & Hines NHRA Prostock V-Rod®


7

larger Battery

• Battery common with Dyna™

models except VRSCR

• Does not retrofit due to size and polarity of battery posts

NEw front Tires

• New tire tread design

• 207 Series Dunlap® front tire changed to 208 Series


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VRSC™

Radiator Trim Covers

• Similar trim cover as 2006 VRSCR models

�Important�Service�Note:

Retrofits with minor modifications to radiator cover.

VRSCR Ergonomic improvements

• Wider and higher handlebar

• Handlebar does not retrofit


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front Electric Caddy

• Front fuse block contains starter relay, dual fan relay, ignition and battery fuse and one spare fuse

• 15-Amp fuses

• Data link is on right side, next to MAXI™ fuse

Right�Side

• New battery tray/electrical caddy accommodates starter solenoid

• Right- and left-hand controls, headlamp jumper harness and front turn signals located under left side Starter�

Solenoid

Left�Side


�0

VRSC™

Rear Electric Caddy

• Under passenger pillion

• Molex® connectors

• ECM located on rear caddy

• ECM, lights, security, spare fuse and accessory circuits located in rear fuse block

NEw wire Harness

• Harness has a new right-side branch that starts behind rear cylinder

• Rear coil and vehicle speed sensor leads are moved to the center of the motorcycle

• All VRSC™ motorcycles have Molex® connectors

Molex is a registered trademark of Molex Products Company.


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Compensator Bowl

• Wide compensator bowl accommodates new frame

• VRSCR compensator bowl remains unchanged

NEw Exhaust Shield Retention

• New hardware

• Fasteners do not retrofit to prior models

• New kit consists of new auxiliary volume and hardware to retrofit prior models

Old New


�2

VRSC™

Split Rear wheel Bearing

• New bearing for models equipped with 240 mm tires

• CVO VRSC™ motorcycles used this bearing in 2006

H-D 07

SPORTSTER® family

The Sportster® family Celebrates 50 years

• 50thAnniversary1200model

• Limitedproductionof2,000

• Serializednameplateonhandlebarclamp

• Gold“50th”emblemonfueltank

• New“H”silk-screeningonsidecoversrepresentstheculturalhistoryoftheSportster®family

• Embroideredseat

• XLcustomrearshocks

NEw 883l model

• Lowered25.25in.seatheight

• Newfrontandrearshocks

• Newseat

• Partsretrofit

• Highertorquefor883models

• All2007XLmotorcyclesuse“W”cams

• 15%Moretorqueat2500rpm

• Requires1200mufflersforJapanmarket

2007 mODEl yEaR TECHNiCal fORUm SPORTSTER®

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2

SPORTSTER®

Electronic Sequential Port fuel injection (E.S.P.f.i.) for all Xl models

• 45mminductionmoduleforallmodels

• 15-Degreeinjectors

• NewwiringharnesswithMolex®connectors

• Frameupdatedwithnewbracketstosecurenewwireharness

• Lowfuellight

• 91Octaneforall2007Sportster®models


Redesigned Oil Pump

• Redesignedpumpbody,feedandscavengegerotors

• Newfeedandscavengeporting

• Scavengegerotorshavelargerdiameterandaretallerformorecapacity

• Feedgerotorsarethinnertoaccommodatetallerscavengegerotorsinoriginalpumpbodyheightbutredesignedfornolossofcapacity

• Internalpartsdonotinter-changewithearlierpumps

• Pumpassemblywillretrofit

Old New


3

• HeadtemperaturesensorislocatedinrearcylinderheadsimilartoBuell®models

• Specialtoolavailable

Electronic Sequential Port fuel injection (E.S.P.f.i.) Sensors

• NewTMAPsensor

• CombinedsensorMAP/IAT

• TopofInductionModule(IM)

• IAC:topofIM

• TPsensor:leftsideofIM

TMAP Sensor

IAC

TP Sensor


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SPORTSTER®

fuel Pump

• Mountedinnewfueltank

• CheckSportster®modelServiceManualforpressurespecifications

• Usescurrentfuelpressuregaugeadapter(P/NHD-44061)

