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HARLEY- DAVIDSON UNIVERSITY

TECH N I CAL F O R U M
2007 MODEL YEAR

H-D 07

ALL MODELS

2007 MODEL YEAR TECHNICAL FORUM

ALL MODELS

NEW Smart Security System Option


ands/button-free H security key fob ystem arms itself within S five seconds of turning ignition off, and disarms when ignition is turned on or motorcycle is moved with fob present ecurity system is S transparent to the customer ttempts to move the A motorcycle with fob on the seat or within 4 in. from antenna could activate the system

arley-Davidson Smart H Security System impacts: DI process P ervice Writers and Sales S ransportation T of motorcycle ervicing of motorcycle S ustomer expectations C torage mode eliminated; S current draw drops from 3.2 mA to .7 mA &A siren upgrades system P with chirp disable feature DI motorcycles, excluding H Japan, feature OE sirenequipped security systems

Important Service Note: Fob requires serial # assignment with DT, and PIN # must be entered before fob assignment.

 

ALL MODELS

2007 MODEL YEAR TECHNICAL FORUM

NEW Speedometers, Tachometers and Indicators (except VRSC )

imilar features as the S 2006 VRSC models

lock function C th Gear indicator for 6 Big Twin motorcycles ual trip meters D etrofit gauges R (suffix change) &A tachometer output P signal on 4 in. speedometer ower standby current L K dual-face U speedometers change to 130 mph (200 km/h)

Clock Function
isplayed on LCD D (odometer window) elected with trip switch S button (press release) et with trip switch button S (press hold/press release) 2/24-Hour selectable 1

2007 MODEL YEAR TECHNICAL FORUM

ALL MODELS

NEW LED Indicators


(except VRSC )

asier-to-read LED E indicators replace incandescent bulbs

Reduced-Effort Clutch Cable


006 Dyna design 2

ew clutch cable N educed-effort R clutch lever: % Reduction for 8 Sportster models

0% Reduction for 1 Softail models

% Reduction for 7 Touring models

 

ALL MODELS

2007 MODEL YEAR TECHNICAL FORUM

Clutch Interlock Switch


lutch interlock C switch functions as an or function with the neutral switch witch verifies if the S motorcycle is in neutral and if not, the clutch lever must be disengaged (pulled in) before motorcycle will start xcellent feature for E new riders

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


imilar design was S incorporated for the 2006 Dyna models

2 feedback system O eliminates the need for catalysts (except VRSC models)

DI motorcycles H are equipped with O 2 sensor feedback ystem adjusts to provide S optimal air/fuel mixture ome CVO motorcycles S require catalyst

2007 MODEL YEAR TECHNICAL FORUM

ALL MODELS

NEW Molex Connectors

(except Buell )

olex connectors M are smaller than Deutsch connectors


olex connectors M are internally sealed from moisture

RSC models feature Molex V connectors exclusively


onnector is only serviced C from the mated side

Molex is a registered trademark of Molex Products Company.

 

ALL MODELS

2007 MODEL YEAR TECHNICAL FORUM

Final Drive Belt


in. wide X7N belt 1 econd generation S carbon fiber hicker fabric for T increased tooth strength and wear resistance ouring models receive T a 137T belt -D Japan Touring models H receive a 136T belt Important Service Note: New belt tension specifications for all models. Polyurethane Body
Same material as previous belts

Tensile Cord
Second generation carbon fiber

Tooth Jacket
Thicker fabric for increased tooth strength and wear resistance

H-D 07

BIG TWIN eNGINes

2007 MODeL YeAR TeCHNICAL FORUM

BIG TWIN

NeW Twin Cam 96 engine Powertrain specifications

isplacement: D 96 cu. in. 1584 cc up from 88 in. 1450 cc chieved by stroke A increase to 4.375 in. (111.13) ouring Alpha engines T have increased torque to 93 ft. lbs. (126 NM) @ 3500 rpm

oftail Beta engines S have increased torque to 90 ft. lbs. (122 NM) @ 2750 rpm

yna Alpha engines D have increased torque to 92 ft. lbs. (125 NM) @ 3000 rpm

BIG TWIN

2007 MODeL YeAR TeCHNICAL FORUM

Twin Cam 96 Connecting Rods and Pistons

ighter pistons and L connecting rods for lower reciprocating weight horter wrist pin S

25-Degree Injectors
006 running change to 2 25-degree fuel injectors (P/N H-D-27709-06A)

2007 MODeL YeAR TeCHNICAL FORUM

BIG TWIN

Twin Cam 96 Components Follow 2006 Dyna Powertrain


ompensator C assembly/alternators our spring pack F design for domestic and HDI models ompensator C spring pack now welded to rotor

win Cam 96 Alpha T engine/transmission gasket

BIG TWIN

2007 MODeL YeAR TeCHNICAL FORUM

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


ngine cases with E integral oil filter adapter

xternal oil lines have E been eliminated for Dyna and Touring Big Twin engines

oftail engines continue S with external oil lines

2007 MODeL YeAR TeCHNICAL FORUM

BIG TWIN

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


am plate changes C rimary hydraulic P cam chain tensioner

am plate changes C econdary hydraulic S cam chain tensioner

BIG TWIN

2007 MODeL YeAR TeCHNICAL FORUM

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


am plate changes C am plate uses parent C material bearings

rankshaft assembly C and cases Inner cam bearings

2007 MODeL YeAR TeCHNICAL FORUM

BIG TWIN

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


ssembled cams A

il pump assembly O 0% More flow and 1 23% scavenging capacity improvement -ring between oil pump O and cam support plate has been eliminated 0/11 Lobe gerotor set 1

