2010 Model Year Technical Forum
-
Upload
pablosag18 -
Category
Documents
-
view
115 -
download
5
Transcript of 2010 Model Year Technical Forum
2010 Harley-Davidson® New Model and Technical Information
• Tire pressures commonized across models
• Lead free wheel weights– this is a running change– the segments will be a different weight
• they were 0.25 oz (7 gm)• they now are 0.18 oz (5 gm)
All Big Twin Models
2010 Big Twin Transmission Changes
5th Gear (Input)
Guide Hub5th Gear (Countershaft)
5th Gear (Input)
5th Gear (Countershaft) Guide Hub
2009 - Earlier 2010 Model Year
What changed and why?
• Helical 5th gear – Has greater thrust loads.
• Snap ring groove moved inboard by about 0.90” to add material behind the snap ring.
• Moving the groove resulted in a change to the guide hub, adding the counterbore.
• The new mainshaft will be used for all replacement parts and transmissions.
2010 Big Twin Transmission Changes
Retrofitability2010 Big Twin Transmission Changes
• The mainshaft is retrofitable as a kit that contains the mainshaft, guide hub, snap ring and needle bearing.– Will require the new mainshaft inner primary bearing
race.
• All replacement transmissions will come with the new mainshaft assembly (with the new gear hub).
• Upgrading to helical 5th is Not Retrofitable– Results of upgrading to the helical 5th gear
• Vehicle Speed slower than indicated by speedometer• The 6th gear light may not function correctly• No plan for new calibration
2009 VIN Scheme
2010 VIN SchemeChanges in the 8th and 9th
character
BX
BX
2010 VIN Changes
POSITION DESCRIPTION POSSIBLE VALUES
1 Market designation 1=Originally manufactured for sale within the United States5=Originally manufactured for sale outside of the United States
2 Manufacturer HD=Harley-Davidson
3 Motorcycle type 1=Heavyweight motorcycle (901 cc or larger)
4 Model See V.I.N. model table
5 Engine type 4=Twin Cam 96™, 1584 cc air cooled, fuel injected
6 Introduction date/ calibration 1 = Regular introduction date/ 49 State calibration2 = Mid-year introduction date/ 49 State calibration3 = Regular introduction date/ California calibration4 = Cosmetic changes and/or special introductory date/
California calibration5 = cosmetic changes and/or special introductory date/
California calibration6 = California/mid-year/ California calibrationA = Regular introduction date CAN Calibration B = Mid-year introduction date/ CAN Calibration C = Regular introduction date HDI Calibration D = Mid-year introduction date/ HDI Calibration E = Regular introduction date JPN Calibration F = Mid-year introduction date/ JPN Calibration G = Regular introduction date AUS Calibration H = Mid-year introduction date/ AUS Calibration J = Regular introduction date BRZ CalibrationK = Mid-year introduction date/ BRZ Calibration
7 V.I.N. check digit Can be 0-9 or X
8 Model year 5 = 2005 6 = 2006 7 = 2007 8 = 20089 = 2009
A = 2010B = 2011C = 2012D = 2013E = 2014
9 Assembly plant 1981 T0 2009T = Tomahawk, WIY = York, PA K = Kansas City, MOM = Manaus, Brazil3 = Buell East Troy
2010 TO 2039A = Tomahawk, WIB = York, PA C = Kansas City, MOD = Manaus, BrazilE = Buell East Troy
10 Sequential number Varies
2010 VIN Changes
New spherical exhaust port pipe endform offers improved seal and fitment.
All Big Twin Models
New Battery
Same external geometry and cable interface with a new internal design.
2010 Dyna® Models
2010 Dyna® Models(Returning Models)
FXD FXDB FXDC
FXDFFXDL(Japan only)
2010 Dyna® Suspension Changes
• No changes to front forks except for torques and fork oil level
• No changes to FXDF or FXDL
• All Dyna® models now use the FXDB belt tension specification
• The chart to the right explains which rear shocks were used on 2009 models and which shocks will be used on 2010 models.
