2010 Harley-Davidson® New Model and Technical Information

2010 Harley-Davidson® New
Model and Technical Information
All Big Twin Models
•
•
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)
2010 Big Twin
Transmission Changes
2009 - Earlier
2010 Model Year
5th Gear (Input)
5th Gear
(Countershaft)
Guide Hub
5th Gear (Input)
5th Gear
(Countershaft)
Guide Hub
2010 Big Twin
Transmission Changes
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
Retrofitability
•
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
2010 VIN Changes
2009 VIN Scheme
BX
2010 VIN Scheme
BX
Changes in
the 8th and 9th
character
2010 VIN Changes
POSITION
DESCRIPTION
POSSIBLE VALUES
1
Market designation
1=Originally manufactured for sale within the United States
5=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 calibration
2 = Mid-year introduction date/ 49 State calibration
3 = Regular introduction date/ California calibration
4 = Cosmetic changes and/or special introductory date/
California calibration
5 = cosmetic changes and/or special introductory date/
California calibration
6 = California/mid-year/ California calibration
A = 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 Calibration
K = Mid-year introduction date/ BRZ Calibration
7
V.I.N. check digit
Can be 0-9 or X
8
Model year
9
Assembly plant
1981 T0 2009
T = Tomahawk, WI
Y = York, PA
K = Kansas City, MO
M = Manaus, Brazil
3 = Buell East Troy
10
Sequential number
Varies
5 = 2005
6 = 2006
7 = 2007
8 = 2008
9 = 2009
A = 2010
B = 2011
C = 2012
D = 2013
E = 2014
2010 TO 2039
A = Tomahawk, WI
B = York, PA
C = Kansas City, MO
D = Manaus, Brazil
E = Buell East Troy
All Big Twin Models
New spherical exhaust port pipe endform offers improved seal
and fitment.
New Battery
Same external geometry and
cable interface with a new
internal design.
2010 Dyna® Models
2010 Dyna® Models
(Returning Models)
FXD
FXDC
FXDB
FXDF
FXDL
(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® Models
Exhaust System Updates
•
Meet MY2010 EPA Emissions regulations for all HarleyDavidson® vehicles sold in 50 state and Canadian markets
•
Reduce oxygen intrusion into the exhaust system
– Promotes catalyst health and efficiency
2010 Dyna® Models
New rib/curl pipe end feature offers positive muffler stop and
improved pipe consistency.
2010 Dyna® Models
Updated joint
Crossover joints updated with
new clamp and gasket.
New Gasket
New clamp
(Comes w/gasket)
Torque 15-19 ft-lbs
(20.3-25.8 Nm)
New 2010 FXDWG
Wide Glide®
New 2010 FXDWG
Wide Glide®
*All Dyna® Models
New handlebar with
FXDF risers/caps
New sissybar
34 degree frame with tank
mount boss raised by ¾”
New fuel tank with
wider tunnel*
Current FXDC battery cover with
chrome Wide Glide® trim
New rear fender
Gloss black
rear forging
covers
New pillion
Current FXDB
rear shocks with
top covers
Current FXDB solo seat
with new cover
Current FXDWG front forks
with 1” shorter overall
length
FXDWG front fender
New Floating Front Brake
Rotors*
FXDB rear wheel
(black rim with
chrome spokes)
(17x4.5) (18060x17), rear tire
pattern – GT502
(Screamin’ Eagle®)
Forward foot controls
*Michelin® tires on all but FXDF
and FXDWG
FXDF exhaust pipes & mufflers with chrome
exhaust shields
Current FXDWG front wheel (steel) (21x2.15) black rim with
chrome spokes & machined hub; Front tire pattern – GT402
New 2010 FXDWG
Wide Glide®
Domestic tail lights
Side mount
license plate
Domestic only
Canada & all International
tail lights
Taillight
(HDI/Canada)
New 2010 FXDWG
Wide Glide®
•
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)
2010 Softail® Models
2010 Softail® Models
(Returning Models)
Heritage® Custom
Softail® Standard
(Brazil only)
(Australia & Japan only)
Softail® Custom
Softail® Deluxe
Softail® Rocker™ C
Heritage Softail®
Classic
Softail® Cross Bones®
Fat Boy®
2010 Softail® Models
2 Softail® models have
been dropped for 2010
Night Train®
Rocker®
NEW 2010 FLSTFB
Fat Boy® Lo
(Fat Boy® Special in HDI and HDE markets)
Seat and pillion with
carryover base and new
contour / cover
Mufflers/Shields in Satin
Chrome finish
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
2010 Softail® Models
Rear Fender Electrical Routing
• Rocker rear fender – change rivets to
push pins
• Add grommet to rear lighting harness on
all Bobtails
Rocker Main Harness
• Changes to facilitate
commonizing gnd. location
with the rest of the Softail
family
New Master Cylinder Cap/Gasket
• Changes to the master cylinder cap and
gasket to improve sealing
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
Exhaust Pipes
Transmission
• New end forms at head &
muffler joints
• New pipe to muffler clamp &
gasket
• Helical 5th gear in
transmission
2010 FLSTC Softail® Models
Fuel Tank Panel
Change holes
Adding ABS Back and UV
Protection to Leather
2010 Softail® Models
Softail® Engine Bracket
• Change to zinc plated
finish for better clamp
load retention
2010 Softail® Models
FLSTF
56206-96
New 56248-08
Grip
Removed rib to allow for
more compliance with the
switch housing location.