BIG TWIN

2007 MODeL YeAR TeCHNICAL FORUM

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


yna -style roller cam chains D

ll Big Twin models A feature hydraulic chain tensioners and new cam chains

lywheel sprocket F shaft splines match 2006 Dyna models

2007 MODeL YeAR TeCHNICAL FORUM

BIG TWIN

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


-Speed Cruise Drive 6 transmission

th Gear is direct drive 1:1 6 ower cruising rpm in 6th L gear is achieved with new primary ratio nd, 3rd, 4th and 6th are 2 helical gears st and 5th are spur gears 1 st, 2nd, 3rd and 4th gears 1 are integral on mainshaft

th and 6th gears are 5 integral on countershaft ix of 12 gears are S individually serviceable hristmas tree gear layout C on shafts RSC -style dog ring shifting V

L/XB-style shifter design X

BIG TWIN

2007 MODeL YeAR TeCHNICAL FORUM

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


th Main drive gear 6 uad-ring replaced by O-ring Q on new main drive gear eedle bearings for N 6th gear mainshaft eedle bearings secured N by retaining rings ouble-row output bearing D procket spacer S incorporated into bearing

rimary drive system P rive ratio is 1.35:1 D yna clutch shell D

tarter ring gear moved S to inboard on clutch hub

0

2007 MODeL YeAR TeCHNICAL FORUM

BIG TWIN

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


utomatic mechanical A primary chain tensioner

ew inner primary housings N nner primary must be I removed to service rotor and stator



BIG TWIN

2007 MODeL YeAR TeCHNICAL FORUM

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


rimary gasket/fasteners P

rimary chain inspection P cover has been removed

2

2007 MODeL YeAR TeCHNICAL FORUM

BIG TWIN

6th Gear Indicator


amp activates during L motorcycle operation in 6th gear ehicle speed and engine V rpm determine light activation; not a switch

Charging system
oftail and Dyna models S feature a new 40-amp alternator



BIG TWIN

2007 MODeL YeAR TeCHNICAL FORUM

NeW One-Piece Horn Cover


or ease of assembly F

Oe exhaust
mproved sound quality I



2007 MODeL YeAR TeCHNICAL FORUM

BIG TWIN

HDI Only Active Intake


olenoid controls the S opening and closing of baffle in the air cleaner backing plate to reduce intake noise -D Japan motorcycles do H not feature active intake

olenoid attached to S backside of air cleaner backing plate

5

BIG TWIN

2007 MODeL YeAR TeCHNICAL FORUM

HDI Active exhaust


(except Japan)

ctuator closes valve A in the exhaust system during higher engine loads ptimizes power while O meeting noise regulations omposite cable mount C and cable are sold as a kit

Important Service Note: Never move the actuator by hand (or with a tool). Actuator cannot be dropped or it will need replacement. Active exhaust systems are to be replace only service items, no repairs.

6

2007 MODeL YeAR TeCHNICAL FORUM

BIG TWIN

Twin Cam 96B Balanced engine

ew 1584 cc Twin Cam 96B N balanced engine

-Speed Cruise Drive 6 transmission is part of this powertrain

Twin Cam 96B Balancers

ew balancer is first N pressed into bearing new tool shown here A to press assembly

7

H-D 07

VRSC family

2007 mODEl yEaR TECHNiCal fORUm

VRSC

NEw Brake Pads on VRSC models

Old

New brake pad material Reduced brake noise Reduced rotor wear Brake pads retrofit to 2006 models

New

Two-Piece Rear Caliper assembly


New brake lines Two-piece assembly is easier to service VRSCR rear caliper unchanged I mportantServiceNote: Rotor does not need to be removed during tire changes.

VRSC

2007 mODEl yEaR TECHNiCal fORUm

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

VRSC

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

VRSC

2007 mODEl yEaR TECHNiCal fORUm

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

2007 mODEl yEaR TECHNiCal fORUm

VRSC

NEw Coolant Tank


Coolant tank relocated VRSCR coolant tank remains unchanged

20 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

VRSC

2007 mODEl yEaR TECHNiCal fORUm

VRSCX Unique Styling


New paint scheme incorporates the #1 logo Based on the Screamin Eagle /Vance & Hines NHRA Prostock V-Rod

1250 cc engine Limited production of 1,400 units Laced front wheel

2007 mODEl yEaR TECHNiCal fORUm

VRSC

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

VRSC

2007 mODEl yEaR TECHNiCal fORUm

Radiator Trim Covers


Similar trim cover as 2006 VRSCR models I mportantServiceNote: Retrofits with minor modifications to radiator cover.