2009 vs. 2010 Dyna® Shocks
2009 Rear Shocks
2010 Rear Shocks
FXD 54517-06 54615-01
FXDB 54615-01 54615-01
FXDC 54512-90A 54615-01
FXDL 54534-09 54615-01
FXDF 54537-08A 54537-08A
FXDWG 54615-01 54615-01
2010 Dyna® Models
• Wider tunnels on all fuel tanks• New Guide for Assembly to Protect Paint
2010 Dyna® Models
• 7-pin design floating rotors on all models with laced wheels
2010 Dyna® ModelsExhaust System Updates
• Meet MY2010 EPA Emissions regulations for all Harley-Davidson® vehicles sold in 50 state and Canadian markets
• Reduce oxygen intrusion into the exhaust system– Promotes catalyst health and efficiency
New rib/curl pipe end feature offers positive muffler stop and improved pipe consistency.
2010 Dyna® Models
Crossover joints updated with new clamp and gasket.
Updated joint
New clamp (Comes w/gasket)
New Gasket
Torque 15-19 ft-lbs(20.3-25.8 Nm)
2010 Dyna® Models
New 2010 FXDWG Wide Glide®
New 2010 FXDWG Wide Glide®
New rear fender
New Floating Front Brake Rotors*
New fuel tank with wider tunnel*
*All Dyna® Models
Current FXDB solo seat with new cover
New sissybar
New pillion
Current FXDWG front forks with 1” shorter overall length
Current FXDWG front wheel (steel) (21x2.15) black rim with chrome spokes & machined hub; Front tire pattern – GT402
FXDWG front fender
34 degree frame with tank mount boss raised by ¾”New handlebar with
FXDF risers/caps
*Michelin® tires on all but FXDF and FXDWG
FXDB rear wheel (black rim with chrome spokes) (17x4.5) (180-60x17), rear tire pattern – GT502 (Screamin’ Eagle®)
FXDF exhaust pipes & mufflers with chrome exhaust shields
Gloss black rear forging covers
Current FXDB rear shocks with top covers
Current FXDC battery cover with chrome Wide Glide® trim
Forward foot controls
New 2010 FXDWG Wide Glide®
Domestic tail lights Canada & all International tail lights
Taillight (HDI/Canada)
Side mount license plate
Domestic only
• Internally wired handlebar
• 34 degree frame with tank mount boss raised by ¾” & rear forgings moved out 2mm each side from FXDF
• Flame tank replacement part is VIN restricted
• Two new rear fenders (Domestic & HDI/Canada)
New 2010 FXDWG Wide Glide®
2010 Softail® Models
Softail® Custom
Heritage Softail®Classic
Softail® Standard (Australia & Japan only)
Softail® Deluxe Softail® Rocker™ C
Heritage® Custom (Brazil only)
Softail® Cross Bones® Fat Boy®
2010 Softail® Models(Returning Models)
2 Softail® models havebeen dropped for 2010
Night Train® Rocker®
2010 Softail® Models
NEW 2010 FLSTFB Fat Boy® Lo
(Fat Boy® Special in HDI and HDE markets)
Mufflers/Shields in Satin Chrome finish
Seat and pillion with carryover base and new contour / cover
Oil Tank finish Denim Black
Lowered rear suspension (uses FLSTN shocks – except
for HDI and HDE models)
Exhaust shields in Cermet high temp ceramic coating
Exhaust Pipes• New end forms at head &
muffler joints• New pipe to muffler clamp &
gasket
Mufflers• New internals – better
sealing at the catalyst• New pipe to muffler seal• California & 49-state
mufflers commonized
Rocker crossover tube• Mounting wedges removed• New interconnect gasket• Adding clamps at interconnect
joints
Rocker Main Harness• Changes to facilitate
commonizing gnd. location with the rest of the Softail family
Rear Fender Electrical Routing • Rocker rear fender – change rivets to
push pins• Add grommet to rear lighting harness on
all Bobtails
Transmission• Helical 5th gear in
transmission
New Master Cylinder Cap/Gasket• Changes to the master cylinder cap and
gasket to improve sealing
2010 Softail® Models
Fuel Tank Panel
Change holes
Adding ABS Back and UV Protection to Leather
2010 FLSTC Softail® Models
Softail® Engine Bracket• Change to zinc plated
finish for better clamp load retention
2010 Softail® Models
56206-96
Old
56248-08
New
Removed rib to allow for more compliance with the switch housing location.
