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"The Twin Cam 96 has been the biggest new-engine program in the history of Harley-Davidson," said Skip Metz, Program Manager-Big Twin Powertrain. "There are more than 700 new part numbers associated with TC96. The only areas that didn't change are the cylinders, rocker arms, rocker boxes, and items in the top part of the engine. Crankshafts, connecting rods, crankcases, transmission cases, and all the transmission parts are new. We think this next-generation Twin Cam will set the standard for the industry."
This fresh mill gets its displacement increase to 1584cc via a stroke job from 4.00 inches to 4.38 inches. The engine also receives a bump in compression and revised cam timing, as well as numerous other internal detail changes designed to make the mill quieter and more reliable. These changes to the now-retired 1450cc TC88 results in a notable 17% boost in peak torque. Lighter con-rods and pistons result in less reciprocating weight despite the added displacement.
All Big Twins are now fed by H-D's Electronic Sequential Port Fuel Injection (ESPFI) that has been upgraded with new 25-degree fuel-injector nozzles (instead of 8-degree squirters) that are said to offer better fuel atomization. The addition of oxygen sensors lets the Big Twin get away without catalytic converters in the U.S. market, and new exhaust systems with redesigned mufflers emit a burlier but still EPA-friendly bark.
The TC96B is the counterbalanced version fitted to the Softail family. Depending on the platform, the TC96 produces between 90 and 93 lb-ft of torque at the crankshaft compared to the 78-82 lb-ft of the TC88. The additional punch these engines have is something that is readily apparent to the rider, transforming an adequate powerplant into an eager one.
Also new to the TC96 is the six-speed Cruise Drive transmission first seen last year in the totally revamped Dyna family. Although sixth gear isn't a true overdrive, its 1:1 ratio reduces highway revs by 11% over the previous tranny's fifth gear. In addition, the Cruise Drivealso includes helical-cut gears that cut down on the whine inherent in straight-cut gears. Internal changes to a dog-ring design makes for lighter and shorter-throw gear changes, and it is claimed to be 28% stronger.
A new primary-drive system features an auto-adjust hydraulic chain tensioner system, a redesigned starter operation and better sealing. (H-D says this component is retrofittable to the TC88). A new carbon-fiber final-drive belt is narrower but 30% stronger.
An interesting new option available on all Harleys is the slick Smart Security System which operates based off a proximity sensor in the key fob. Simply shutting off the bike and walking away arms it so that it can't started. When the rider returns to the bike, the sensor automatically disarms the system to allow the bike to be switched on and ridden away.
the popular Deuce (which for 2007 is slammed 1.0 inch to a seat height of 25.0 inches).
The Best of Harley-Davidson for Lifelong Riders