Old
New
2010 Softail® Models
Positive Battery Cable Boot
• Used on all Softail®
Models
• No tie-wrap needed
Retention ring
to slide cable
through
2010 Softail® Models
46953-08A
FXCWC
FXCWC left hand slider
change
Changes in radii
2010 Softail® Models
FXCWC Front Brake line
Added Grommet with
P-clip to bottom of
steering stem
2010 Softail® Models
New Horn
Isolator Design
Two-Piece insert (current)
One-Piece insert
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 Sportster® Models
2010 Sportster® Models
883 Models (Domestic / HDI)
XL 883N
XL 883L
XL 883R (HDI only)
2010 Sportster® Models
1200 Models (Domestic / HDI)
XL 1200C
XL 1200L
XL 1200N
XR1200™
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 of
fuses 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
FLHT
FLHRC
FLHR
(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.
Inner Fairing to Frame Stamped Mount
-Studs are moved 7/8” higher
-Clearance made to bottom
front edge of mount
1.5” Angled Fairing Brackets
Two parts
•Left Side
•Right Side
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
2010 FLHTK
Electra Glide® Ultra Limited
• 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
Other Touring Changes for the
2010 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)
Saddlebag Bracket
Improvement
Bracket change to
accommodate the new 2
into 1 exhaust on FLHX
and FLTRX
NEW
OLD
NEW
OLD
2010 Touring Passenger
Foot 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
2010 Trike Models
•
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)
Solenoid and Circuit breaker
under right side cover.
2010 FLHXXX Street Glide®
Trike
• 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
Ground Plate captured
by body fasteners in
4 places
Antenna wire from
main harness.
2010 FLHTCUTG Tri Glide™
Ultra Classic® Models
2010 FLHTCUTG GRAB
HANDLE MOUNT
FLHTCU Seat
Grab Handle
2010 FLHXXX Street Glide®
Trike Models
2010 FLHXXX GRAB STRAP MOUNT
Grab Strap
2010 Trike Models
P&A Options
• 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 VRSC™ Models
2010 VRSC™ Models
VRSCAW
VRSCDX
VRSCF
2010 VRSC™ Models
•
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 CVO™ Models
2010 FXDFSE2 CVO™
Fat Bob®
2010 FXDFSE2 CVO™
Fat Bob®
Paint colors:
Cryptic Black w/Hellfire Flames
Midnight Pearl Headlight Bucket, Derby
Cover, Horn Cover, Fender Strut Cover
Satin Pewter w/Sandstorm Grind
Opal Blue w/Hellfire Flames
Distressed Brown Leather Seat –
Convertible to Solo
Chrome and Rubber
Custom Fender
Protector (not shown)
Denim Tinted Clear Frame and
Swing Arm (Satin Pewter only)
Diamond Black Collection
Pegs and Grips
Slotted Sprocket
Shor’tee Belt Guard
2010 FXDFSE2 CVO™
Fat Bob®
Midnight Pearl Taillight
Cover, Fender Strut
Cover, Timer Cover,
Console Cover
Profile Custom Mirrors
with Solid Stem
Diamond Black Accents – Battery Cover
Trim, Timer Cover Insert, Derby Cover
Insert, Caliper Inserts, Intake Emblem Insert,
Spoiler Insert, Gauge Faces
Fang
Wheels
Black Header Pipes
Diamond Black Brake Pedal Pad
Black Solid
Rotors
2010 FLHTCUSE5 CVO™ Ultra
Classic® Electra Glide®
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
New Adjustable passenger