VRSCR Ergonomic improvements


Wider and higher handlebar Handlebar does not retrofit

2007 mODEl yEaR TECHNiCal fORUm

VRSC

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

RightSide

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

LeftSide

VRSC

2007 mODEl yEaR TECHNiCal fORUm

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.

0

2007 mODEl yEaR TECHNiCal fORUm

VRSC

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

Compensator Bowl
Wide compensator bowl accommodates new frame VRSCR compensator bowl remains unchanged



VRSC

2007 mODEl yEaR TECHNiCal fORUm

Split Rear wheel Bearing


New bearing for models equipped with 240 mm tires CVO VRSC motorcycles used this bearing in 2006

2

H-D 07

SPORTSTER family

2007 mODEl yEaR TECHNiCal fORUm

SPORTSTER

The Sportster family Celebrates 50 years

0th Anniversary 1200 model 5 imited production of 2,000 L erialized nameplate on S handlebar clamp old 50th emblem on G fuel tank ew H silk-screening N on side covers represents the cultural history of the Sportster family

mbroidered seat E L custom rear shocks X

NEw 883l model


owered 25.25 in. L seat height ew front and rear shocks N ew seat N arts retrofit P igher torque for H 883 models ll 2007 XL motorcycles A use W cams 5% More torque 1 at 2500 rpm equires 1200 mufflers R for Japan market

SPORTSTER

2007 mODEl yEaR TECHNiCal fORUm

Redesigned Oil Pump


edesigned pump body, R feed and scavenge gerotors ew feed and N scavenge porting cavenge gerotors have S larger diameter and are taller for more capacity eed gerotors are thinner F to accommodate taller scavenge gerotors in original pump body height but redesigned for no loss of capacity nternal parts do not interI change with earlier pumps ump assembly will retrofit P

Old

New

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


5 mm induction module 4 for all models 5-Degree injectors 1 ew wiring harness N with Molex connectors

rame updated with F new brackets to secure new wire harness Low fuel light 1 Octane for all 2007 9 Sportster models

Molex is a registered trademark of Molex Products Company.

2007 mODEl yEaR TECHNiCal fORUm

SPORTSTER

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


ew TMAP sensor N Combined sensor MAP/IAT Top of Induction Module (IM) AC: top of IM I P sensor: left side of IM T IAC TMAP Sensor

TP Sensor

ead temperature sensor H is located in rear cylinder head similar to Buell models

pecial tool available S

SPORTSTER

2007 mODEl yEaR TECHNiCal fORUm

Oxygen Sensors
ront and rear exhaust F O 2 sensors losed loop system C like 2006 Dyna models

Front sensor shown

fuel Pump
ounted in new fuel tank M heck Sportster model C Service Manual for pressure specifications

ses current fuel U pressure gauge adapter (P/N HD-44061)

2007 mODEl yEaR TECHNiCal fORUm

SPORTSTER

intake flanges
ew intake flanges N and fasteners ider flanges allow for W better fastener access ses four hex bolts U rather than allen bolts ew cylinder heads to N accommodate new flanges 1200 Heads have changes to intake port and intake valve seat No service procedure changes to new heads, only part number changes

NEw ignition Coils


ew coil mounting bracket N ew spark plug wires N ew primary and secondary N resistance values Check Sportster model Electrical Diagnostics Manual for proper specifications

SPORTSTER

2007 mODEl yEaR TECHNiCal fORUm

NEw ECm and fuse location


CM is located underneath E the seat on the rear fender dditional fuses are A required ew rear fenders and N seats accommodate ECM

2007 mODEl yEaR TECHNiCal fORUm

SPORTSTER

NEw Rocker Boxes


ocker boxes have been R changed to feature an improved sealing cavity ew press-in-place gaskets N Gaskets do not retrofit

32-amp Charging System


ncreased power to I 32 amps from 22 amps to power the E.S.P.F.I. system heck Electrical C Diagnostic Manual for proper specifications otor does retrofit R ew stator and N voltage regulator do not retrofit

SPORTSTER

2007 mODEl yEaR TECHNiCal fORUm

Reduced-Effort front Brake lever


OT 4 brake fluid is used D in all 2007 XL motorcycles

ew calipers N ew master cylinders N ew brake lines N hanges result in an 11% C effort reduction for 883, 883L, 883C, 1200L and 1200C models hanges result in a 14% C effort reduction for 883R and 1200R models ew rear brake pads N improve rear brake feel ear brake pads R do not retrofit

NEw Handlebar wiring


arnesses are lengthened H by 2 in. to allow for easier changing of handlebars xtra harness is tucked E into the electrical caddy underneath the fuel tank

H-D 07

Dyna family

2007 mODEl yEaR TECHniCal fORUm

Dyna

all Dyna models

ll 2006 model year A redesigns carry forward for 2007 Dyna models

nEW lower-Profile Transmission Cover


esign common D with the Softail model

ew smaller J-hose vent N and routing; new hose is shaped to accommodate HDI exhaust actuator etrofits to 2006 R Dyna models

Dyna

2007 mODEl yEaR TECHniCal fORUm

nEW final Drive Gearing, Belt and Belt Guard Change


inal drive gearing is F matched to optimize the new Twin Cam 96 powertrain

ew rear sprockets N DI and domestic H models: 66-tooth rear sprocket/ 131-tooth drive belt -D Japan models only: H 64-tooth rear sprocket/ 130-tooth belt