2010 Softail® Models
FLSTF New Grip
• Used on all Softail®Models
• No tie-wrap needed Retention ring to slide cable through
Positive Battery Cable Boot
2010 Softail® Models
FXCWC left hand slider change
46953-08A FXCWC
Changes in radii
2010 Softail® Models
FXCWC Front Brake line
Added Grommet with P-clip to bottom of
steering stem
2010 Softail® Models
One-Piece insert
Two-Piece insert (current)
New Horn Isolator Design
2010 Softail® Models
New Horn
Breather hole re-located from diaphragm to bottom side of connector.
2010 Softail® Models
New Master Cylinder Cap and Gasket
2010 Softail® Models
Rear Fender Lighting Harness Grommet• Improvement to address possible wire chafing• Only on Bobtail rear lighting harnesses
2010 Softail® Models
®
2010 Sportster® Models
2010 Sportster® Models883 Models (Domestic / HDI)
XL 883L XL 883N
XL 883R (HDI only)
XL 1200C
XL 1200N
XL 1200L
XR1200™
2010 Sportster® Models1200 Models (Domestic / HDI)
2010 XL Sportster® Content
• ECM relocation to down tube behind rear cylinder– Design allows for XL harness to be installed in the same
assembly location as XR harness
• Consolidation and reorientation of fuse block– Addresses current warranty concern (water intrusion/corrosion)
by positioning the fuse block in a downward sloping orientation and adding a protective cover
– Consolidation of wire harness circuits has reduced the amount offuses within the fuse block
• New oil tank
• New oil tank bracket– Dual purpose mounting of oil tank and ECM Caddy
2010 Sportster® Oil Tank
1. Added 10 psi. Pressure Relief Valve Assembly:– The oil tank has a pressure relief
valve in the top of the tank– If the vent line is pinched, restricted
or if the tank is overfilled, excessive pressure is created in the oil tank
– The valve opens if the pressure in the tank exceeds 10 psi. to prevent damage to the oil tank
2. New XL Oil Return Line location, moved to right hand side of XL models due to the ECM relocation.
New 2010 XR1200X™(International)
New 2010 XR1200X™(International)
• Project Description – Higher specification XR variant that complements the base XR1200™ model and provides key chassis performance features.
• Key Features:– Blacked out theme; engine, exhaust, paint, graphics– Fully adjustable high performance suspension– Highlighted wheels– Floating front rotors – New graphics and denim paint
New 2010 XR1200X™(International)
• New Big Piston Forks– High performance light weight front fork– Adjustable rebound and compression on top of the fork– Spring pre-load adjuster on the bottom of the fork– Requires the use of Harley-Davidson® BPF Performance Fork Oil (99885-10)
• New Rear Shock Absorbers– Fully adjustable (adjustable compression damping, rebound damping and spring
preload), with attached reservoir.
• Consolidation and reorientation of fuse block– Addresses current warranty concern (water intrusion/corrosion) by positioning
the fuse block in a downward sloping orientation and adding a protective cover.– Consolidation of wire harness circuits has reduced the amount of fuses within the
fuse block.
• New oil tank
• New oil tank bracket– Dual purpose mounting of oil tank and the H-Clip.
XL/XR 2010 Exhaust Content
• Carryover XL Interconnect/Support Bar– Move to a common interconnect/support bar for all
models– 65339-04 will go across all models
• New XR Header Pipes– Updated Catalyst– Catalyst is still located in header pipe assembly
(same as 2009)
2010 Touring Models
2010 Touring Models(Returning Models)
FLHTCU FLHTC FLHX
FLHRC FLHRFLHT(England, HDI, Japan)
NEW 2010 FLTRX Road Glide® Custom
• Shared content with the FLHX– Cruise Optional– 2 into 1 exhaust– Stop-tail-turn rear light bar and
new fender harness
Road Glide®Headlamp Changes
• Bubble replaced with shroud (similar to the P&A 2009 design)
• Headlamp mounting bracket modified to service bulbs without removing fairing. Allows replacement from the front.
