TECHNICAL FORUM TECHNICAL FORUM
Contents
1. HARLEY DAVIDSON HARLEY DAVIDSON UNIVERSITY 2007 MODEL YEAR oS HARLEY DAVIDSON NG ALL MODELS 07 2007 MODEL YEAR NEW Smart Security System Option e Hands button free security key fob e System arms itself within five seconds of turning ignition off and disarms when ignition is turned on or motorcycle is moved with fob present e Security system is transparent to the customer e Attempts to move the motorcycle with fob on the seat or within 4 in from antenna could activate the system e Harley Davidson Smart Security System impacts PDI process Service Writers and Sales Transportation of motorcycle Servicing of motorcycle Customer expectations e Storage mode eliminated current draw drops from 3 2 mA to 7 mA e P amp A siren upgrades system with chirp disable feature e HDI motorcycles excluding Japan feature OE siren equipped security systems Important Service Note Fob requires serial assignment with DT and PIN must be entered before fob assignment ALL MODELS HARLEY DAVIDSON ALL MODELS 2007 MODEL YEAR Speedometers Tachometers and Indicators e Similar features as the 2006 VRSC models Clock function 6th Gear indicator for Big Twin motorcycles Dual trip meters Retrofit gauges suffix change e P amp A tachometer output signal on 4 in soeedometer e Lower standby current e UK dual face speed2. Pear pia pa par pa F om o o Frona i E H DSSS ID Information e System ID displays fob assignment auet 12 EREN wee m _____ BFI Futam FET WF k ebi te bleidi Cn iari LELLI Hiii Didi at Mila el Tak plated Tamsi u Ekaia cable his WFT aes Firs Pe Fi TORU AEA a Fihi Homan Free Peb og TEA a thm aiki atira I a cep T aibu Fae Hamim ripe ee rao Carton T ribami HTA T nd Fen hamia Piet me Fb Faiy Pan himnar Tala Wii TAT hibai Rami Ep Bapa Cede ET aad ear PRED adie miaran Tew eee Spigkar Campar Lima Cikta es Cr TT f 2007 MODEL YEAR SERVICE AND TOOLS H DSSS Diagnostics e Clutch interlock switch and neutral indicator functionality displayed in data items screen Digital Technician Calibrations e Phase 19 software has OE performance street legal and off road race calibrations for Stock O E Calibeation Use with ECAs laboled 32852 06 32438 08 or 32534 064 2006 and earlier motorcycles NOTE DO HOT install stak calibrations on BOM ICM Modules that e 2007 motorcycles can be hawe boen Roce Tuned or have Sorpamin Engle Performance Parts calibrated with OE and performance street legal x downloads e Off road race calibrations for 2007 motorcycles require the Screamin Eagle Race Tuner HARLEY DAVIDSON SERVICE AND TOOLS Performance Legal Important Service Note Tech Tip 236 explains the differences between legal and race cal
3. compensating sprocket assembly and clutch hub e Touring models only Important Service Note Tech Tip 212 explains primary drive locking tool usage for 2006 Dyna models which applies to this new tool as well e Head Temperature Sensor Socket for XL Models P N HD 48116 e Used to remove install head temperature sensors from the rear cylinder of XL models huer pen 5 TECHNICAL FORUM Essential Tools cont e O Sensor Socket e P N HD 48262 e Used on all H D models e Sprocket Shaft Adapter and Collar e P N HD 97225 1 P N HD 97225 2 e Adapts the sprocket shaft bearing installer tool to P N HD 497225 55C for servicing new Twin Cam 96 and 2006 Dyna engines e Collar is used to install the bearing inner race CT l ie 2007 MODEE YEAR i e ior 5 me 548 SERVICE AND TOOLS Essential Tools cont e Sprocket Shaft Seal Installer P N HD 39361B e Allows the simultaneous installation of the sprocket shaft seal and spacer e Installing both parts at the same time ensures the seal is protected e Balancer Bearing Installer for Softail Models e P N HD 48309 Installs the new bearing and balancer for the Twin Cam 96B engine e New bearing must be pressed onto balancer before pressing assembly into case e Case must be supported when pressing in balancer bearing assembly Buen SERVICE AND TOOL
4. Internal handlebar wiring e New front panel nacelle CM TH 2007 MODEL YEAR Extended Rear Brake Control and Footrest Mounts on FX Bobtail Models Right side components extended outward approximately 1 in Allows for more stretched out rider comfort Rear brake pedal styling improved SOFTAIL NEW Three Electric Caddys e One caddy is located under fuel tank uet SOFTAIL 2007 MODELYEAR NEW Three Electric Caddys wont e A second caddy is behind the voltage regulator e A third caddy is under the rear fender cover auet l 2007 MODEL YEAR SOFTAIL Rear Fenders e Sound dampening material added to fender Four Hole Fender Supports on FLSTN e Allows more P amp A accessory opportunities CMAR Cie NU 7 TOURING FAMILY 07 2007 MODEL YEAR NEW Idle Temperature Management Download Option For prolonged engine idle conditions In hot riding conditions an optional dealer enabled engine calibration is available New download cuts combustion to rear cylinder Engine must be at certain operating temperature Vehicle must be at idle and not moving to activate Exhaust changes tone with only front cylinder firing Exhaust may have slightly different odor Installation of download is free one time only under warranty Removal of download is free one time only under w