backrest w/ perforated
leather insert (black knob)
New CVO™
fuel door
medallion
Air Wing Tour-Pak®
luggage rack
New Colormatched LED
wrap-around (HDI
will include side
covers)
New 12V, Power outlet
Roulette
Wheels
New Rear fender, CVO™
medallion
Teardrop rotors
Rumble Collection
Shifter pegs
Midframe deflectors
Rumble Collection
Saddlebag Latches
5 – Riptide
FLHTCUSE
2010
FLHTCUSE5
CVO™ Ultra
Classic® Electra Glide®
Adj. rider backrest w/ New
Perforated leather insert
New Tour-Pak® bottom liner
(integrated map, sunglass &
phone pouches)
New Tour-Pak®
lid insert w/
dimple design
New CB
pod insert
w/dimple
design
Rumble Collection
heated hand grips
& mirrors
Dual Heated
Seat w/ New
Perforated
leather
insert
New Tour-Pak®
and saddlebag
lights
Rumble Highway
pegs
New A/C insert
Rumble Collection w/dimple design Rumble Collection
Passenger Inserts
Rider Inserts
2010 FLHXSE CVO™
Street 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 Graphics
Color 3: Tequila Sunrise with Pale Gold Leaf Graphics
Gloss Black Inner
Fairing for All 3
Colors
New Timer Cover
Insert w/Engine
Turn
New A/C Insert
w/Engine Turn
Seat Buckle w/New
Seat Strap
New French Stitched
Passenger Backrest
OE Color Matched
Saddlebag Latches
New 18” Contrast Chrome
7 Spoke Cast Wheels
D407 180/55 B18 Rear Tire
D407 130/70 B18 Front Tire
P+A Fairing Trim
FLHX T/S with
Smoked Lens
Color Matched Beer Cans &
Fairing Skirt
Mustache Engine
Guard with New
Rubber Pad
New Custom Seat
New Trimmed Front Fender
New Directional 7
Spoke Rotors
Floating Design
New Helical 5 Gear
th
New One Piece Extended Saddlebags
OE Black Rubber
Tank Tab Cover
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
2010 FLHXSE CVO™
Street Glide®
Standard FLHX
Windscreen (2
versionsDOM/HDI)
New Hand
Adjustable Rear
Suspension
(adjustment on
left side)
Spun Aluminum
Metal Faced
Gages
Standard FLHX
Mirrors
Handlebars With
Chrome Controls
Color Matched
Frame Covers
Chrome Gas
Cap Cover
Color Matched
Rear Fascia
New ACR
Bracket to hold
wires
Full Extended Saddlebags
LED Stop Tail Turn
Signals
Color Matched
LP Light Cover
Mufflers and End Caps
2010 FLSTSE CVO™ Softail®
Convertible
2010 FLSTSE CVO™ Softail®
Convertible
Paint Colors
Inferno Orange w/ Vivid Black
Abyss Blue w/ Sapphire
Crimson Red Sunglo w/ Autumn Haze
New Handlebar w/
Rumble Collection
Grips and Mirrors
New 2 Piece
Console w/
Painted Accents
New Seat w/
Genuine
Buffalo Insert
New Clean
Front Fender
New Detachable
Passenger Pillion w/
Genuine Buffalo Insert
New Detachable
Passenger Backrest
& Upright
New Skirted
Wide Rear
Fender
New
Waved
Brake
Rotors
New 18”
Stinger
Wheels
Rumble Collection
Floorboards &
Shifter Peg
New 200mm Rear Tire with
18” x 6” Stinger Wheel
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
New High
Flow Intake w/
Rain Sock
Color Match
Frame w/
Frame Inserts
New Quick-Detach
Wind Deflector w/
Smoked Windshield
Chrome Front End
Color
Matched
Oil Tank
Rumble Collection
Brake Pad w/ Billet
Lever
2010 FLSTSE CVO™ Softail®
Convertible
Chrome Headlight
Trim Ring
New Rear Fender
Support Covers w/
Saddlebag Locking
Points
New Rear
Lighting w/
Integrated
Stop/Tail/Turn
Functions
New Rear Fender
Accent Strips