Oxygen Sensors

• FrontandrearexhaustO2sensors

• Closedloopsystemlike2006Dyna™models

Frontsensorshown


5

NEw ignition Coils

• Newcoilmountingbracket

• Newsparkplugwires

• Newprimaryandsecondaryresistancevalues

• CheckSportster®modelElectricalDiagnosticsManualforproperspecifications

intake flanges

• Newintakeflangesandfasteners

• Widerflangesallowforbetterfasteneraccess

• Usesfourhexboltsratherthanallenbolts

• Newcylinderheadstoaccommodatenewflanges

• 1200Headshavechangestointakeportandintakevalveseat

• Noserviceprocedurechangestonewheads,onlypartnumberchanges


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SPORTSTER®

NEw ECm and fuse location

• ECMislocatedunderneaththeseatontherearfender

• Additionalfusesarerequired

• NewrearfendersandseatsaccommodateECM


7

NEw Rocker Boxes

• Rockerboxeshavebeenchangedtofeatureanimprovedsealingcavity

• Newpress-in-placegaskets

• Gasketsdonotretrofit

32-amp Charging System

• Increasedpowerto32ampsfrom22ampstopowertheE.S.P.F.I.system

• CheckElectricalDiagnosticManualforproperspecifications

• Rotordoesretrofit

• Newstatorandvoltageregulatordonotretrofit


8

SPORTSTER®

Reduced-Effort front Brake lever

• DOT4™brakefluidisusedinall2007XLmotorcycles

• Newcalipers

• Newmastercylinders

• Newbrakelines

• Changesresultinan11%effortreductionfor883,883L,883C,1200Land1200Cmodels

• Changesresultina14%effortreductionfor883Rand1200Rmodels

• Newrearbrakepadsimproverearbrakefeel

• Rearbrakepadsdonotretrofit

NEw Handlebar wiring

• Harnessesarelengthenedby2in.toallowforeasierchangingofhandlebars

• Extraharnessistuckedintotheelectricalcaddyunderneaththefueltank

H-D 07

Dyna™ family

2007 mODEl yEaR TECHniCal fORUm Dyna™

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all Dyna™ models

• All2006modelyearredesignscarryforwardfor2007Dyna™models

nEW lower-Profile Transmission Cover

• DesigncommonwiththeSoftail®model

• NewsmallerJ-hoseventandrouting;newhoseisshapedtoaccommodateHDIexhaustactuator

• Retrofitsto2006Dyna™models

2007 mODEl yEaR TECHniCal fORUm

2

Dyna™

nEW 40-amp Charging System

• Three-phase,40-ampoutputchargingsystemOE(Dyna™andSoftail®models)

• Consistsof:

• New12-magnetrotor

• Newstator

• Statorandrotorassemblyretrofitsto2006Dyna™models

nEW final Drive Gearing, Belt and Belt Guard Change

• FinaldrivegearingismatchedtooptimizethenewTwinCam96™powertrain

• Newrearsprockets

• HDIanddomesticmodels:66-toothrearsprocket/131-toothdrivebelt

• H-DJapanmodelsonly:64-toothrearsprocket/130-toothbelt

FXDDyna™SuperGlide®model


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nEW Steering Head adjustment access area

• Notchedaccessareaprovidesimprovedaccessforservicing

• NotchallowsserviceproceduretobecommonwithSoftail®andTouringmodels

Transmission Shift Detent and Roller Change

• Shiftdetentarm,springandrollerdesignchange

• Partnumberrevisionsto“A”suffix

• 2007Transmissiondetentassemblyretrofitstopost-recall2006Dyna™motorcycles

• Thisassemblyissoldasakitfor2006Dyna™models 2006 Dyna™ Model 2007 Big Twin

2007 mODEl yEaR TECHniCal fORUm

4

Dyna™

fXDBi Dyna™ Street Bob™ and fXDi Dyna™ Super Glide® models

• Newstainlesssteelrearfendersupports

• BrushedstainlesssteelcoversonFXDBmodel

• Recommendedcosmeticcareproduct:Harley-Davidson®BrightChromeCleaner(P/N94683-99)

• PolishedstainlesssteelcoversonFXDmodel

• Recommendedcosmeticcareproduct:Harley-Davidson®BrightMetalPolish(P/N99725-89)


SurfacecareproductsfornewfinishesareintheDyna™modelOwner’sManual.