FXD Dyna Super Glide model

nEW 40-amp Charging System


hree-phase, 40-amp output T charging system OE (Dyna and Softail models)

onsists of: C ew 12-magnet rotor N ew stator N tator and rotor S assembly retrofits to 2006 Dyna models

2007 mODEl yEaR TECHniCal fORUm

Dyna

Transmission Shift Detent and Roller Change


hift detent arm, spring S and roller design change art number revisions to P A suffix 007 Transmission detent 2 assembly retrofits to post-recall 2006 Dyna motorcycles

his assembly is sold as T a kit for 2006 Dyna models

2006 Dyna Model

2007 Big Twin

nEW Steering Head adjustment access area


otched access area N provides improved access for servicing otch allows service N procedure to be common with Softail and Touring models

Dyna

2007 mODEl yEaR TECHniCal fORUm

fXDBi Dyna Street Bob and fXDi Dyna Super Glide models

ew stainless steel rear N fender supports rushed stainless steel B covers on FXDB model ecommended R cosmetic care product: Harley-Davidson Bright Chrome Cleaner (P/N 94683-99)

olished stainless steel P covers on FXD model ecommended R cosmetic care product: Harley-Davidson Bright Metal Polish (P/N 99725-89)

Important Service Note: Surface care products for new finishes are in the Dyna model Owners Manual.

2007 mODEl yEaR TECHniCal fORUm

Dyna

nEW on fXDC model


ased on 35th Anniversary B Super Glide model

nique model features: U ank trim and cloisonn T ibbed seat R attery cover trim B andlebars and H front brake line lectrical caddy E cover trim eather tank panel L with the #1 logo

H-D 07

softail family

2007 moDEl yEaR tECHNiCal foRUm

softail

NEw twin Cam 96B Engine Balancers

ew one-piece balancer N support bracket ew bearing N installer/removal tool required for service

flstf and fX Bobtail models New tire


00 mm rear tire with 2 new tread design

softail

2007 moDEl yEaR tECHNiCal foRUm

NEw for fX softail models

ew handlebars, risers N and clamps

UK Dual-face speedometer Change


ew speedometer face reads N up to 130 mph (200 km/h)

Touring model example shown

2007 moDEl yEaR tECHNiCal foRUm

softail

25 mm wheel Bearings and axle


ll Softail models, except A the Springer model, receive 25 mm front wheel bearings

Old 1 in. I.D.

New 25 mm I.D.

New front axle

softail

2007 moDEl yEaR tECHNiCal foRUm

fat Boy model front End Changes

ew-style handlebars N and risers nternal handlebar wiring I

fPo

ew front panel/nacelle N

2007 moDEl yEaR tECHNiCal foRUm

softail

Extended Rear Brake Control and footrest mounts on fX Bobtail models


ight side components R extended outward approximately 1 in. llows for more A stretched-out rider comfort ear brake pedal R styling improved

NEw three Electric Caddys


ne caddy is located O under fuel tank

softail

2007 moDEl yEaR tECHNiCal foRUm

NEw three Electric Caddys (cont.)


second caddy is behind A the voltage regulator

third caddy is under A the rear fender cover

2007 moDEl yEaR tECHNiCal foRUm

softail

Rear fenders
ound-dampening material S added to fender

NEw four-Hole fender supports on flstN


llows more P&A A accessory opportunities

H-D 07

touring family

2007 moDEl yEar tECHniCal forum

touring

nEw idle temperature management Download option


or prolonged F engine idle conditions n hot riding conditions, I an optional dealer- enabled engine calibration is available ew download cuts N combustion to rear cylinder ngine must be at certain E operating temperature ehicle must be at idle and V not moving to activate xhaust changes tone with E only front cylinder firing

xhaust may have slightly E different odor nstallation of download I is free one time only (under warranty) emoval of download R is free one time only (under warranty) rior systems have been P removed for 2007 models

touring

2007 moDEl yEar tECHniCal forum

Sidecar Brake reservoir


elocated in order to provide R necessary clearance for the O2 sensors ounts to the outside of the M front frame support bracket

ew design N

2007 moDEl yEar tECHniCal forum

touring

Shift lever and floorboard Changes


ew shift lever, left-hand N rider floorboard supports and passenger floorboard supports hanges accommodate C additional clearance necessary due to new engine, transmission and primary drive hift lever retrofits to prior S models but pre-2007 levers do not fit new Touring motorcycles ew board mounts retrofit N to prior motorcycles ld board mounts do not O retrofit to 2007 models

frame and Swingarm Changes


rame, swingarm and F engine mounts accom- modate new engine wingarm forging S moved to the rear ew swingarm support N brackets (end caps) ew forged, front engine N mount bracket clears new crankcase wingarm mounts S do not retrofit 007 Touring frame 2 does not retrofit to prior models

touring

2007 moDEl yEar tECHniCal forum

Jiffy Stand Change


ouring motorcycles T come with a new Jiffy stand to accommodate changes from new engine ew bumper N ount has changed M