5. P F I system e Check Electrical Diagnostic Manual for proper specifications e Rotor does retrofit e New stator and voltage regulator do not retrofit Chua SPORTSTER Reduced Effort Front Brake Lever DOT 4 brake fluid is used in all 2007 XL motorcycles New calipers New master cylinders New brake lines Changes result in an 11 effort reduction for 883 883L 883C 1200L and 1200C models Changes result in a 14 effort reduction for 883R and 1200R models New rear brake pads improve rear brake feel Rear brake pads do not retrofit 2007 MODEL YEAR a ai an NEW Handlebar Wiring e Harnesses are lengthened 8 by 2 in to allow for easier changing of handlebars Extra harness is tucked into the electrical caddy underneath the fuel tank DYNA FAMILY 07 2007 MODEL YEAR All Dyna Models e All 2006 model year redesigns carry forward for 2007 Dyna models DYNA NEW Lower Profile Transmission Cover e Design common with the Softail model e New smaller J hose vent and routing new hose is shaped to accommodate HDI exhaust actuator e Retrofits to 2006 Dyna models Buer DYNA 2007 MODEL YEAR NEW Final Drive Gearing Belt and Belt Guard Change e Final drive gearing is matched to optimize the new Twin Cam 96 powertrain e New rear sprockets gt HDI and domestic mode
6. Tinted windscreens BUELL XB Lightning Model e New color combinations available for wheels and bodywork e CityX seat has new cover material BUELL 2007 MODEL YEAR Ulysses Models e New P amp A camouflage bodywork e Ulysses seat has new cover material e 1 3 in lower seat height laden e 2 2 in lower seat height unladen e Seat does retrofit Seat is reshaped Buell Blast e New Arctic White color added auet 2 SL 2007 MODEL YEAR NEW Inner Rocker Cover with Press in Place Gasket e Redesigned press in place gasket e Inner rocker cover has been redesigned to accommodate new gasket design e Inner rocker cover fits previous XB models P N 17598 07 Important Service Note 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 BUELL NEW Rocker Cover Cylinder Head Gasket e New design has coated gasket CE IE 3 BUELL 2007 MODEL YEAR NEW Throttle Position Sensor TPS Identified by one or two orange paint dots on top of TPS e New TPS rotor tangs are at 1 and 7 o clock positions Old style TPS rotor tangs are at 4 and 10 o clock positions e TPS sensors do not interchange New TPS P N PO279 3AA Old TPS P N 29537 99Y NEW Throttle Bod
7. and rear 2007 suspension specifications CANY HARLEY DAVIDSON UY Buel 7 mam PERFORMANCE PARTS SCREAMIN EAGLE 07 TECHNICAL FORUM Big Bore Stage 1 Kit 103 cu in Increase displacement from 96 in to 103 in 1584 cc to 1690 cc Big bore cylinders and pistons High flow A C kit 50 State street legal Digital Technician calibration Big Bore Stage 2 Kit 103 cu in e Increase displacement from 96 in to 103 in 1584 cc to 1690 cc e Big bore cylinders and pistons e High flow A C kit e 255 Cams Catalyst exhaust 50 State street legal Digital Technician calibration Ruen 1 SCREAMIN EAGLE 2007 MODEL YEAR 110 cu in Stage 1 Kit Increase displacement from 96 in to 110 in 1584 cc to 1800 cc 255 Cams produce low rpm torque e Gin bore cylinders and forged pistons e 9 3 1 Compression ratio e 50 State street legal Digital Technician calibration ered o7 S i e Cylinder heads have many features and functions New combustion chamber Port cores and intake valve S Automatic compression W i r release O s0 e Dyna and Softail models have a high flow A C kit e Touring kit has special high flow A C element auet 2 eri 2007 MODEL YEAR SCREAMIN EAGLE Screamin Eagle Exhaust e New street performance exhaust systems are street legal for 2007 models e Each exhaust system
8. helpful review Initial Care Programs e 2007 Twin Cam 96 Powertrain e Warranty pre authorization from Technical Service required for any Twin Cam 96 powertrain repair lt P amp A and Screamin Eagle performance parts installation does not require authorization 7 15 06 through 12 22 06 e 2007 XL Sportster Models Fuel pumps ECM and fuel lines require pre authorization for replacement under warranty e Powertrain repairs require pre authorization 7 15 06 through 10 13 06 HARLEY DAVIDSON 2007 MODEL YEAR 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 Ibs of force at the midpoint of the bottom strand 2007 belt deflection should be as follows MODEL sd VEHICLE ORIENTATION BELT DEFLECTION IN FLHT FLHR FLHTCU Vehicle upright with 3 8 7 16 FLHTC FLHRC FLTR rear wheel in air or on Jiffy stand without rider or luggage FLHRS FLHX Vehicle upright with 1 4 5 16 rear wheel in air or on Jiffy stand without rider or luggage TABLE 1 FLT Belt Deflection Specifications MODEL BELT DEFLECTION IN FXD FXDWG FXDC Vehicle upright with 1 2 9 16 rear wheel in air FXD FXDWG FXDC On Jiffy stand without 5 16 3 8 rider or luggage FXDL FXDB Vehicle upright with 5 1