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nEW on fXDC model

• Basedon35thAnniversarySuperGlide®model

• Uniquemodelfeatures:

• Tanktrimandcloisonné

• Ribbedseat

• Batterycovertrim

• Handlebarsandfrontbrakeline

• Electricalcaddycovertrim

• Leathertankpanelwiththe“#1”logo

H-D 07

softail® family

2007 moDEl yEaR tECHNiCal foRUm softail®

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NEw twin Cam 96B™ Engine Balancers

• Newone-piecebalancersupportbracket

• Newbearinginstaller/removaltoolrequiredforservice

flstf and fX “Bobtail” models – New tire

• 200mmreartirewithnewtreaddesign

2007 moDEl yEaR tECHNiCal foRUm

2

softail®

NEw for fX softail® models

• Newhandlebars,risersandclamps

UK Dual-face speedometer Change

• Newspeedometerfacereadsupto130mph(200km/h)

Touringmodelexampleshown


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• Newfrontaxle

25 mm wheel Bearings and axle

• AllSoftail®models,excepttheSpringer®model,receive25mmfrontwheelbearings

Old1 in. I.D. New

25 mm I.D.


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softail®

• Newfrontpanel/nacelle

fPo

fat Boy® model front End Changes

• New-stylehandlebarsandrisers

• Internalhandlebarwiring


5

NEw three Electric Caddys

• Onecaddyislocatedunderfueltank

Extended Rear Brake Control and footrest mounts on fX “Bobtail” models

• Rightsidecomponentsextendedoutwardapproximately1in.

• Allowsformorestretched-outridercomfort

• Rearbrakepedalstylingimproved


6

softail®

NEw three Electric Caddys (cont.)

• Asecondcaddyisbehindthevoltageregulator

• Athirdcaddyisundertherearfendercover


7

Rear fenders

• Sound-dampeningmaterialaddedtofender

NEw four-Hole fender supports on flstN

• AllowsmoreP&Aaccessoryopportunities

H-D 07

touring family

2007 moDEl yEar tECHniCal forum touring

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nEw idle temperature management Download option

• Forprolongedengineidleconditions

• Inhotridingconditions,anoptionaldealer-enabledenginecalibrationisavailable

• Newdownloadcutscombustiontorearcylinder

• Enginemustbeatcertainoperatingtemperature

• Vehiclemustbeatidleandnotmovingtoactivate

• Exhaustchangestonewithonlyfrontcylinderfiring

• Exhaustmayhaveslightlydifferentodor

• Installationofdownloadisfreeonetimeonly(underwarranty)

• Removalofdownloadisfreeonetimeonly(underwarranty)

• Priorsystemshavebeenremovedfor2007models

2007 moDEl yEar tECHniCal forum

2

touring

Sidecar Brake reservoir

• RelocatedinordertoprovidenecessaryclearancefortheO2sensors

• Mountstotheoutsideofthefrontframesupportbracket

• Newdesign


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Shift lever and floorboard Changes

• Newshiftlever,left-handriderfloorboardsupportsandpassengerfloorboardsupports

• Changesaccommodateadditionalclearancenecessaryduetonewengine,transmissionandprimarydrive

• Shiftleverretrofitstopriormodelsbutpre-2007leversdonotfitnewTouringmotorcycles

• Newboardmountsretrofittopriormotorcycles

• Oldboardmountsdonotretrofitto2007models

frame and Swingarm Changes

• Frame,swingarmandenginemountsaccom-modatenewengine

• Swingarmforgingmovedtotherear

• Newswingarmsupportbrackets(endcaps)

• Newforged,frontenginemountbracketclearsnewcrankcase

• Swingarmmountsdonotretrofit

• 2007Touringframedoesnotretrofittopriormodels


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touring

Jiffy Stand Change

• TouringmotorcyclescomewithanewJiffystandtoaccommodatechangesfromnewengine

• Newbumper

• Mounthaschanged

Saddlebag Supports

• NewcastzincI-bracketsandendbulletsforsaddlebags

• Newbracketsappearthesamebuthaveasmootherfinishonallsides

• Reducesscratchingofsaddlebagswhenremoving


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twin Cam �0�™ cu. in. Engine for Police models

• 1690ccCVOengine

• 9.6:1Compressionratio

• Uniquecalibration

• ABSandHarley-Davidson®SmartSecuritySystemoptionalequipment

• Uniqueclutchspring

• Catalystmufflers

• ActiveintakeandexhaustonHDIPolicemotorcycles

Sidecars for Police motorcycles

• PoliceTouringmotorcycleswithABSdonotacceptasidecar

• Hydrauliclineroutingontherightsideinterferes


PoliceandTouringmotorcyclesequippedwithsidecarswillnotaccommodateanoilcooler.