Saddlebag Supports
ew cast zinc I-brackets N and end bullets for saddlebags ew brackets appear N the same but have a smoother finish on all sides educes scratching R of saddlebags when removing

2007 moDEl yEar tECHniCal forum

touring

twin Cam 0 cu. in. Engine for Police models

690 cc CVO engine 1


.6:1 Compression ratio 9 nique calibration U BS and Harley-Davidson A Smart Security System optional equipment

nique clutch spring U atalyst mufflers C ctive intake and exhaust A on HDI Police motorcycles

Sidecars for Police motorcycles


olice Touring motorcycles P with ABS do not accept a sidecar ydraulic line routing on H the right side interferes Important Service Note: Police and Touring motorcycles equipped with sidecars will not accommodate an oil cooler. Oil cooler assembly needs to be removed before sidecar installation.

touring

2007 moDEl yEar tECHniCal forum

nEw Handlebar Clamps


andlebar control clamps H are modified improving clearance for wire harness

Old NEW

front Electrical Caddy


ew caddy mounts N under voltage regulator retaining connector for crank position sensor

H-D 07

CVO family

2007 mODEl yEaR TECHNiCal fORUm

CVO

NEW CVO Engine


110 cu. in. 1800 cc engine 9.3:1 Compression ratio ew heads, combustion N chamber, ports and intake valve 255 Cams 4 in. bore 10-Scripted derby cover 1 and air cleaner insert Syn 3 engine oil 1.4 Kw starter

.375 (111.13 mm) stroke; 4 same as OE engines CR solenoids to ease A start-up located in each cylinder head orque range of T 105-115 ft. lbs. measured at crankshaft (depending on model) ll CVO models have A hydraulic clutch DOT 4 Important Service Note: Do not use chrome polish on the new flush-mount LED fuel gauge (FXSTSSE, FLHRSE and FXDSE all feature this gauge).
3

CVO

2007 mODEl yEaR TECHNiCal fORUm

flHTCUSE Screamin Eagle Ultra Classic Electra Glide


2

eated seat and grips H elocated intercom plug R integrated with left rear speaker pod ultifunctional switch for M cruise control and spotlights ight smoked L short windshield djustable passenger A footboards ower locks on Tour-Pak P and bags are dash controlled

arley-Davidson Smart H Security System (H-DSSS) with self-powered alarm

M Satellite Radio X (three months of service) and amplifier, except HDI dvanced audio integrated A navigation system and/foot controls, H footboards and highway pegs are from Ironside Collection Paint with Pearl highlights: ight Candy Cherry L with Black Ice ightning Blue Pearl L with Midnight Pearl lack Ice with B Electric Orange

2007 mODEl yEaR TECHNiCal fORUm

CVO

flHRSE Screamin Eagle Road King




lush-mount gas cap and F fuel gauge Oil cooler and chrome cover eather saddlebags and L seat with chrome trim and flame insert; detachable rider and passenger backrests; also available from P&A, optional matching leather Tour-Pak with flame insert adial tires: R 1 8 in. x 3.5 in. front wheel; 17 in. x 4.5 in. rear wheel; 130 mm front and 170 mm rear; tire pressure change to 36 psi front/38 psi rear (solo rider); 38 psi front/42 psi rear (rider and passenger) ustom spun-metal faced C speedometer/tachometer combination Dual halogen headlamp -DSSS with H self-powered alarm ark smoked D mini wind deflector Lowered P&A shocks .25 in. chrome handlebar 1 with internal wiring loorboards, passenger F pegs, highway pegs and hand/foot controls are from Ironside Collection at Boy front fender; wide F rear fender, swingarm and rear axle aint with leafing graphics P and marble accents: azor Red with Burnt Gold R andy Cobalt with C Pale Gold lack Ice with Pewter B

CVO

2007 mODEl yEaR TECHNiCal fORUm

fXSTSSE Screamin Eagle Softail Springer


.25 in. chrome handlebar 1 with internal wiring hrome forward controls C hrome handlebar risers C ini-tach and M new chrome tach mounts evolver chrome 10-spoke R forged-aluminum wheels evolver chrome R 66-tooth sprocket evolver brake rotors R 200 mm rear tire New tri-bar LED tail lamp ow-profile, chrome L fuel tank console

and/foot controls and H footpegs are from new Centerline Collection lush-mount fuel cap F and gauge -DSSS with H self-powered alarm ustom leather two-up seat C with ribbed insert olor-matched frame, C swingarm, rigid forks, upper triple clamp, oil tank, frame inserts, seat post and muffler support brackets ribal Flame paint: T byss Blue with Blue Pearl A anyon Copper with C Candy Red marillo Gold with A Candy Tangerine

2007 mODEl yEaR TECHNiCal fORUm

CVO

fXDSE Screamin Eagle Dyna

ustom spun-aluminum C gauge package xtended headlamp trim ring E olished stainless steel P rear brake push rod and shifter rod raided line package B hrome package C Inverted front forks overed low rear shocks C with hand-adjust preload Custom 1.25 in. handlebar nurled chrome handgrips K and footpegs Rolled-back front fender

olor-matched frame, C battery box, electrical panel cover, coil cover and chin spoiler 70 mm rear tire 1 ustom bucket seat with C perforated inserts ull-length fuel tank console F lush-mount, aircraft-style F gas cap Layback license plate aint options: P ilver Rush and S Midnight Black nferno Red and I Desert Black wilight Blue with T Ice Blue, Granite and Ice Blue Pearl