9. 6 3 8 rear wheel in air FXDL FXDB On Jiffy stand without 1 4 5 16 rider or luggage TABLE 2 Dyna Belt Deflection Specifications SERVICE AND TOOLS 2007 MODEL YEAR 2007 Model Year Drive Belt Tension Specifications iont MODEL BELT DEFLECTION IN FLSTN FXSTD Vehicle upright with 5 16 3 8 rear wheel in air FLSTN FXSTD On Jiffy stand without 1 4 5 16 rider or luggage FLST FLSTC FLSTSC Vehicle upright with 11 16 3 4 FXSTC FLSTF FXST rear wheel in air or FXSTB FXSTS on Jiffy stand without rider or luggage FLST FLSTC FLSTSC On Jiffy stand without 9 16 5 8 FXSTC FLSTF FXST rider or luggage FXSTB FXSTS TABLE 3 Softail Belt Deflection Specifications MODEL VEHICLE ORIENTATION BELT DEFLECTION IN XL883 STD XL883R Vehicle upright with 9 16 5 8 XL1200R rear wheel in air or on Jiffy stand without rider or luggage XL883C XL1200C Vehicle upright with 1 4 5 16 XL883L XL1200L rear wheel in air or on Jiffy stand without rider or luggage TABLE 4 XL Belt Deflection Specifications
10. Eagle Road King e Flush mount gas cap and fuel gauge e Oil cooler and chrome cover e Leather saddlebags and seat with chrome trim and flame insert detachable rider and passenger backrests also available from P amp A optional matching leather Tour Pak with flame insert e Radial tires 18 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 e Custom spun metal faced speedometer tachometer combination e Dual halogen headlamp e H DSSS with self powered alarm Dark smoked mini wind deflector e Lowered P amp A shocks e 1 25 in chrome handlebar with internal wiring e Floorboards passenger pegs highway pegs and hand foot controls are from Ironside Collection e Fat Boy front fender wide rear fender swingarm and rear axle Paint with leafing graphics and marble accents Razor Red with Burnt Gold Candy Cobalt with Pale Gold Black Ice with Pewter CVO 2007 MODEL YEAR FXSTSSE Screamin Eagle Softail Springer e 1 25 in chrome handlebar with internal wiring e Chrome forward controls e Chrome handlebar risers e Mini tach and new chrome tach mounts e Revolver chrome 10 spoke forged aluminum wheels e Revolver chrome 66 tooth sprocket e Revolver brake rotors e 200 mm rear tire e New tri bar LED tail lam
11. S 2007 MODEL YEAR Essential Tools cont e Twin Cam 96B Outboard Balancer Bearing Remover Installer P N HD 48474 e Removes and installs bearings from the chain guide support plate Twin Cam 96B Balancer Puller P N HD 48457 e Puller extracts the Twin Cam 96B balancer bearing assembly e Plate is reversible for front and rear balancers CHA Tid 2007 MODEL YEAR it U M SERVICE AND TOOLS Essential Tools icont e Terminal Remover e P N HD 48114 Removes socket and pin terminals from Molex connectors e Used on all models Important Service Note Refer to the instruction sheet to prevent damage e Electrical Crimp Tool e P N HD 48119 e Crimps Molex terminals Molex is a registered trademark of Molex Products Company Buell el 9 SERVICE AND TOOLS 2007 MODEL YEAR Essential Tools cont e TMAP Sensor Pin Probes e P N HD 41404 15 e New probes required for electrical diagnostics on TMAP sensor terminals on XL models e Probes are a light orange color e H DSSS Antenna Pin Probes e P N HD 41404 20 e Used on all models with security systems e Probes area light blue color e Barcode Reader for Security Systems P N HD 48263 e Functionality is enabled through Digital Technician Phase 19 software e Assigns fobs during PDI e Increases accuracy and efficiency e USB connectivity e Optional fob
12. arranty Prior systems have been removed for 2007 models TOURING pm 32903 07C DT Stock United States O E Calibration that offers limited rear c Winder cooling while Vehicle is stepped and at idle Engine idle Temperature Management Use with ECH labeled 32952 407 of 4348 07 BE HARLEY DAVIDSON TOURING 2007 MODEL YEAR Sidecar Brake Reservoir e Relocated in order to provide necessary clearance for the O sensors e Mounts to the outside of the front frame support bracket e New design CMN 2 pese 2007 MODEL YEAR Shift Lever and Floorboard Changes New shift lever left hand rider floorboard supports and passenger floorboard supports Changes accommodate additional clearance necessary due to new engine transmission and primary drive Shift lever retrofits to prior models but pre 2007 levers do not fit new Touring motorcycles New board mounts retrofit to prior motorcycles Old board mounts do not retrofit to 2007 models TOURING Frame and Swingarm Changes Frame swingarm and engine mounts accom modate new engine Swingarm forging moved to the rear New swingarm support brackets end caps New forged front engine mount bracket clears new crankcase Swingarm mounts do not retrofit 2007 Touring frame does not retrofit to prior models TOURING 2007 MODEL YEAR Jiffy Stand Change e Touring motorcycles c
13. assignment can be input by reading the 24 character security ID behind fob cover 24 Character security ID matches the system ID for the HFSM cou 10 2007 MODEL YEAR 3 SERVICE AND TOOLS Essential Tools cont USB Hub P N HD 44750 15 e CF27 and CF28 laptops do not supply enough power through the USB port to properly power the Barcode Reader e 4 Port USB 2 0 hub with AC power supply e Permits connection of multiple devices such as USB Barcode Reader USB Mouse and USB Printer Authorization Protocol e Authorization numbers are not a guarantee for payment e Revised Warranty Manual on h dnet com e Authorization protocol not applicable if under initial care HARLEY DAVIDSON 11 SERVICE AND TOOLS NEW Digital Technician Service Procedures Harley Davidson Smart Security System H DSSS set up Scan barcode on fob packaging e Test fob functionality e Enable security by entering PIN once fobs are assigned e Disable security during service at dealership 2007 MODEL YEAR ar a e PH lagd rr Vera akin ta ahh bel oi ts aie pnay Prpa Fan farsa beg eh geen To Eira ien i Beau Byte panes Fol feed Pees Pe Ft ed Pe aa Ciri Fiep ee ee he ds Pb Leal ki a ee gee des eek Pd ee ce ol kimie n pirga aged GT Poko man ia chid om s si pabi hy sp Fe ee Bia r is Femi ras faa faran fr a mr we me