Oilcoolerassemblyneedstoberemovedbeforesidecarinstallation.


front Electrical Caddy

• Newcaddymountsundervoltageregulatorretainingconnectorforcrankpositionsensor

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touring

nEw Handlebar Clamps

• Handlebarcontrolclampsaremodifiedimprovingclearanceforwireharness

NEW

Old

H-D 07

CVO family

NEW CVO Engine

• 110cu.in.1800ccengine


• Newheads,combustionchamber,portsandintakevalve

• 255Cams

• 4in.bore

• 110-Scriptedderbycoverandaircleanerinsert

• Syn3engineoil

• 1.4Kwstarter

• 4.375(111.13mm)stroke;sameasOEengines

• ACRsolenoidstoeasestart-up–locatedineachcylinderhead

• Torquerangeof105-115ft.lbs.measuredatcrankshaft(dependingonmodel)

• AllCVOmodelshavehydraulicclutch–DOT4™


Donotusechromepolishonthenewflush-mountLEDfuelgauge(FXSTSSE,FLHRSE3andFXDSEallfeaturethisgauge).

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2007 mODEl yEaR TECHNiCal fORUm CVO


• Harley-Davidson®SmartSecuritySystem(H-DSSS)withself-poweredalarm

• XMSatelliteRadio(threemonthsofservice)andamplifier,exceptHDI

• Advancedaudiointegratednavigationsystem

• Hand/footcontrols,footboardsandhighwaypegsarefromIronsideCollection

• PaintwithPearlhighlights:

• LightCandyCherrywithBlackIce

• LightningBluePearlwithMidnightPearl

• BlackIcewithElectricOrange

flHTCUSE2 Screamin’ Eagle® Ultra Classic® Electra Glide®

• Heatedseatandgrips

• Relocatedintercomplugintegratedwithleftrearspeakerpod

• Multifunctionalswitchforcruisecontrolandspotlights

• Lightsmokedshortwindshield

• Adjustablepassengerfootboards

• PowerlocksonTour-Pak®andbagsaredashcontrolled

2

CVO


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flHRSE� Screamin’ Eagle® Road King®

• Flush-mountgascapandfuelgauge

• Oilcoolerandchromecover• Leathersaddlebagsand

seatwithchrometrimandflameinsert;detachableriderandpassengerbackrests;alsoavailablefromP&A,optionalmatchingleatherTour-Pak®withflameinsert

• Radialtires:18in.x3.5in.frontwheel;17in.x4.5in.rearwheel;130mmfrontand170mmrear;tirepressurechangeto36psifront/38psirear(solorider);38psifront/42psirear(riderandpassenger)

• Customspun-metalfacedspeedometer/tachometercombination

• Dualhalogenheadlamp• H-DSSSwith

self-poweredalarm• Darksmoked

miniwinddeflector• LoweredP&Ashocks• 1.25in.chromehandlebar

withinternalwiring• Floorboards,passenger

pegs,highwaypegsandhand/footcontrolsarefromIronsideCollection

• FatBoy®frontfender;widerearfender,swingarmandrearaxle

• Paintwithleafinggraphicsandmarbleaccents:

• RazorRedwithBurntGold • CandyCobaltwith

PaleGold • BlackIcewithPewter


• Hand/footcontrolsandfootpegsarefromnewCenterlineCollection

• Flush-mountfuelcapandgauge

• H-DSSSwithself-poweredalarm

• Customleathertwo-upseatwithribbedinsert

• Color-matchedframe,swingarm,rigidforks,uppertripleclamp,oiltank,frameinserts,seatpostandmufflersupportbrackets