• It is not recommended to retrofit the shroud on earlier model year vehicles since the head lamps also changed to tolerate exposure.
Bubble
Shroud
Road Glide®Fairing Mount Changes
The outer/inner fairing is lifted up 0.800” and tipped 2 degrees forward.
1.5” Angled Fairing BracketsTwo parts
•Left Side •Right Side
Inner Fairing to Frame Stamped Mount-Studs are moved 7/8” higher-Clearance made to bottom front edge of mount
Canadian Rear Lighting(FLHX/FLTRX)
Conventional tail light with amber directionals.
HDI Rear Lighting(FLHX/FLTRX)
• Directional is LED, amber circle inset for turn signal• Red LED panel for stop/running light
2010 FLHTK Electra Glide® Ultra Limited
• FLHTK - Electra Glide® Ultra Limited• The upgrade for the average Ultra Classic® Electra
Glide® customer• Top of the line in touring and rider comfort• Unique Two – Tone paint
• Twin Cam 103™ Engine (1690cc)• with Oil Cooler (no Cover)• with chrome accents
• Heated Hand Grips
• Cruise Control
• ABS
• Security System
• Tour-Pak® assembly with luggage rack and 12V power supply
2010 FLHTK Electra Glide® Ultra Limited
Other Touring Changes for the2010 Model Year
• Brembo® Front Plastic Master Cylinder Piston– Plastic Master Cylinder pistons are an industry
standard
• Brembo® Plastic Rear Master Cylinder Cap (Running Change for 2010)
NEWOLD
NEWOLD
Saddlebag Bracket Improvement
Bracket change to accommodate the new 2 into 1 exhaust on FLHX and FLTRX
2010 Touring PassengerFoot Board Bracket Update
• Passenger Foot Board Bracket change– Adding bolt to bottom of bracket– Upper bolt can be removed to adjust bracket, lower bolt is a
shoulder bolt and remains in place during bracket adjustment
New Heated Oxygen Sensor for 2010 Touring Models Only
• New smaller heated oxygen sensors will be integrated into the front pipe casting.
• New sensor is a 4 wire narrow band sensor.
• New service tool (HD-50017) is needed to torque the new heated O2 sensors.
New Old
2010 Trike Models
2010 Trike Offerings
2010 Trike Models
FLHTCUTG
FLHXXX
2010 Trike Models
• Powertrain: Twin Cam 103™ Engine (1690cc); unique reinforced trans case, Trike specific Engine Mounts, unique snubber nuts, and pivot shaft torque
• Driveline: 70T sprocket, 1 1/8” belt, rear axle/diff assembly, rear drive compensation, reverse
• Suspension: Tuned rear shocks, Extended front forks – Unique sliders, Fork Tubes, Springs
• Exhaust: Header pipes – modified 2010 Touring• Wheels: Matching front and rear cast alum wheels. Center rear hub cap.• Triple clamp: Unique triple clamp with reduced trail for optimized steer
effort, reduced steer angle
• Triple clamp integration: Unique inner fairing, and fairing skirt, CVO™ Passing lamp/ turn signal bar for Tri Glide™, FLHX front turn signals for Street Glide® Trike
• Steer Damper: Ohlins® damper• Tires: Automotive type Dunlop® Rears 205/65R15, front tire is a 16”
43022-91A• Brakes: Brembo® dual front, Hayes® Rear disc brakes, Parking brake• Speedo: Unique Calibration• Front fender: Bumper removed FLHTCUTG and FLHX front fender on
FLHXXX
2010 Trike Models
• New Main Wiring Harnesses (reverse integrated rather than overlay)
• New Interconnect Harness (includes heated grip connectors)• New Tail Light Harness• Common Lower Fairing Caps with Touring models• Improved Trunk Door Seal
– Will retro-fit• Updated Reverse Switch Housing with Revised Switch Graphics
– Will retro-fit
2010 Trike® Models
• Relocated Reverse Circuit Breaker and Solenoid
• Reduced Rear Brake Effort(New Master Cylinder and Calipers – will retro-fit)
• Steer Damper (improved temperature range-will retro-fit)
2010 Trike® Models
• Heated O2 Sensors
• Exhaust Catalyst / New right side exhaust for North America
• Helical 5th Gear
• Passenger Floorboard Support
2010 Trike® Models
Reverse Circuit Breaker Relocation(New for 2010)
2010 Trike® Models
Solenoid and Circuit breakerunder right side cover.