Buell 07

Buell family

2007 mODel yeaR TeCHNiCal fORum

Buell

XB firebolt models

ew wheel colors N ew bodywork colors N inted windscreens T

XB lightning model

ew color combinations N available for wheels and bodywork ityX seat has new C cover material

Buell

2007 mODel yeaR TeCHNiCal fORum

ulysses models

ew P&A camouflage N bodywork lysses seat has new U cover material

.3 in. lower 1 seat height laden .2 in. lower 2 seat height unladen eat does retrofit S eat is reshaped S

Buell Blast

ew Arctic White N color added

2007 mODel yeaR TeCHNiCal fORum

Buell

New inner Rocker Cover with Press-in-Place Gasket


edesigned R press-in-place gasket nner rocker cover has been I redesigned to accommodate new gasket design nner rocker cover fits I previous XB models (P/N 17598-07) I mportantServiceNote: Do not stretch gasket while installing; position gasket in cover and use top rocker cover to press gasket into position. Gasket kits include both early and new gaskets.

New Rocker Cover/ Cylinder Head Gasket


ew design has N coated gasket

Buell

2007 mODel yeaR TeCHNiCal fORum

New Throttle Position Sensor (TPS)


dentified by one or two I orange paint dots on top of TPS ew TPS rotor tangs are N at 1 and 7 oclock positions ld-style TPS rotor tangs are O at 4 and 10 oclock positions PS sensors do not T interchange ew TPS (P/N PO279.3AA) N ld TPS (P/N 29537-99Y) O Old NEW

New Throttle Body manifold


ew throttle shaft TPS N engagement pins oriented at 6 and 12 oclock positions ld-style engagement O pins are orientated at 2 and 8 oclock positions

NEW

Old

2007 mODel yeaR TeCHNiCal fORum

Buell

New Primary Chain Cover


dditional material added A to the casting at the primary adjuster shoe screw support

Redesigned Oil Pump


edesigned pump body, R feed and scavenge gerotors ew feed and N scavenge porting cavenge gerotors have S larger diameter and are taller for more capacity eed gerotors are thinner F to accommodate taller scavenge gerotors in original pump body height, but redesigned for no capacity loss nternal parts do not interI change with earlier pumps ump assembly fits earlier P XB models

Old

NEW

Buell

2007 mODel yeaR TeCHNiCal fORum

additional Holes in airbox functional Cover


evised calibration R for new airbox

Tire Changes
irelli Diablo tires except on P XB9SX and XB12X (Ulysses )

irelli Scorpion Sync tires P used on XB9SX and XB12X (Ulysses )


2007 mODel yeaR TeCHNiCal fORum

Buell

ulysses Seat limiter

eparates underseat S components from bottom-of-seat pan

ulysses Progressive Rate fork Spring

rovides wider range of P smooth progressive control of front suspension over long fork travel evised fork service R specifications oes retrofit and requires D the new front and rear 2007 suspension specifications

H-D 07

screamin eagle

2007 mODel Year TecHnical FOrUm

screamin eagle

Big Bore stage  Kit 03 cu. in.


ncrease displacement I from 96 in. to 103 in. (1584 cc to 1690 cc) ig bore cylinders B and pistons igh-flow A/C kit H 0-State street legal 5 igital Technician calibration D

Big Bore stage 2 Kit 03 cu. in.


ncrease displacement I from 96 in. to 103 in. (1584 cc to 1690 cc) ig bore cylinders B and pistons igh-flow A/C kit H 55 Cams 2 atalyst exhaust C 0-State street legal 5 igital Technician calibration D

screamin eagle

2007 mODel Year TecHnical FOrUm

0 cu. in. stage  Kit


ncrease displacement I from 96 in. to 110 in. (1584 cc to 1800 cc) 55 Cams produce 2 low rpm torque in. bore cylinders 4 and forged pistons .3:1 Compression ratio 9 0-State street legal 5 igital Technician calibration D

ylinder heads have many C features and functions ew combustion chamber N ort cores and intake valve P utomatic compression A release yna and Softail models D have a high-flow A/C kit

ouring kit has special T high-flow A/C element

2007 mODel Year TecHnical FOrUm

screamin eagle

screamin eagle exhaust

ew street performance N exhaust systems are street legal for 2007 models ach exhaust system E is designed to optimize the Twin Cam 96 engine performance and provide premium sound and style while complying with noise regulations

e.s.P.F.i. calibrations
alibration cartridges C discontinued early in the 2007 model year ll street-legal calibrations A for 1995-2007 models are available on Digital Technician ace calibrations for R 1995-2006 models are available on Digital Technician ace calibrations for R 2007 models require Screamin Eagle Race Tuner