• TribalFlamepaint: • AbyssBluewithBluePearl • CanyonCopperwith

CandyRed • AmarilloGoldwith

CandyTangerine

fXSTSSE Screamin’ Eagle® Softail® Springer®

• 1.25in.chromehandlebarwithinternalwiring

• Chromeforwardcontrols• Chromehandlebarrisers• Mini-tachand

newchrometachmounts• Revolverchrome10-spoke

forged-aluminumwheels• Revolverchrome

66-toothsprocket• Revolverbrakerotors• 200mmreartire• Newtri-barLEDtaillamp• Low-profile,chrome

fueltankconsole

�

CVO


fXDSE Screamin’ Eagle® Dyna™

• Customspun-aluminumgaugepackage

• Extendedheadlamptrimring

• Polishedstainlesssteelrearbrakepushrodandshifterrod

• Braidedlinepackage

• Chromepackage

• Invertedfrontforks

• Coveredlowrearshockswithhand-adjustpreload

• Custom1.25in.handlebar

• Knurledchromehandgripsandfootpegs

• Rolled-backfrontfender

• Color-matchedframe,batterybox,electricalpanelcover,coilcoverandchinspoiler

• 170mmreartire

• Custombucketseatwithperforatedinserts

• Full-lengthfueltankconsole

• Flush-mount,aircraft-stylegascap

• Laybacklicenseplate

• Paintoptions:

• SilverRushandMidnightBlack

• InfernoRedandDesertBlack

• TwilightBluewithIceBlue,GraniteandIceBluePearl

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Buell 07

Buell® family

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XB firebolt® models

• Newwheelcolors

• Newbodyworkcolors

• Tintedwindscreens

XB lightning® model

• Newcolorcombinationsavailableforwheelsandbodywork

• CityXseathasnewcovermaterial

2007 mODel yeaR TeCHNiCal fORum Buell®

2007 mODel yeaR TeCHNiCal fORum

2

Buell®

ulysses® models

• NewP&Acamouflagebodywork

• Ulysses®seathasnewcovermaterial

• 1.3in.lowerseatheight–laden

• 2.2in.lowerseatheight–unladen

• Seatdoesretrofit

• Seatisreshaped

Buell® Blast®

• NewArcticWhitecoloradded


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New inner Rocker Cover with Press-in-Place Gasket

• Redesignedpress-in-placegasket

• Innerrockercoverhasbeenredesignedtoaccommodatenewgasketdesign

• InnerrockercoverfitspreviousXBmodels(P/N17598-07)

�Important�Service�Note:Donotstretchgasketwhileinstalling;positiongasketincoverandusetoprockercovertopressgasketintoposition.

Gasketkitsincludebothearlyandnewgaskets.

New Rocker Cover/ Cylinder Head Gasket

• Newdesignhascoatedgasket


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Buell®

NEW

Old

New Throttle Body manifold

• NewthrottleshaftTPSengagementpinsorientedat6and12o’clockpositions

• Old-styleengagementpinsareorientatedat2and8o’clockpositions

New Throttle Position Sensor (TPS)

• IdentifiedbyoneortwoorangepaintdotsontopofTPS

• NewTPSrotortangsareat1and7o’clockpositions

• Old-styleTPSrotortangsareat4and10o’clockpositions

• TPSsensorsdonotinterchange

• NewTPS(P/NPO279.3AA)

• OldTPS(P/N29537-99Y)

OldNEW


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New Primary Chain Cover

• Additionalmaterialaddedtothecastingattheprimaryadjustershoescrewsupport

Redesigned Oil Pump

• Redesignedpumpbody,feedandscavengegerotors

• Newfeedandscavengeporting

• Scavengegerotorshavelargerdiameterandaretallerformorecapacity

• Feedgerotorsarethinnertoaccommodatetallerscavengegerotorsinoriginalpumpbodyheight,butredesignedfornocapacityloss

• Internalpartsdonotinter-changewithearlierpumps

• PumpassemblyfitsearlierXBmodels

Old NEW


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Buell®

Tire Changes

• Pirelli®DiablotiresexceptonXB9SXandXB12X(Ulysses®)

• Pirelli®ScorpionSynctiresusedonXB9SXandXB12X(Ulysses®)

additional Holes in airbox functional Cover

• Revisedcalibrationfornewairbox


7

ulysses® Seat limiter

• Separatesunderseatcomponentsfrombottom-of-seatpan

ulysses® Progressive Rate fork Spring

• Provideswiderrangeofsmoothprogressivecontroloffrontsuspensionoverlongforktravel

• Revisedforkservicespecifications

• Doesretrofitandrequiresthenewfrontandrear2007suspensionspecifications

H-D 07

screamin’ eagle®

2007 mODel Year TecHnical FOrUm screamin’ eagle®

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Big Bore stage � Kit �03 cu. in.