14. ated in rear fuse block NEW Wire Harness e Harness has a new right side branch that starts behind rear cylinder e Rear coil and vehicle speed sensor leads are moved to the center of the motorcycle e All VRSC motorcycles have Molex connectors Molex is a registered trademark of Molex Products Company HARLEY DAVIDSON TECHNICAL FORUM NEW Exhaust Shield Retention e New hardware e Fasteners do not retrofit to prior models e New kit consists of new auxiliary volume and hardware to retrofit prior models Compensator Bowl e Wide compensator bowl accommodates new frame e VRSCR compensator bowl remains unchanged HARLEY DAVIDSON TECHNICAL FORUM Split Rear Wheel Bearing e New bearing for models equipped with 240 mm tires e CVO VRSC motorcycles used this bearing in 2006 12 07 SPORTSTER FAMILY 2007 MODEL YEAR The Sportster Family Celebrates 50 Years 50th Anniversary 1200 model Limited production of 2 000 Serialized nameplate on handlebar clamp Gold 50th emblem on fuel tank New H silk screening on side covers represents the cultural history of the Sportster family Embroidered seat XL custom rear shocks SPORTSTER NEW 883L Model Lowered 25 25 in seat height New front and rear shocks New seat Parts retrofit Higher torque for 883 models e All 2007 XL motorcycl
15. en miar is BIG TWIN HDI Active Exhaust except Japan e Actuator closes valve in the exhaust system during higher engine loads e Optimizes power while meeting noise regulations e Composite cable mount 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 HARLEY DAVIDSON 2007 MODEL YEAR 2007 MODEL YEAR Twin Cam 96B Balanced Engine e New 1584 cc Twin Cam 96B balanced engine e 6 Speed Cruise Drive transmission is part of this powertrain BIG TWIN Twin Cam 96B Balancers e New balancer is first pressed into bearing e A new tool shown here to press assembly HARLEY DAVIDSON Buell 17 VRSC FAMILY 07 2007 MODEL YEAR NEW Brake Pads on VRSC Models e New brake pad material e Reduced brake noise e Reduced rotor wear e Brake pads retrofit to 2006 models VRSC Two Piece Rear Caliper Assembly e New brake lines e Two piece assembly is easier to service e VRSCR rear caliper unchanged Important Service Note Rotor does not need to be removed during tire changes Fuer 1 TECHNICAL FORUM Fuel Sending Unit for All VRSC Models e Ultrasonic sending unit reads fue
16. es use W cams lt 15 More torque at 2500 rom e Requires 1200 mufflers for Japan market HARLEY DAVIDSON huer SPORTSTER 2007 MODEL YEAR Redesigned Oil Pump e Redesigned pump body feed and scavenge gerotors e New feed and scavenge porting e Scavenge gerotors have larger diameter and are taller for more capacity e Feed gerotors are thinner to accommodate taller scavenge gerotors in original pump body height but redesigned for no loss of capacity Internal parts do not inter change with earlier pumps Pump assembly will retrofit Electronic Sequential Port Fuel Injection E S P F I for All XL Models 45 mm induction module for all models e 15 Degree injectors e New wiring harness with Molex connectors e Frame updated with new brackets to secure new wire harness e Low fuel light e 91 Octane for all 2007 Sportster models Molex is a registered trademark of Molex Products Company 2007 MODEL YEAR Electronic Sequential Port Fuel Injection E S P F 1 Sensors New TMAP sensor e Combined sensor MAP IAT Top of Induction Module IM IAC top of IM TP sensor left side of IM Head temperature sensor is located in rear cylinder head similar to Buell models Special tool available SPORTSTER TP Sensor Buell a 3 SPORTSTER Oxygen Sensors e Front and rear exhaust O2 se
17. ibrations 2007 MODEL YEAR 34267 06 0T 1550 Stage Strat Legal Performance Calibration Use with ECM s labeled r 3205206 J2498 08 of I2634064 l NOTE DO HOT install stock calibrations on BOM ICM Modules that have been Race Tuned or have Screamin Eagle Performance Parts BEIM Compliant Conditions and Cautions HARLEY DAVIDSON 2007 MODEL YEAR Compliant Conditions and Cautions cont SERVICE AND TOOLS 32876 06B 0T 103 Cu In Stage Legal Street Legal Performance Calibration Use with BCM s labeled S2052 06 32498 06 of 32594 05A NOTE DO MOT install stock colibratians on ECM 7 ICM Modules that have been Race Tuned or have Screamin Eagle Performance Parts Performance Warning Screen Race Use Only HARLEY DAVIDSON TECHNICAL FORUM Vehicle Recalibration Report Ie j onpi ei bir I riie ers irer ee ee e ha mm j y am lpi i jabi a a japa abhi E Gej kaip amie egoi g ai bamn ope l ay a ep jean Bara Tonei r Bpan Bory Fei Fan i a ee AH BaL ee ee eee eee ee ee M E ee eh mrn ete j HRS e ey Bes b areri p i P brt he p ee Ss es Pe eed n E Ria Ph oe oe Miia a mir ien m aF a eni har a ae paian tacis m Earm miri maa m mg ha taii edni ia bmad mrn en Digital Technician Active Exhaust Test e Cycles active exhaust actuator and monitors feedback circuit HARLEY DAVIDSON 2007 MODEL YEAR it U M SERVICE AND TOOLS Fork Oil and Spark Plug Service e Additional
