HARLEY-DAVIDSON UNIVERSITY TECHNICAL FORUM

1 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 H. ands/button-free security key fob S. ystem arms itself within five seconds of turning ignition off, and disarms when ignition is turned on or motorcycle is moved with fob present S. ecurity system is transparent to the customer A. ttempts to move the motorcycle with fob on the seat or within 4 in. from antenna could activate the system H arley-Davidson Smart . Security System impacts: PDI process Service Writers and Sales Transportation of motorcycle Servicing of motorcycle Customer expectations Storage mode eliminated;. current draw drops from mA to .7 mA. P&A siren upgrades system with chirp disable feature 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.

2 ALL MODELS 2007 MODEL year TECHNICAL FORUM . New Speedometers, Tachometers and Indicators (except VRSC ) . S. imilar features as the 2006 VRSC models . Clock function 6. th Gear indicator for Big Twin motorcycles Dual trip meters R. etrofit gauges (suffix change). P. &A tachometer output signal on 4 in. speedometer Lower standby current U. K dual-face speedometers change to 130 mph (200 km/h). Clock Function D. isplayed on LCD (odometer window). S. elected with trip switch button (press release). S. et with trip switch button (press hold/press release). 12/24-Hour selectable . 2007 MODEL year TECHNICAL FORUM ALL MODELS. New LED Indicators (except VRSC ) . E. asier-to-read LED indicators replace incandescent bulbs Reduced-Effort Clutch Cable 2006 Dyna design . New clutch cable R. educed-effort clutch lever: 8. % Reduction for Sportster models . 1. 0% Reduction for Softail models . 7. % Reduction for Touring models.

3 ALL MODELS 2007 MODEL year TECHNICAL FORUM . Clutch Interlock Switch C. lutch interlock switch functions as an or function with the neutral switch S. witch verifies if the motorcycle is in neutral and if not, the clutch lever must be disengaged (pulled in) before motorcycle will start E. xcellent feature for new riders Electronic Sequential Port Fuel Injection ( ). S. imilar design was incorporated for the 2006 Dyna models . O. 2 feedback system eliminates the need for catalysts (except VRSC models).. H. DI motorcycles are equipped with O 2 sensor feedback S. ystem adjusts to provide optimal air/fuel mixture S. ome CVO motorcycles require catalyst . 2007 MODEL year TECHNICAL FORUM ALL MODELS. New Molex Connectors . (except Buell ) . M. olex connectors . are smaller than Deutsch connectors . M. olex connectors . are internally sealed from moisture V. RSC models feature Molex . connectors exclusively C. onnector is only serviced from the mated side Molex is a registered trademark of Molex Products Company.

4 ALL MODELS 2007 MODEL year TECHNICAL FORUM . Final Drive Belt Tensile Cord 1 in. wide X7N belt Second generation S. econd generation carbon fiber carbon fiber T. hicker fabric for increased tooth strength and wear resistance T. ouring models receive a 137T belt H. -D Japan Touring models Polyurethane Body receive a 136T belt Same material as previous belts Important Service Note: Tooth Jacket New belt tension Thicker fabric for specifications for all models. 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 Displacement: 96 cu. in. 1584 cc up from 88 in. 1450 cc A. chieved by stroke increase to in. ( ). Touring Alpha engines have increased torque to 93 ft. lbs. (126 NM) @ 3500 rpm Softail Beta engines . have increased torque to 90 ft. lbs. (122 NM) @ 2750 rpm Dyna . Alpha engines have increased torque to 92 ft.

5 Lbs. (125 NM) @ 3000 rpm . BIG TWIN 2007 MODEL year TECHNICAL FORUM . Twin Cam 96 Connecting . Rods and Pistons Lighter pistons and connecting rods for lower reciprocating weight Shorter wrist pin 25-Degree Injectors 2006. running change to 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 . Compensator assembly/alternators F. our spring pack design for domestic and HDI models C. ompensator spring pack now welded to rotor Twin Cam 96 Alpha . engine/transmission gasket . BIG TWIN 2007 MODEL year TECHNICAL FORUM . Twin Cam 96 Components . Follow 2006. Dyna Powertrain (cont.).. Engine cases with integral oil filter adapter External oil lines have been eliminated for Dyna and Touring . Big Twin engines Softail engines continue . with external oil lines . 2007 MODEL year TECHNICAL FORUM BIG TWIN. Twin Cam 96 Components . Follow 2006.