• Increasedisplacementfrom96in.to103in.(1584ccto1690cc)

• Bigborecylindersandpistons

• High-flowA/Ckit

• 50-Statestreetlegal

• DigitalTechniciancalibration

Big Bore stage 2 Kit �03 cu. in.


• Bigborecylindersandpistons

• High-flowA/Ckit

• 255Cams

• Catalystexhaust



2007 mODel Year TecHnical FOrUm

2

screamin’ eagle®

��0 cu. in. stage � Kit


• 255Camsproducelowrpmtorque

• 4in.borecylindersandforgedpistons




• Cylinderheadshavemanyfeaturesandfunctions

• Newcombustionchamber

• Portcoresandintakevalve

• Automaticcompressionrelease

• Dyna™andSoftail®modelshaveahigh-flowA/Ckit

• Touringkithasspecialhigh-flowA/Celement

2007 mODel Year TecHnical FOrUm screamin’ eagle®

3

screamin’ eagle® exhaust

• Newstreetperformanceexhaustsystemsarestreetlegalfor2007models

• EachexhaustsystemisdesignedtooptimizetheTwinCam96™engineperformanceandprovidepremiumsoundandstylewhilecomplyingwithnoiseregulations

e.s.P.F.i. calibrations

• Calibrationcartridgesdiscontinuedearlyinthe2007modelyear

• Allstreet-legalcalibrationsfor1995-2007modelsareavailableonDigitalTechnician

• Racecalibrationsfor1995-2006modelsareavailableonDigitalTechnician

• Racecalibrationsfor2007modelsrequireScreamin’Eagle®RaceTuner

• AllracecalibrationscontinuetobeavailableinScreamin’Eagle®RaceTuner

H-D 07

service anD tools

new calibrations search – h-dnet.com

• Customizedtoallmodelsworldwide

• Activescreencapturehelp

• Calibration-specificselection

• Revisedsearchbuttons

• ReverselookupfeaturewithcalibrationI.D.#

several P&a cast wheels sold Differently

• Bearingsandsleevesarenotinstalledinthewheelsfromthefactory

• Bearingsandsleevesareorderedseparately

• Bearingsandsleevesofferedasakit

• Softail®frontwheels,19in.and21in.frontwheels,and17in.x4.5in.wheelsareaffected

2007 MoDel Year tecHnical ForUM service anD tools

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2007 MoDel Year tecHnical ForUM

new Xl Fuel lines

• Fuellinesmayappeartobekinkedupondeliveryuntilignitionisturnedontoexpandtheline

vrscDX wheels

• 240mmtires

• Blackpaintedwheelsneedtobeservicedwithcautionascosmeticdamagecanoccurifproperproceduresarenotused

2

service anD tools


essential tools

• Wheel Bearing Collet

• P/NHD-44060-10

• AddedtoEssentialToolKit

• ColletaddedtotheWheelBearingKit(P/NHD-44060-A)

• Removes25mmwheelbearingsfeaturedonSoftail®frontwheels

• Springer®modelscontinuewith1in.wheelbearings/collets

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crankshaft rotating wrench

• P/NHD-48283

• Madefornewsplinesoncrankshaft

• Usedon2006Dyna™modelsand2007TwinCam96™engines

• CrankshaftRotatingWrenchisnotpartofthe2007EssentialToolKit


• Triple Trees Wedge for VRSCR

• P/NHD-48287

• Spreadsclamptopreventdamagingpaintedforktubesduringservicing

• Twowedgescomeinthekit

essential tools (cont.)