18. ion chamber ports and intake valve e 255 Cams e 4in bore e 110 Scripted derby cover and air cleaner insert e Syn 3 engine oil e 1 4 Kw starter 4 375 111 13 mm stroke same as OE engines e ACR solenoids to ease start up located in each cylinder head e Torque range of 105 115 ft Ibs measured at crankshaft depending on model e All CVO models have 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 CVO 2007 MODEL YEAR FLHTCUSE Screamin Eagle Ultra Classic Electra Glide e Heated seat and grips e Relocated intercom plug integrated with left rear speaker pod e Multifunctional switch for cruise control and spotlights e Light smoked short windshield e Adjustable passenger footboards e Power locks on Tour Pak and bags are dash controlled e Harley Davidson Smart Security System H DSSS with self powered alarm e XM Satellite Radio three months of service and amplifier except HDI e Advanced audio integrated navigation system e Hand foot controls footboards and highway pegs are from lronside Collection e Paint with Pearl highlights Light Candy Cherry with Black Ice Lightning Blue Pearl with Midnight Pearl Black Ice with Electric Orange 2007 MODEL YEAR CVO FLHRSE Screamin
19. 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 Calibration cartridges discontinued early in the 2007 model year All street legal calibrations for 1995 2007 models are available on Digital Technician Race calibrations for 1995 2006 models are available on Digital Technician Race calibrations for 2007 models require Screamin Eagle Race Tuner All race calibrations continue to be available in Screamin Eagle Race Tuner 07 SERVICE AND TOOLS TECHNICAL FORUM NEW Calibrations Search h dnet com EFA e Customized to all models Sn m worldwide aches Di pare eerie i i hiisi Sr mpm o ll cs a a e ge ige e et e Active screen capture help Sar ee ae pe e Calibration specific selection SSS 7 l mpgs Per e e Revised search buttons _ IA e Reverse lookup feature with calibration I D Fii bed A A a m m Pa san ae Several P amp A Cast Wheels Sold Differently e Bearings and sleeves are not installed in the wheels from the factory e Bearings and sleeves are ordered separately e Bearings and sleeves offered as a kit e Softail front wheels 19 in and 21 in front wheels and 17 in x 4 5 in wheels are affected HARLEY DAVIDSON SERVICE AND TOOLS 2007 MODEL YEAR VRSCDX Wheels e 240 mm tires e Black
20. istons e Lighter pistons and connecting rods for lower reciprocating weight e Shorter wrist pin 2007 MODEL YEAR 25 Degree Injectors e 2006 running change to 25 degree fuel injectors P N H D 27709 06A Buell l TECHNICAL FORUM Twin Cam 96 Components Follow 2006 Dyna Powertrain e Compensator assembly alternators e Four spring pack design for domestic and HDI models Compensator spring pack now welded to rotor e Twin Cam 96 Alpha engine transmission gasket 3 BIG TWIN Twin Cam 96 Components Follow 2006 Dyna Powertrain iont e Engine cases with integral oil filter adapter e External oil lines have been eliminated for Dyna and Touring Big Twin engines e Softail engines continue with external oil lines HARLEY DAVIDSON 2007 MODEL YEAR ii fi ii i II vi TECHNICAL FORUM Twin Cam 96 Components Follow 2006 Dyna Powertrain cont e Cam plate changes e Primary hydraulic cam chain tensioner e Cam plate changes e Secondary hydraulic cam chain tensioner SMOTOR __ Ruel BIG TWIN 2007 MODEL YEAR Twin Cam 96 Components Follow 2006 Dyna Powertrain cont e Cam plate changes Cam plate uses parent material bearings e Crankshaft assembly and cases Inner cam bearings HARLEY DAVIDSON TECHNICAL FORUM Twin Cam 96 Com
21. l levels via sound waves that reflect off the fuel level e Fuel lines connectors are easier to service e Fuel line routing e Does not retrofit Fuel Tank on VRSCA VRSCD VRSCDX and VRSCX Models e Five gallon fuel tank for new frame e Does not retrofit MOTOR Biel VWA 2007 MODEL YEAR 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 e 240 mm rear tire e Wide rear fender New rear axle Lowered rear shocks Lowest ride height 25 2 in to date VRSC Buet TECHNICAL FORUM Frame Change e New seat pan assembly e VRSCA VRSCD frame accommodates new five gallon fuel tank e Ignition switch moved to right front side e Passenger footpegs relocated to frame 4 2007 MODEL YEAR NEW Coolant Tank Coolant tank relocated e VRSCR coolant tank remains unchanged VRSC 240 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 VRSCX Unique Styling e New paint scheme incorporates the 1 logo e Based o