• Unique steer damper bracket on the frame due to no engine guard.
• Unique body for antenna and no Tour-Pak® assembly.
2010 FLHXXX Street Glide®Trike
Antenna Location
2010 FLHXXX Street Glide®Trike
Antenna wire from main harness.
Ground Plate capturedby body fasteners in4 places
2010 FLHXXX Street Glide®Trike
2010 FLHTCUTG GRAB HANDLE MOUNT
Grab HandleFLHTCU Seat
2010 FLHTCUTG Tri Glide™Ultra Classic® Models
2010 FLHXXX GRAB STRAP MOUNT
Grab Strap
2010 FLHXXX Street Glide®Trike Models
• FLHXXX unique Tour-Pak® kit – to keep antenna on body
• Passenger Backrest and Rack for FLHXXX• Shown below - FLHTCUTG with Chrome Rear
Guard and H-D® V-Logo Mud Flaps
2010 Trike Models P&A Options
2010 VRSC™ Models
2010 VRSC™ Models
VRSCAW
VRSCF
VRSCDX
• No major changes
• New wheel assemblies for lead free wheel weights – running change
• New battery part number suffix
• New Brembo® front brake master cylinder and plastic piston
• No changes for V-Rod® exhaust systems between 2009 & 2010 model year
• Japan Muffler e-mark
2010 VRSC™ Models
2010 CVO™ Models
2010 FXDFSE2 CVO™Fat Bob®
2010 FXDFSE2 CVO™Fat Bob®
Diamond Black Collection Pegs and Grips
Paint colors:Cryptic Black w/Hellfire Flames
Satin Pewter w/Sandstorm Grind
Opal Blue w/Hellfire Flames
Denim Tinted Clear Frame and Swing Arm (Satin Pewter only)
Midnight Pearl Headlight Bucket, Derby Cover, Horn Cover, Fender Strut Cover
Distressed Brown Leather Seat –Convertible to Solo Chrome and Rubber
Custom Fender Protector (not shown)
Shor’tee Belt GuardSlotted Sprocket
Midnight Pearl Taillight Cover, Fender Strut Cover, Timer Cover, Console Cover
Diamond Black Accents – Battery Cover Trim, Timer Cover Insert, Derby Cover Insert, Caliper Inserts, Intake Emblem Insert, Spoiler Insert, Gauge Faces
Black Header Pipes
Fang Wheels
Black Solid RotorsDiamond Black Brake Pedal Pad
Profile Custom Mirrors with Solid Stem
2010 FXDFSE2 CVO™Fat Bob®
2010 FLHTCUSE5 CVO™ Ultra Classic® Electra Glide®
Paint colors:Color 1:Scarlet Red Pearl/Dark Slate (as shown)
Color 2: Riptide Blue/Titanium Dust
Color 3: Burnt Amber/Hot Citrus
Rumble Collection windshield trim
Roulette Wheels
Teardrop rotors
New Adjustable passenger backrest w/ perforated leather insert (black knob)
New Color-matched LED wrap-around (HDI will include side covers)
New CVO™fuel door medallion
New Rear fender, CVO™medallion
Rumble Collection Shifter pegs
Midframe deflectors Rumble Collection Saddlebag Latches
Air Wing Tour-Pak®luggage rack
New 12V, Power outlet
2010 FLHTCUSE5 CVO™ Ultra Classic® Electra Glide®
FLHTCUSE5 – Riptide
Dual Heated Seat w/ NewPerforated leather insert
Adj. rider backrest w/ New Perforated leather insert
New Tour-Pak® bottom liner (integrated map, sunglass & phone pouches)
Rumble Collection heated hand grips & mirrors
New Tour-Pak®lid insert w/ dimple design