• Vehicle Alignment Tools

• P/NHD-46247-1P/NHD-46247-2

• Newpivotshaftalignmentblocksfor2007FLmodels

• Framechangesmadeblocksnecessary

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service anD tools



• Short Primary Drive Locking Tool

• P/NHD-48219

• Locksprimarydriveforremoval/installationofcompensatingsprocketassemblyandclutchhub

• Touringmodelsonly


TechTip#212explainsprimarydrivelockingtoolusagefor2006Dyna™models,whichappliestothisnewtoolaswell.

• Head Temperature Sensor Socket for XL Models

• P/NHD-48116

• Usedtoremove/installheadtemperaturesensorsfromtherearcylinderofXLmodels

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• Sprocket Shaft Adapter and Collar

• P/NHD-97225-1P/NHD-97225-2

• AdaptsthesprocketshaftbearinginstallertooltoP/NHD-497225-55CforservicingnewTwinCam96™and2006Dyna™engines

• Collarisusedtoinstallthebearinginnerrace


• O2 Sensor Socket

• P/NHD-48262

• UsedonallH-Dmodels

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service anD tools



• Sprocket Shaft Seal Installer

• P/NHD-39361B

• Allowsthesimultaneousinstallationofthesprocketshaftsealandspacer

• Installingbothpartsatthesametimeensuresthesealisprotected

7

• Balancer Bearing Installer for Softail® Models

• P/NHD-48309

• InstallsthenewbearingandbalancerfortheTwinCam96B™engine

• Newbearingmustbepressedontobalancerbeforepressingassemblyintocase

• Casemustbesupportedwhenpressinginbalancer/bearingassembly


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service anD tools


• Twin Cam 96B™ Outboard Balancer Bearing Remover/Installer

• P/NHD-48474

• Removesandinstallsbearingsfromthechainguidesupportplate

• Twin Cam 96B™ Balancer Puller

• P/NHD-48457

• PullerextractstheTwinCam96B™balancer/bearingassembly

• Plateisreversibleforfrontandrearbalancers


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• Terminal Remover

• P/NHD-48114

• RemovessocketandpinterminalsfromMolex®connectors

• Usedonallmodels


Refertotheinstructionsheettopreventdamage.

• Electrical Crimp Tool

• P/NHD-48119

• CrimpsMolex®terminals



• Barcode Reader for Security Systems

• P/NHD-48263

• FunctionalityisenabledthroughDigitalTechnicianPhase19software

• AssignsfobsduringPDI

• Increasesaccuracyandefficiency

• USBconnectivity

• Optionalfobassignmentcanbeinputbyreadingthe24-charactersecurityIDbehindfobcover

• 24-CharactersecurityIDmatchesthesystemIDfortheHFSM

�0

service anD tools


• TMAP Sensor Pin Probes

• P/NHD-41404-15

• NewprobesrequiredforelectricaldiagnosticsonTMAPsensorterminalsonXLmodels

• Probesarealightorangecolor

• H-DSSS Antenna Pin Probes

• P/NHD-41404-20

• Usedonallmodelswithsecuritysystems

• Probesarealightbluecolor



• USB Hub

• P/NHD-44750-15

• CF27andCF28laptopsdonotsupplyenoughpowerthroughtheUSBporttoproperlypowertheBarcodeReader

• 4-PortUSB2.0hubwithACpowersupply

• PermitsconnectionofmultipledevicessuchasUSBBarcodeReader,USBMouseandUSBPrinter

��

authorization Protocol

• Authorizationnumbersarenotaguaranteeforpayment

• RevisedWarrantyManualonh-dnet.com

• Authorizationprotocolnotapplicableifunderinitialcare


H-Dsss iD information

• SystemIDdisplaysfobassignment

new Digital technician service Procedures

• Harley-Davidson®SmartSecuritySystem(H-DSSS)set-up

• Scanbarcodeonfobpackaging

• Testfobfunctionality

• EnablesecuritybyenteringPIN#oncefobsareassigned

• Disablesecurityduringserviceatdealership

�2

service anD tools


H-Dsss Diagnostics

• Clutchinterlockswitchandneutralindicatorfunctionalitydisplayedindataitemsscreen

��

Digital technician calibrations

• Phase19softwarehasOE,performancestreetlegalandoff-roadracecalibrationsfor2006andearliermotorcycles

• 2007motorcyclescanbecalibratedwithOEandperformancestreetlegaldownloads

• Off-roadracecalibrationsfor2007motorcyclesrequiretheScreamin’Eagle®RaceTuner


Performance – legal


TechTip#236explainsthedifferencesbetweenlegalandracecalibrations.