22. ls 66 tooth rear sprocket 131 tooth drive belt gt H D Japan models only 64 tooth rear sprocket 130 tooth belt FXD Dyna Super Glide model NEW 40 Amp Charging System e Three phase 40 amp output charging system OE Dyna and Softail models e Consists of gt New 12 magnet rotor e New stator Stator and rotor assembly retrofits to 2006 Dyna models 2007 MODEL YEAR INI LU DYNA Transmission Shift Detent and Roller Change e Shift detent arm spring and roller design change e Part number revisions to A suffix e 2007 Transmission detent assembly retrofits to post recall 2006 Dyna motorcycles e This assembly ts sold as AKRO E cove yea models 2006 Dyna Model 2007 Big Twin NEW Steering Head Adjustment Access Area e Notched access area provides improved access for servicing e Notch allows service procedure to be common with Softail and Touring models Buell 3 DYNA 2007 MODEL YEAR FXDBI Dyna Street Bob and FXDI Dyna Super Glide Models New stainless steel rear fender supports Brushed stainless steel covers on FXDB model e Recommended cosmetic care product Harley Davidson Bright Chrome Cleaner P N 94683 99 Polished stainless steel covers on FXD model e Recommended cosmetic care product Harley Davidson Bright Metal Polish P N 99725 89 Important Service Note S
23. n the Screamin Eagle Vance amp Hines NHRA Prostock V Rod e 1250 cc engine e Limited production of 1 400 units e Laced front wheel SMOTOR Buel QU 2007 MODEL YEAR 2007 MODEL YEAR VRSC Larger Battery e Battery common with Dyna models except VRSCR e Does not retrofit due to size and polarity of battery posts Front Tires e New tire tread design e 207 Series Dunlap front tire changed to 208 Series SMOTORZ Bue NU 7 VRSC 2007 MODEL YEAR Radiator Trim Covers e Similar trim cover as 2006 VRSCR models Important Service Note Retrofits with minor modifications to radiator cover VRSCR Ergonomic Improvements e Wider and higher handlebar e Handlebar does not retrofit fuer l TECHNICAL FORUM 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 New battery tray electrical caddy accommodates starter solenoid Right and left hand controls headlamp jumper harness and front turn signals located under left side Right Side Starter Solenoid Left Side 9 VRSC 2007 MODEL YEAR Rear Electric Caddy e Under passenger pillion e Molex connectors e ECM located on rear caddy e ECM lights security spare fuse and accessory circuits loc
24. nsors e Closed loop system like 2006 Dyna models 2007 MODEL YEAR Front sensor shown Fuel Pump e Mounted in new fuel tank e Check Sportster model Service Manual for pressure specifications e Uses current fuel pressure gauge adapter P N HD 44061 HARLEY DAVIDSON Ruel TRN E TECHNICAL FORUM Intake Flanges e New intake flanges and fasteners e Wider flanges allow for better fastener access e Uses four hex bolts rather than allen bolts e New cylinder heads to accommodate new flanges e 1200 Heads have changes to intake port and intake valve seat e No service procedure changes to new heads only part number changes NEW Ignition Coils e New coil mounting bracket e New spark plug wires e New primary and secondary resistance values e Check Sportster model Electrical Diagnostics Manual for proper specifications HARLEY DAVIDSON SPORTSTER 2007 MODEL YEAR NEW ECM and Fuse Location e ECM is located underneath the seat on the rear fender e Additional fuses are required e New rear fenders and seats accommodate ECM HARLEY DAVIDSON i k l Buell 2007 MODEL YEAR NEW Rocker Boxes e Rocker boxes have been changed to feature an improved sealing cavity e New press in place gaskets e Gaskets do not retrofit SPORTSTER 32 Amp Charging System e Increased power to 32 amps from 22 amps to power the E S
25. ome with a new Jiffy stand to accommodate changes from new engine e New bumper e Mount has changed Saddlebag Supports e New cast zinc l brackets and end bullets for saddlebags New brackets appear the same but have a smoother finish on all sides e Reduces scratching of saddlebags when removing 2007 MODEL YEAR Twin Cam 103 cu in Engine for Police Models e 1690 cc CVOengine e 9 6 1 Compression ratio e Unique calibration e ABS and Harley Davidson Smart Security System optional equipment e Unique clutch spring e Catalyst mufflers Active intake and exhaust on HDI Police motorcycles TOURING Sidecars for Police Motorcycles e Police Touring motorcycles with ABS do not accept a sidecar e Hydraulic line routing on 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 Buell a 5 TECHNICAL FORUM NEW Handlebar Clamps e Handlebar control clamps are modified improving clearance for wire harness Front Electrical Caddy e New caddy mounts under voltage regulator retaining connector for crank position sensor uei 6 CVO FAMILY 07 2007 MODEL YEAR CVO NEW CVO Engine e 110 cu in 1800 cc engine e 9 3 1 Compression ratio e New heads combust
26. ometers change to 130 mph 200 km h Clock Function Displayed on LCD odometer window e Selected with trip switch button press release e Set with trip switch button press hold press release e 12 24 Hour selectable QU 2007 MODEL YEAR NEW LED Indicators except VRSC e Easier to read LED indicators replace incandescent bulbs ALL MODELS Reduced Effort Clutch Cable e 2006 Dyna design e New clutch cable e Reduced effort clutch lever 8 Reduction for Sportster models 10 Reduction for Softail models 7 Reduction for Touring models ALL MODELS 2007 MODEL YEAR Clutch Interlock Switch e Clutch interlock switch functions as an or function with the neutral switch e Switch verifies if the motorcycle is in neutral and if not the clutch lever must be disengaged pulled in before motorcycle will start e Excellent feature for new riders Electronic Sequential Port Fuel Injection E S P F 1 e Similar design was incorporated for the 2006 Dyna models e O2 feedback system eliminates the need for catalysts except VRSC models e HDI motorcycles are equipped with O2 sensor feedback e System adjusts to provide optimal air fuel mixture e Some CVO motorcycles require catalyst SMTA mano CBOE A WUE TECHNICAL FORUM NEW Molex Connectors except Buell e Molex connectors are smaller