ll race calibrations A continue to be available in Screamin Eagle Race Tuner

H-D 07

service anD tools

2007 MoDel Year tecHnical ForUM

service anD tools

new calibrations search h-dnet.com


ustomized to all models C worldwide ctive screen capture help A alibration-specific selection C evised search buttons R everse lookup feature R with calibration I.D. #

several P&a cast wheels sold Differently


earings and sleeves B are not installed in the wheels from the factory earings and sleeves B are ordered separately earings and sleeves B offered as a kit oftail front wheels, 19 in. S and 21 in. front wheels, and 17 in. x 4.5 in. wheels are affected

service anD tools

2007 MoDel Year tecHnical ForUM

vrscDX wheels
40 mm tires 2 lack painted wheels need B to be serviced with caution as cosmetic damage can occur if proper procedures are not used

new Xl Fuel lines


uel lines may appear to F be kinked upon delivery until ignition is turned on to expand the line

2007 MoDel Year tecHnical ForUM

service anD tools

crankshaft rotating wrench


/N HD-48283 P ade for new splines M on crankshaft sed on 2006 Dyna U models and 2007 Twin Cam 96 engines

rankshaft Rotating C Wrench is not part of the 2007 Essential Tool Kit

essential tools
heel Bearing Collet W P/N HD-44060-10 dded to A Essential Tool Kit ollet added to the C Wheel Bearing Kit (P/N HD-44060-A) emoves 25 mm wheel R bearings featured on Softail front wheels

pringer models S continue with 1 in. wheel bearings/collets

service anD tools

2007 MoDel Year tecHnical ForUM

essential tools (cont.)


ehicle Alignment Tools V /N HD-46247-1 P P/N HD-46247-2 ew pivot shaft alignment N blocks for 2007 FL models rame changes made F blocks necessary

riple Trees Wedge T for VRSCR /N HD-48287 P preads clamp to S prevent damaging painted fork tubes during servicing wo wedges come T in the kit

2007 MoDel Year tecHnical ForUM

service anD tools

essential tools (cont.)


hort Primary Drive S Locking Tool /N HD-48219 P ocks primary drive for L removal/installation of compensating sprocket assembly and clutch hub ouring models only T Important Service Note: Tech Tip #212 explains primary drive locking tool usage for 2006 Dyna models, which applies to this new tool as well.

ead Temperature Sensor H Socket for XL Models /N HD-48116 P sed to remove/install U head temperature sensors from the rear cylinder of XL models

service anD tools

2007 MoDel Year tecHnical ForUM

essential tools (cont.)


2 Sensor Socket O /N HD-48262 P sed on all H-D models U

procket Shaft Adapter S and Collar /N HD-97225-1 P P/N HD-97225-2 dapts the sprocket shaft A bearing installer tool to P/N HD-497225-55C for servicing new Twin Cam 96 and 2006 Dyna engines

ollar is used to install C the bearing inner race

2007 MoDel Year tecHnical ForUM

service anD tools

essential tools (cont.)


procket Shaft Seal S Installer /N HD-39361B P llows the simultaneous A installation of the sprocket shaft seal and spacer nstalling both parts at I the same time ensures the seal is protected

alancer Bearing Installer B for Softail Models

/N HD-48309 P nstalls the new bearing I and balancer for the Twin Cam 96B engine

ew bearing must be N pressed onto balancer before pressing assembly into case ase must be supported C when pressing in balancer/ bearing assembly

service anD tools

2007 MoDel Year tecHnical ForUM

essential tools (cont.)


win Cam 96B Outboard T Balancer Bearing Remover/ Installer

P/N HD-48474 emoves and installs R bearings from the chain guide support plate

win Cam 96B T Balancer Puller

/N HD-48457 P uller extracts the P Twin Cam 96B balancer/ bearing assembly

late is reversible for P front and rear balancers

2007 MoDel Year tecHnical ForUM

service anD tools

essential tools (cont.)


erminal Remover T /N HD-48114 P emoves socket and R pin terminals from Molex connectors

Used on all models Important Service Note: Refer to the instruction sheet to prevent damage.

E lectrical Crimp Tool /N HD-48119 P rimps Molex terminals C

Molex is a registered trademark of Molex Products Company.

service anD tools

2007 MoDel Year tecHnical ForUM

essential tools (cont.)


MAP Sensor Pin Probes T /N HD-41404-15 P ew probes required for N electrical diagnostics on TMAP sensor terminals on XL models robes are a light P orange color H-DSSS Antenna Pin Probes /N HD-41404-20 P sed on all models U with security systems robes are a P light blue color

arcode Reader for B Security Systems /N HD-48263 P unctionality is enabled F through Digital Technician Phase 19 software ssigns fobs during PDI A ncreases accuracy and I efficiency SB connectivity U ptional fob assignment O can be input by reading the 24-character security ID behind fob cover 4-Character security ID 2 matches the system ID for the HFSM

0

2007 MoDel Year tecHnical ForUM

service anD tools

essential tools (cont.)