��

service anD tools

compliant conditions and cautions


compliant conditions and cautions (cont.)

��

Performance warning screen (race Use only!)


vehicle recalibration report

��

service anD tools

Digital technician active exhaust test

• Cyclesactiveexhaustactuatorandmonitorsfeedbackcircuit


�7

Fork oil and spark Plug service

• Additionalserviceinfo:

• Forkoilserviceintervalextendedto50,000miles(80,000km)

• Sparkpluginspectionserviceintervalorreplacementextendedto20,000miles(32,000km)

Formula+ Primary levels

• AllFLTouringBigTwinmodelsprimarydrivesrequire45oz.drycapacityand38oz.wetcapacityofFormula+

• AllSoftail®andDyna™modelsrequire32oz.wetanddrycapacityofFormula+

• Thereisnolongeravisualinspection

• Primaryserviceintervals:increasedservicetoevery10,000miles(16,000km)from5,000miles(8,000km)

• TransmissionFormula+changeintervalincreasedto20,000miles(32,000km)from10,000miles(16,000km)


��

service anD tools

advanced audio system website – Harley-Davidson.com

• Insidethemotorcycles/2006/Touringsection

• Newlistingofcompatiblecellphones

• Updatedsoundsystemdownloads

• BurnCD’sfromsiteatlowspeedfornochargesoundsystemupdating

• TechTip#243isahelpfulreview

initial care Programs

• 2007 Twin Cam 96™ Powertrain

• Warrantypre-authorizationfromTechnicalServicerequiredforanyTwinCam96™powertrainrepair

• P&AandScreamin’Eagle®

performancepartsinstallationdoesnotrequireauthorization7/15/06through12/22/06

• 2007 XL Sportster® Models • Fuelpumps,ECM

andfuellinesrequirepre-authorizationforreplacementunderwarranty

• Powertrainrepairsrequirepre-authorization7/15/06through10/13/06


��

2007 Model Year Drive Belt tension specifications

Checkbeltdeflectionattheloosestspotonthebeltwiththetransmissioninneutralandthemotorcycleatambienttemperature.Usebelttensiongauge(P/NH-D-35381A)andapply10lbs.offorceatthemidpointofthebottomstrand.2007beltdeflectionshouldbeasfollows:

MoDel veHicle orientation Belt DeFlection (in.)

FLHT,FLHR,FLHTCU,FLHTC,FLHRC,FLTR

VehicleuprightwithrearwheelinairoronJiffystandwithoutriderorluggage

3/8–7/16

FLHRS,FLHX VehicleuprightwithrearwheelinairoronJiffystandwithoutriderorluggage

1/4–5/16

TABLE 1:FLTBeltDeflectionSpecifications


FXD,FXDWG,FXDC Vehicleuprightwithrearwheelinair

1/2–9/16

FXD,FXDWG,FXDC OnJiffystandwithoutriderorluggage

5/16–3/8

FXDL,FXDB Vehicleuprightwithrearwheelinair

5/16–3/8

FXDL,FXDB OnJiffystandwithoutriderorluggage

1/4–5/16

TABLE 2: Dyna™BeltDeflectionSpecifications


20

service anD tools

2007 Model Year Drive Belt tension specifications (cont.)


FLSTN,FXSTD Vehicleuprightwithrearwheelinair

5/16–3/8

FLSTN,FXSTD OnJiffystandwithoutriderorluggage

1/4–5/16

FLST,FLSTC,FLSTSC,FXSTC,FLSTF,FXST,FXSTB,FXSTS


11/16–3/4

FLST,FLSTC,FLSTSC,FXSTC,FLSTF,FXST,FXSTB,FXSTS

OnJiffystandwithoutriderorluggage

9/16–5/8

TABLE 3:Softail®BeltDeflectionSpecifications


XL883STD,XL883R,XL1200R


9/16–5/8

XL883C,XL1200C,XL883L,XL1200L


1/4–5/16

TABLE 4:XLBeltDeflectionSpecifications

Documents

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