Rumble Collection Passenger Inserts
Rumble Collection Rider Inserts
Rumble Highway pegs
New A/C insert w/dimple design
New CB pod insert w/dimple design
New Tour-Pak®and saddlebag lights
2010 FLHTCUSE5 CVO™ Ultra Classic® Electra Glide®
2010 FLHXSE CVO™Street Glide®
Three Color Selections:Color 1: Spiced Rum with Gold Leaf Graphics Color 2: Candy Concord with Pale Gold Leaf GraphicsColor 3: Tequila Sunrise with Pale Gold Leaf Graphics
D407 130/70 B18 Front Tire
New 18” Contrast Chrome 7 Spoke Cast Wheels
Seat Buckle w/New Seat Strap
New Custom SeatNew French Stitched Passenger Backrest
New One Piece Extended Saddlebags
New Helical 5th Gear
OE Color Matched Saddlebag Latches
D407 180/55 B18 Rear Tire
Mustache Engine Guard with New Rubber Pad
Color Matched Beer Cans & Fairing Skirt
P+A Fairing Trim
Gloss Black Inner Fairing for All 3 Colors
FLHX T/S with Smoked Lens
New Timer Cover Insert w/Engine Turn New A/C Insert
w/Engine Turn
New Trimmed Front Fender
New Black Brake/Clutch Lines w/Chrome Fittings Except for Braiding to the Front Calipers
Black Front Caliper Chrome Screen/CVO™ Insert
Chrome Oil Cooler Cover
OE Black Rubber Tank Tab Cover
New Directional 7 Spoke Rotors Floating Design
2010 FLHXSE CVO™Street Glide®
Full Extended Saddlebags
LED Stop Tail Turn Signals
New Hand Adjustable Rear Suspension (adjustment on left side)
Standard FLHX Mirrors
Spun Aluminum Metal Faced Gages
Standard FLHX Windscreen (2 versions-DOM/HDI)
Mufflers and End CapsColor Matched LP Light Cover
Color Matched Frame Covers
Color Matched Rear Fascia
New ACR Bracket to hold wires
Chrome Gas Cap Cover
Handlebars With Chrome Controls
2010 FLHXSE CVO™Street Glide®
2010 FLSTSE CVO™ Softail®Convertible
New 18”Stinger Wheels
New Clean Front Fender
New Waved Brake Rotors
New Handlebar w/ Rumble Collection Grips and Mirrors
New 2 Piece Console w/ Painted Accents
Rumble Collection Floorboards & Shifter Peg
New Seat w/ Genuine Buffalo Insert
New Detachable Passenger Pillion w/ Genuine Buffalo Insert
New Detachable Passenger Backrest & Upright
New 200mm Rear Tire with 18” x 6” Stinger Wheel
New Skirted Wide Rear Fender
Paint Colors
Inferno Orange w/ Vivid Black
Abyss Blue w/ Sapphire
Crimson Red Sunglo w/ Autumn Haze
2010 FLSTSE CVO™ Softail®Convertible
New 1.25” internally wired handlebars
New Digital Speedometer w/ Radial Tachometer
New Quick-Detach Saddle Bags
Slash Cut Dual Mufflers Color Match
Frame w/ Frame Inserts
Color Matched Oil Tank
Rumble Collection Brake Pad w/ Billet Lever
New High Flow Intake w/ Rain Sock Chrome Front End
New Quick-Detach Wind Deflector w/ Smoked Windshield
2010 FLSTSE CVO™ Softail®Convertible
New Rear Lighting w/ Integrated Stop/Tail/Turn Functions
New Rear Fender Support Covers w/ Saddlebag Locking Points
New Rear Fender Accent Strips
Chrome Headlight Trim Ring
2010 FLSTSE CVO™ Softail®Convertible