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 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


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)


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®


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


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


56206-96

Old

56248-08

New

Removed rib to allow for more compliance with the switch housing location.


FLSTF New Grip

• Used on all Softail®Models

• No tie-wrap needed Retention ring to slide cable through

Positive Battery Cable Boot


FXCWC left hand slider change

46953-08A FXCWC

Changes in radii


FXCWC Front Brake line

Added Grommet with P-clip to bottom of

steering stem


One-Piece insert

Two-Piece insert (current)

New Horn Isolator Design


New Horn

Breather hole re-located from diaphragm to bottom side of connector.


New Master Cylinder Cap and Gasket


Rear Fender Lighting Harness Grommet• Improvement to address possible wire chafing• Only on Bobtail rear lighting harnesses


®

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)


• 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 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


Antenna wire from main harness.

Ground Plate capturedby body fasteners in4 places


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®


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 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


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 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


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 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


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


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 Model Year Technical Forum

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