HARLEY-DAVIDSON® MOTORCYCLE MECHANIC COURSES

Harley-Davidson Late Model

H-D Tech 1: Introduction to Vehicle Service

Parts and Service Literature Usage and Lookup Exercises

Students will become familiar with proprietary Harley-Davidson electronic dealer management systems, TALONes™ and service literature. This preliminary training and research supports students’ performing the hands-on service tasks in the lab.¹⁸

Harley-Davidson University™

Students will be encouraged to participate in the optional Harley-Davidson University PHD (Professional Harley-Davidson) program as part of their motorcycle training courses. This program is designed to allow students to begin the PHD assessment process while performing the lab tasks for the course. Assessment in the PHD-aligned courses is the first step in the Harley-Davidson Technician Recognition program, which upon completion makes it possible for graduates to enter the industry with important dealer training classes satisfied.^1.1

Combined with the skills learned in hands-on training labs, participation and achievement in this program will make MMI graduates more appealing to prospective employers in the Harley-Davidson dealership network. Students who participate in this program use the web-based Harley-Davidson University learning management site HDU Online™.

Setup and Service

Students are taught hands-on servicing of the various Harley-Davidson steering head assemblies and suspensions components. They will be taught tasks a technician is required to perform during scheduled vehicle maintenance to provide safe and proper handling. Students also have opportunities to complete the hands-on pre-assessment components required for eligibility to participate in the optional Harley-Davidson University PHD course equivalency.

H-D Tech 2: Introduction to Powertrain

Engines

Engine design fundamentals and operation, and the latest service bulletins from Harley-Davidson will be covered. Students disassemble and reassemble air-cooled and liquid-cooled engines to gain familiarity with the systems, including the oil pump and cam compartment. Students are also taught to inspect wear patterns and develop a detailed understanding of late-model Harley-Davidson lubrication systems. Current service publications will be used to explain service bulletins and updates in detail.

Transmissions

Students are taught the design fundamentals and functions of the six-speed, late-model transmission. Students will disassemble and reassemble these transmissions to gain familiarity with the systems.

Fuel Injection

Students will be introduced to the design and function of the Harley-Davidson fuel injection system and components. They also will learn about the H-D^® engine management system, including troubleshooting through use of authorized computer test equipment.

H-D Vehicle Maintenance

Vehicle Maintenance

Students get hands-on training as they put their service literature skills to use on Harley-Davidson motorcycles. Through interactive demonstrations, they are taught about rear-wheel services, drive system adjustments, cable replacements and brake services. Students also are introduced to the Harley-Davidson Digital Technician II. Students use this diagnostic computer to perform initial setup and servicing of Harley-Davidson motorcycles. After interactive demonstrations, students perform scheduled tasks with assistance as needed from the instructor. Students are graded on job quality, as well as their work productivity and efficiency.

Service Procedures

The Vehicle Maintenance course also begins to teach the process of organizing all procedures covered in prior courses into scheduled maintenance jobs involving the entire vehicle. Students are graded according to industry standards, which includes their performance and procedural accuracy. They also have opportunities to complete the hands-on pre-assessment components required for eligibility to participate in the optional Harley-Davidson University PHD course equivalency.

H-D Electrical Diagnostics

Students will be taught design, function, test procedures, technical updates and troubleshooting. They are taught the systematic approach to diagnostics using factory-authorized computer test equipment to test and troubleshoot electrical problems on late model Harley-Davidson motorcycles. The systems covered in this course include charging, starting and H-D engine management. This course will follow current electrical diagnostic curriculum as offered in the Harley-Davidson University PHD Electrical Diagnostics class. The tasks in this course are aligned with those in HDU’s ED course, allowing participating students more opportunities to complete the pre-assessments required to achieve PHD eligibility.

H-D Chassis Service

Students are taught basic service procedures for chassis and suspension components on late-model H-D vehicles. They will perform bearing replacement and adjustments, springer front-end service and chassis service on the Harley-Davidson Tri Glide® trike models. Students also will be taught about brake systems, including ABS service procedures. The tasks in this course are aligned with those in HDU’s Vehicle and Chassis Service (VCS) course, allowing participating students more opportunities to complete the pre-assessments required to achieve PHD eligibility.

H-D Powertrain Service

Students perform in-depth services, inspections and repairs focused on the powertrain of the Harley-Davidson motorcycle, including the engine, primary and final drive, and wheel assemblies. All vehicle services are performed on fully operational motorcycles, so good organizational skills and attention to detail are very important. Examples of procedures performed are engine top-end service, clutch service, primary drive service, drive belt replacement and rear tire replacement.

Students also perform full vehicle services per Harley-Davidson’s scheduled maintenance procedures. Participating in a simulated service facility, students are taught to work with repair orders and schedules while diagnosing, repairing and servicing engines, drive systems and related fuel system components. Students also have opportunities to complete more of the hands-on pre-assessment components required for eligibility to participate in the optional Harley-Davidson University PHD course equivalency.