27. p e Low profile chrome fuel tank console Hand foot controls and footpegs are from new Centerline Collection e Flush mount fuel cap and gauge e H DSSS with self powered alarm e Custom leather two up seat with ribbed insert e Color matched frame swingarm rigid forks upper triple clamp oil tank frame inserts seat post and muffler support brackets e Tribal Flame paint Abyss Blue with Blue Pearl Canyon Copper with Candy Red Amarillo Gold with Candy Tangerine 2007 MODEL YEAR FXDSE Screamin Eagle Dyna Custom spun aluminum gauge package Extended headlamp trim ring Polished stainless steel rear brake push rod and shifter rod Braided line package Chrome package Inverted front forks Covered low rear shocks with hand adjust preload Custom 1 25 in handlebar Knurled chrome handgrips and footpegs Rolled back front fender Color matched frame battery box electrical panel cover coil cover and chin spoiler 170 mm rear tire Custom bucket seat with perforated inserts Full length fuel tank console Flush mount aircraft style gas cap Layback license plate Paint options Silver Rush and Midnight Black Inferno Red and Desert Black Twilight Blue with Ice Blue Granite and Ice Blue Pearl CVO HARLEY DAVIDSON BUELL FAMILY 07 2007 MODEL YEAR XB Firebolt Models e New wheel colors e New bodywork colors e
28. painted wheels need to be serviced with caution as cosmetic damage can occur if proper procedures are not used XL Fuel Lines e Fuel lines may appear to be kinked upon delivery until ignition is turned on to expand the line SMT DRA mmo REIT QU 2007 MODEL YEAR INIC IRUM SERVICE AND TOOLS Crankshaft Rotating Wrench e P N HD 48283 e Made for new splines on crankshaft e Used on 2006 Dyna models and 2007 Twin Cam 96 engines e Crankshaft Rotating Wrench is not part of the 2007 Essential Tool Kit Essential Tools e Wheel Bearing Collet e P N HD 44060 10 e Added to Essential Tool Kit Collet added to the Wheel Bearing Kit P N HD 44060 A Removes 25 mm wheel bearings featured on Softail front wheels J J Springer models continue with 1 in wheel bearings collets Buell 3 SERVICE AND TOOLS 2007 MODEL YEAR Essential Tools cont e Vehicle Alignment Tools e P N HD 46247 1 P N HD 46247 2 e New pivot shaft alignment blocks for 2007 FL models e Frame changes made blocks necessary Triple Trees Wedge for VRSCR P N HD 48287 e Spreads clamp to prevent damaging painted fork tubes during servicing Two wedges come in the kit Buell 4 TECHNICAL FORUM Essential Tools cont Short Primary Drive Locking Tool P N HD 48219 e Locks primary drive for removal installation of
29. ponents Follow 2006 Dyna Powertrain cont e Assembled cams e Oil pump assembly 10 More flow and 23 scavenging capacity improvement O ring between oil pump and cam support plate has been eliminated e 10 11 Lobe gerotor set Buell 7 Twin Cam 96 Components Follow 2006 Dyna Powertrain cont e Dyna style roller cam chains All Big Twin models feature hydraulic chain tensioners and new cam chains e Flywheel sprocket shaft splines match 2006 Dyna models 8 TECHNICAL FORUM TECHNICAL FORUM Twin Cam 96 Components Follow 2006 Dyna Powertrain cont e 6 Speed Cruise Drive transmission 6th Gear is direct drive 1 1 Lower cruising rpm in 6th gear is achieved with new primary ratio 2nd 3rd 4th and 6th are helical gears 1st and 5th are spur gears 1st 2nd 3rd and 4th gears are integral on mainshaft 5th and 6th gears are integral on countershaft e Six of 12 gears are individually serviceable e Christmas tree gear layout on shafts e VRSC style dog ring shifting XL XB style shifter design CEN TECHNICAL FORUM Twin Cam 96 Components Follow 2006 Dyna Powertrain cont e 6th Main drive gear e Quad ring replaced by O ring on new main drive gear e Needle bearings for 6th gear mainshaft e Needle bearings secured by retaining rings e Double row output bearing e Sprocket
30. service info e Fork oil service interval extended to 50 000 miles 80 000 km e Spark plug inspection service interval or replacement extended to 20 000 miles 32 000 km Formulat Primary Levels e All FL Touring Big Twin models primary drives require 45 oz dry capacity and 38 oz wet capacity of Formula e All Softail and Dyna models require 32 oz wet and dry capacity of Formula i E e There is no longer a GENUINE visual inspection e Primary service intervals increased service to every 10 000 miles 16 000 km from 5 000 miles 8 000 km e Transmission Formula change interval increased to 20 000 miles 32 000 km from 10 000 miles 16 000 km Buer SERVICE AND TOOLS 2007 MODEL YEAR Advanced Audio System nm Website 1 0 ADVANCED AUDIO SYSTEM BY HARMAN KARDON Harley Davidson com DFT WKAL COMPONENTI 8 EWAME STB LIMA e Inside the motorcycles 2006 Touring section e New listing of compatible pD ONES DOSE se e Updated sound system OP AMES IPR TOW ABVENTURLS VON VEEE ARQ TOT downloads de ghakiinha i amekaa shy teed bri y sd i rt par r eels gh tee oe peg ak Bede obey Sees oe pote abt keale stay vied mahar bara wn spe Se e Burn CD s from site at low M ee speed for no charge sound pirra piierne jei perir ieri th roar eh Tuih piar Tiene PR che ie a ng eer system updating caver i TO RRL EY OS Hia PLUG A PLAT eC Mp ee aes hrpe ack mses