SB Hub U /N HD-44750-15 P F27 and CF28 laptops C do not supply enough power through the USB port to properly power the Barcode Reader -Port USB 2.0 hub with 4 AC power supply ermits connection P of multiple devices such as USB Barcode Reader, USB Mouse and USB Printer

authorization Protocol
uthorization numbers are A not a guarantee for payment evised Warranty Manual R on h-dnet.com uthorization protocol A not applicable if under initial care



service anD tools

2007 MoDel Year tecHnical ForUM

new Digital technician service Procedures


arley-Davidson Smart H Security System (H-DSSS) set-up

can barcode on S fob packaging est fob functionality T nable security by E entering PIN # once fobs are assigned isable security during D service at dealership

H-Dsss iD information
ystem ID displays S fob assignment

2

2007 MoDel Year tecHnical ForUM

service anD tools

H-Dsss Diagnostics
lutch interlock switch C and neutral indicator functionality displayed in data items screen

Digital technician calibrations


hase 19 software has OE, P performance street legal and off-road race calibrations for 2006 and earlier motorcycles 007 motorcycles can be 2 calibrated with OE and performance street legal downloads ff-road race calibrations for O 2007 motorcycles require the Screamin Eagle Race Tuner



service anD tools

2007 MoDel Year tecHnical ForUM

Performance legal
Important Service Note: Tech Tip #236 explains the differences between legal and race calibrations.

compliant conditions and cautions



2007 MoDel Year tecHnical ForUM

service anD tools

compliant conditions and cautions (cont.)

Performance warning screen


(race Use only!)



service anD tools

2007 MoDel Year tecHnical ForUM

vehicle recalibration report

Digital technician active exhaust test


ycles active exhaust C actuator and monitors feedback circuit



2007 MoDel Year tecHnical ForUM

service anD tools

Fork oil and spark Plug service


dditional service info: A ork oil service interval F extended to 50,000 miles (80,000 km) park plug inspection S service interval or replacement extended to 20,000 miles (32,000 km)

Formula+ Primary levels


ll FL Touring Big Twin A models primary drives require 45 oz. dry capacity and 38 oz. wet capacity of Formula+ ll Softail and Dyna A models require 32 oz. wet and dry capacity of Formula+ here is no longer a T visual inspection rimary service intervals: P increased service to every 10,000 miles (16,000 km) from 5,000 miles (8,000 km) ransmission Formula+ T change interval increased to 20,000 miles (32,000 km) from 10,000 miles (16,000 km)

7

service anD tools

2007 MoDel Year tecHnical ForUM

advanced audio system website Harley-Davidson.com


nside the motorcycles/2006/ I Touring section ew listing of compatible N cell phones pdated sound system U downloads urn CDs from site at low B speed for no charge sound system updating ech Tip #243 is a T helpful review

initial care Programs


007 Twin Cam 96 2 Powertrain arranty pre-authorization W from Technical Service required for any Twin Cam 96 powertrain repair &A and Screamin Eagle P performance parts installation does not require authorization 7/15/06 through 12/22/06

2007 XL Sportster Models uel pumps, ECM F and fuel lines require pre-authorization for replacement under warranty owertrain repairs P require pre-authorization 7/15/06 through 10/13/06



2007 MoDel Year tecHnical ForUM

service anD tools

2007 Model Year Drive Belt tension specifications


Check belt deflection at the loosest spot on the belt with the transmission in neutral and the motorcycle at ambient temperature. Use belt tension gauge (P/N H-D-35381A) and apply 10 lbs. of force at the midpoint of the bottom strand. 2007 belt deflection should be as follows:

MoDel

veHicle orientation

Belt DeFlection (in.)

FLHT, FLHR, FLHTCU, FLHTC, FLHRC, FLTR

Vehicle upright with rear wheel in air or on Jiffy stand without rider or luggage Vehicle upright with rear wheel in air or on Jiffy stand without rider or luggage

3/8 7/16

FLHRS, FLHX

1/4 5/16

TABLE 1: FLT Belt Deflection Specifications

MoDel

veHicle orientation

Belt DeFlection (in.)

FXD, FXDWG, FXDC FXD, FXDWG, FXDC FXDL, FXDB FXDL, FXDB

Vehicle upright with rear wheel in air On Jiffy stand without rider or luggage Vehicle upright with rear wheel in air On Jiffy stand without rider or luggage

1/2 9/16 5/16 3/8 5/16 3/8 1/4 5/16

TABLE 2: Dyna Belt Deflection Specifications



service anD tools

2007 MoDel Year tecHnical ForUM

2007 Model Year Drive Belt tension specifications (cont.)

MoDel

veHicle orientation

Belt DeFlection (in.)

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

Vehicle upright with rear wheel in air On Jiffy stand without rider or luggage Vehicle upright with rear wheel in air or on Jiffy stand without rider or luggage On Jiffy stand without rider or luggage

5/16 3/8 1/4 5/16 11/16 3/4

9/16 5/8

TABLE 3: Softail Belt Deflection Specifications

MoDel

veHicle orientation

Belt DeFlection (in.)

XL883 STD, XL883R, XL1200R

Vehicle upright with rear wheel in air or on Jiffy stand without rider or luggage Vehicle upright with rear wheel in air or on Jiffy stand without rider or luggage

9/16 5/8

XL883C, XL1200C, XL883L, XL1200L

1/4 5/16

TABLE 4: XL Belt Deflection Specifications

20