H-D Dealer Service Operations 1

Vehicle and Chassis Service

This capstone course focuses on the service procedures covered and practiced throughout the Late Model portion of the program. Lab tasks are performed in alignment with the VCS course, allowing qualified participating students the opportunity to perform the final assessments required to achieve PHD course equivalency.

In this simulated service environment, students perform routine maintenance and scheduled service tasks without assistance from the instructor. This includes identifying any issues with the motorcycle and making recommendations for repairs and possible up-sells. The students complete all services and repairs then prepare the motorcycle for delivery to the customer.

In addition to performing these tasks, students act in support roles such as service consulting and parts & accessories consulting while other students rotate into their technician roles.

H-D Dealer Service Operations 2

Electrical Diagnostics & Repair/Accessory Installation

This capstone course focuses on the electrical diagnostic procedures covered and practiced throughout the Late Model portion of the program. Lab tasks are performed in alignment with HDU’s Electrical Diagnostics (ED) course, allowing qualified participating students the opportunity to perform the final assessments required to achieve PHD course equivalency.

In this simulated service environment, students apply the systematic approach to diagnostics to determine the cause of various electrical issues and perform the repairs necessary without assistance from the instructor. The students complete all services and repairs then prepare the motorcycle for delivery to the customer.

Students also have the opportunity to perform common accessory installations using products from the Harley-Davidson Motor Parts & Accessories catalog. In addition to performing these tasks, students act in support roles such as service consulting and parts & accessories consulting while other students rotate into their technician roles.

Harley-Davidson Screamin' Eagle^®

Powertrain Performance

Students familiarize themselves with the Harley-Davidson Screamin’ Eagle line of performance options. They are taught about the performance applications of components such as cylinder heads, camshafts, ignition systems, and intake and exhaust systems. The emphasis is on learning the correct application and combination of these performance components. Students are taught how to identify all of the variables in a Harley-Davidson motor that can increase combustion efficiency and drivability performance.

Dynamometer Operations

Students learn to use the Dynojet^® dynamometer as a tool for diagnosing and correcting drivability issues. It is also used to demonstrate the effects of Screamin’ Eagle products on a motorcycle’s performance.

Harley-Davidson Early Model

H-D Early Model 1

Big Twin Engines

Students will be taught Panhead, Knucklehead, Shovelhead and Evolution^® engine design, function and service in this Harley-Davidson mechanic course. Panhead topics will include pan covers and D-rings, gaskets and hardware, rocker arm and rocker bearings, intake manifold inserts, valves, guides and springs, cylinder head updates and unleaded conversion, pistons, rings, cylinder design, pushrods, gearcase covers, gears and shafts, oiling and breathing system functions, circuit breakers, lower-end flywheel assemblies, and case designs.

Knucklehead topics will include cylinder head design, rocker arm and rocker shafts, valves, springs and spring covers, oil feed and return systems, pinion shaft design, and carburetor and manifold designs.

Shovelhead topics will include rocker box and rocker arm, rocker shafts, cylinder heads, valves and springs, pistons, tappets, cam and pinion gear, lower end, and oil pump.

Evolution topics will include engine disassembly, pushrods, rocker box, rocker arm and shafts, cylinder heads, valves and springs, cylinders, pistons lifters, cam, and gearcase.

Side Valve & Iron XL Engines

Students will be taught engine design, function and servicing. Topics include valves and springs, cylinder and piston designs, gearcase covers, cam gears, tappets and guides, feed and return oil pump design and function, timed breather systems, flywheels, rods and case designs, circuit breakers, and carburetor and manifold designs.

Transmissions & Clutches

Students are taught about primary drive and clutch designs, foot clutch and mousetrap adjustment and service, kick-start mechanism designs, hand shift, ratchet top and plate-type shift fork and shaft designs, countershaft and main shaft assemblies, transmission service, three-speed and reverse differences, pushrod and throw out bearing designs, and early chain adjustments.

H-D Early Model 2

Carburetion

Students are taught the design, function, adjustment, troubleshooting and servicing of early model carburetors.

Early Chassis Maintenance

Students are taught about Springer^® front-fork assembly, Big Twin Glide front forks, Sportster^® Glide front forks, Star hub rebuild, ball bearing hub service, hydraulic rear-drum brake design and service, mechanical front and rear brakes, early disc brake design, and frame alignment check.

Early Electrical Systems

Students are taught about electrical systems, including ignition systems (battery point, circuit breaker, magneto and early electronic). Students also will learn about two- and three-brush generators and other charging systems, early AC alternators and basic wiring.

Final Review

Students will have an opportunity to review coursework and practice techniques on school-owned vintage vehicles. In addition, a final review will be conducted to reinforce instruction. Service information on early model Harley-Davidson models not covered in the course also will be provided.