Harley Davidson Mechanics Course

Lesson 1 • Four-Stroke Combustion Cycle

Teaches intake, compression, power, and exhaust strokes with valve timing overlap. Links combustion efficiency to performance tuning decisions.

Lesson 2 • Bottom-End Assembly and Tolerances

Covers crankshaft, connecting rods, and flywheel truing procedures. Learners apply torque specs and bearing clearances to ensure reliable assembly.

Lesson 3 • V-Twin Architecture and Design

Covers 45-degree cylinder angle, crankcase design, and firing order logic. Connects engine geometry to vibration characteristics and power delivery.

Lesson 4 • Engine Lubrication System

Explains dry-sump oil circulation, pump operation, and oil pressure diagnostics. Connects lubrication health to long-term engine reliability.

Lesson 1 • Fuel Delivery and Tank Systems

Covers in‑tank fuel pump modules, line routing, pressure regulators, and return systems, emphasising venting, leak detection, and testing. Learners perform checks, replace pumps, and confirm fuel delivery.

Lesson 2 • Air Intake and Filtration Systems

Covers stock and aftermarket air cleaner designs and airflow impact. Connects intake restriction to engine breathing and tuning requirements.

Lesson 3 • Electronic Fuel Injection Fundamentals

Explains throttle body design, injector operation, and fuel control with map reading, flow testing, and calibration. Shows sensor inputs and ECU algorithms deliver precise fuel for power and drivability.

Lesson 4 • Carburettor Theory and Service

Covers CV carburettor circuits, jet sizing, needle adjustment, cleaning, synchronization, and troubleshooting. Links ratio control to throttle response, idle quality, emissions compliance, and Harley models.

Lesson 1 • Live Data Analysis and Graphing

Teaches PID selection, real‑time graphing, and min/max capture for diagnosing faults using data filtering, overlay comparison, and trend analysis. Links patterns to component failures and sensor anomalies.

Lesson 2 • Actuator Tests and Module Resets

Covers injector, fuel pump, and relay actuator tests using scan tool commands. Learners perform idle relearn, throttle body reset, and adaptations.

Lesson 3 • Fault Code Retrieval and Clearing

Identifies active, stored, and historical DTCs across all Harley modules. Learners interpret code definitions and prioritise diagnostic sequence.

Lesson 4 • Scan Tool Connection and Setup

Covers DLC location, scan tool pairing, and module communication setup. Learners connect to ECM, BCM, and ABS modules for full-system access.

Lesson 1 • Charging System Diagnostics

Teaches stator, regulator/rectifier, and battery interaction under load. Learners perform output tests and identify charging system failures.

Lesson 2 • Lighting and Accessory Circuits

Explains headlight, turn signal, and accessory circuits, covering fuse sizing, relay function, wiring layouts, and common failures. Learners diagnose blown fuses, failed relays, and ground issues.

Lesson 3 • Starting System Components

Identifies starter motor, solenoid, and relay circuit operation. Connects cranking amperage draw to starter and battery condition diagnosis.

Lesson 4 • Wiring Harness and Connectors

Covers Harley wiring diagrams, connector types, and harness routing. Learners use schematics to trace circuits and repair open or short faults.

Lesson 1 • Brake Pad and Rotor Service

Teaches pad thickness measurement, rotor runout, and minimum thickness specs. Learners replace pads and rotors and bed-in new friction material.

Lesson 2 • Brake bleeding and fluid flush

Covers manual, vacuum, and pressure bleeding methods for front and rear circuits. Connects complete air removal to firm lever and pedal feel.

Lesson 3 • ABS Module Diagnostics

Identifies ABS wheel speed sensors, modulator, and fault code retrieval. Learners test sensor ring tone and interpret ABS diagnostic trouble codes.

Lesson 4 • Hydraulic Brake System Fundamentals

Covers master cylinder, caliper, and brake line operation under hydraulic pressure. Links fluid condition and air contamination to brake feel.

Lesson 1 • Air Filter and Spark Plug Service

Teaches filter inspection criteria and spark plug reading for combustion diagnosis. Connects plug condition to fuel mixture and ignition timing accuracy.

Lesson 2 • Pre-Delivery and Safety Inspection

Explains PDI checklist, test ride verification, and customer handoff documentation. Connects thorough inspection to liability reduction and customer confidence.

Lesson 3 • Engine and Transmission Fluids

Identifies correct viscosity grades, capacities, and drain/fill procedures for all sumps. Learners select fluids and perform complete fluid exchanges.

Lesson 4 • Cable, Control, and Fastener Inspection

Covers throttle cable freeplay, brake lever adjustment, and critical fastener torque. Learners identify frayed cables and loose fasteners before failure.

Lesson 1 • Frame Inspection and Geometry

Covers frame rake, trail, and neck bearing inspection for crash damage. Connects geometry measurements to straight-line stability and cornering.

Lesson 2 • Tire Selection and Mounting

Explains tyre load ratings, speed ratings, and bead seating procedure. Connects tyre profile to handling characteristics and rim compatibility.

Lesson 3 • Rear Suspension Setup

Covers shock preload, travel, and linkage inspection on Softail and Touring models, including sag measurement, spring rate selection, and damping adjustment. Learners set sag and damping to match weight goals.

Lesson 4 • Wheel Bearings and Axles

Identifies tapered and sealed wheel bearing types and axle torque specs. Learners replace bearings and set preload for safe wheel retention.

Lesson 1 • Clutch Assembly and Adjustment

Teaches wet clutch plate inspection, spring preload measurement, and cable or hydraulic adjustment, covering wear limits, friction material selection, and break‑in steps. Links setup to feel and power transfer.

Lesson 2 • Belt and Chain Final Drive

Explains rear belt tension, sprocket wear, and chain drive lubrication. Learners inspect and replace final drive components to specification.

Lesson 3 • Primary Drive System Service

Covers primary chain, compensator sprocket, and inner primary removal, inspecting chain wear, sprocket teeth, bearing condition, and lubrication. Links drive health to smooth clutch engagement.

Lesson 4 • Shifter Mechanism and Adjustment

Covers ratchet top, pawl carrier, and shift cam operation. Connects shifter adjustment to positive gear engagement and missed-shift prevention.