31. spacer incorporated into bearing Primary drive system Drive ratio is 1 35 1 e Dyna clutch shell e Starter ring gear moved to inboard on clutch hub 10 TECHNICAL FORUM Twin Cam 96 Components Follow 2006 Dyna Powertrain cont e Automatic mechanical primary chain tensioner e New inner primary housings e Inner primary must be removed to service rotor and stator HARLEY DAVIDSON BIG TWIN 2007 MODEL YEAR Twin Cam 96 Components Follow 2006 Dyna Powertrain cont e Primary gasket fasteners e Primary chain inspection cover has been removed 12 2007 MODEL YEAR 6th Gear Indicator e Lamp activates during motorcycle operation in 6th gear Vehicle speed and engine rpm determine light activation not a switch BIG TWIN Charging System e Softail and Dyna models feature a new 40 amp alternator CANY HARLEY DAVIDSON RUF Buell 13 BIG TWIN 2007 MODEL YEAR One Piece Horn Cover e For ease of assembly OE Exhaust e Improved sound quality Tr ONG 2007 MODEL YEAR xez 07 1E ae 10 y BIG TWIN HDI Only Active Intake e Solenoid controls the opening and closing of baffle in the air cleaner backing plate to reduce intake noise e H D Japan motorcycles do not feature active intake e Solenoid attached to backside of air cleaner backing plate Ru
32. than Deutsch connectors e Molex connectors are internally sealed from moisture e VRSC models feature Molex connectors exclusively e Connector is only serviced from the mated side Molex is a registered trademark of Molex Products Company HARLEY DAVIDSON TECHNICAL FORUM Final Drive Belt e 1in wide X7N belt e Second generation carbon fiber e Thicker fabric for increased tooth strength and wear resistance e Touring models receive a 137T belt e H D Japan Touring models receive a 136T belt Important Service Note New belt tension specifications for all models HARLEY DAVIDSON Tensile Cord Second generation carbon fiber Polyurethane Body Same material as previous belts Tooth Jacket Thicker fabric for increased tooth strength and wear resistance BIG TWIN ENGINES 07 2007 MODEL YEAR NEW Twin Cam 96 Engine Powertrain Specifications e Displacement 96 cu in 1584 cc up from 88 in 1450 cc Achieved by stroke increase to 4 375 in 111 13 e Touring Alpha engines have increased torque to 93 ft Ibs 126 NM 3500 rpm e Softail Beta engines have increased torque to 90 ft Ibs 122 NM 2750 rpm e Dyna Alpha engines have increased torque to 92 ft Ibs 125 NM 3000 rpm aoa ears P a BIG TWIN HARLEY DAVIDSON BIG TWIN Twin Cam 96 Connecting Rods and P
33. urface care products for new finishes are in the Dyna model Owner s Manual SMTA mano CBOE A WUE TECHNICAL FORUM NEW on FXDC Model e Based on 35th Anniversary Super Glide model e Unique model features e Tank trim and cloisonne e Ribbed seat e Battery cover trim e Handlebars and front brake line Electrical caddy cover trim e Leather tank panel with the 1 logo uel SOF TAIL FAMILY 07 2007 MODEL YEAR NEW Twin Cam 96B Engine Balancers e New one piece balancer support bracket e New bearing installer removal tool required for service SOFTAIL FLSTF and FX Bobtail Models New Tire e 200 mm rear tire with new tread design SOFTAIL 2007 MODEL YEAR for FX Softail Models e New handlebars risers and clamps UK Dual Face Speedometer Change e New speedometer face reads up to 130 mph 200 km h mi TA B Sa Oi t MPH keh TO ii i hn il hn 12018 130 k i F f a ty Touring model example shown SMOTORZ QU TECHNICAL FORUM 25 mm Wheel Bearings and Axle e All Softail models except the Springer model receive 25 mm front wheel bearings 1 in I D NEW 25 mm I D e New front axle uet 3 SOFTAIL 2007 MODEL YEAR Fat Boy Model Front End Changes e New style handlebars and risers e
34. y Manifold e New throttle shaft TPS engagement pins oriented at 6 and 12 o clock positions e Old style engagement pins are orientated at 2 and 8 o clock positions CHA Ti 2007 MODEL YEAR it U M BUELL NEW Primary Chain Cover e Additional material added to the casting at the primary adjuster shoe screw support Redesigned Oil Pump Redesigned pump body feed and scavenge gerotors New feed and scavenge porting Scavenge gerotors have larger diameter and are taller for more capacity Feed gerotors are thinner to accommodate taller scavenge gerotors in original pump body height but redesigned for no capacity loss Internal parts do not inter change with earlier pumps Pump assembly fits earlier XB models Buell 5 BUELL Additional Holes in Airbox Functional Cover e Revised calibration for new airbox 2007 MODEL YEAR Tire Changes e Pirelli Diablo tires except on XB9SX and XB12X Ulysses e Pirelli Scorpion Sync tires used on XB9SX and XB12X Ulysses SMOTOR2 Bier QU 2007 MODEL YEAR Ulysses Seat Limiter e Separates underseat components from bottom of seat pan BUELL Ulysses Progressive Rate Fork Spring e Provides wider range of smooth progressive control of front suspension over long fork travel e Revised fork service specifications e Does retrofit and requires the new front
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