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