6 Dyna Powertrain (cont.).. Cam plate changes P. rimary hydraulic cam chain tensioner Cam plate changes S. econdary hydraulic cam chain tensioner . BIG TWIN 2007 MODEL year TECHNICAL FORUM . Twin Cam 96 Components . Follow 2006. Dyna Powertrain (cont.).. Cam plate changes C. am plate uses parent material bearings C. rankshaft assembly and cases Inner cam bearings . 2007 MODEL year TECHNICAL FORUM BIG TWIN. Twin Cam 96 Components . Follow 2006. Dyna Powertrain (cont.).. Assembled cams Oil pump assembly 10%. More flow and 23% scavenging capacity improvement O-ring between oil pump and cam support plate has been eliminated 10/11 Lobe gerotor set . BIG TWIN 2007 MODEL year TECHNICAL FORUM . Twin Cam 96 Components . Follow 2006. Dyna Powertrain (cont.).. Dyna -style roller cam chains . All Big Twin models feature hydraulic chain tensioners and new cam chains F. lywheel sprocket shaft splines match 2006 Dyna models .. 2007 MODEL year TECHNICAL FORUM BIG TWIN.

7 Twin Cam 96 Components . Follow 2006. Dyna Powertrain (cont.).. 6. -Speed Cruise Drive . transmission 6th Gear is direct drive 1:1. L. ower cruising rpm in 6th gear is achieved with new primary ratio 2. nd, 3rd, 4th and 6th are helical gears 1st and 5th are spur gears 1. st, 2nd, 3rd and 4th gears are integral on mainshaft 5. th and 6th gears are integral on countershaft S. ix of 12 gears are individually serviceable C. hristmas tree gear layout on shafts VRSC -style dog ring shifting . XL/XB-style shifter design . BIG TWIN 2007 MODEL year TECHNICAL FORUM . Twin Cam 96 Components . Follow 2006. Dyna Powertrain (cont.).. 6th Main drive gear Q. uad-ring replaced by O-ring on new main drive gear N. eedle bearings for 6th gear mainshaft N. eedle bearings secured by retaining rings Double-row output bearing S. procket spacer incorporated into bearing Primary drive system Drive ratio is :1. Dyna clutch shell . S. tarter ring gear moved to inboard on clutch hub 10.

8 2007 MODEL year TECHNICAL FORUM BIG TWIN. Twin Cam 96 Components . Follow 2006. Dyna Powertrain (cont.).. A. utomatic mechanical primary chain tensioner New inner primary housings I nner primary must be removed to service rotor and stator 11. BIG TWIN 2007 MODEL year TECHNICAL FORUM . Twin Cam 96 Components . Follow 2006. Dyna Powertrain (cont.).. Primary gasket/fasteners Primary chain inspection cover has been removed 12. 2007 MODEL year TECHNICAL FORUM BIG TWIN. 6th Gear Indicator Lamp activates during motorcycle operation in 6th gear Vehicle speed and engine rpm determine light activation; not a switch Charging System S. oftail and Dyna models . feature a new 40-amp alternator 13. BIG TWIN 2007 MODEL year TECHNICAL FORUM . New One-Piece Horn Cover For ease of assembly OE Exhaust Improved sound quality 14. 2007 MODEL year TECHNICAL FORUM BIG TWIN. HDI Only Active Intake Solenoid controls the opening and closing of baffle in the air cleaner backing plate to reduce intake noise H-D Japan motorcycles do not feature active intake Solenoid attached to backside of air cleaner backing plate 15.

9 BIG TWIN 2007 MODEL year TECHNICAL FORUM . HDI Active Exhaust (except Japan). A. ctuator closes valve in the exhaust system during higher engine loads O. ptimizes power while meeting noise regulations C. omposite 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. 16. 2007 MODEL year TECHNICAL FORUM BIG TWIN. Twin Cam 96B . Balanced Engine N. ew 1584 cc Twin Cam 96B . balanced engine 6. -Speed Cruise Drive . transmission is part of this powertrain Twin Cam 96B Balancers . N. ew balancer is first pressed into bearing A. new tool shown here to press assembly 17. 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 Important Service Note: Rotor does not need to be removed during tire changes.

10 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 ( 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.