New Twin Cam 96

The new engine, which will only be available with Electronic Sequential Port Fuel Injection (ESPFI), offers a 9 percent increase in displacement and up to a 17 percent increase in torque (varies by model) over the Twin Cam 88/88B engines it replaces, and features a number of design enhancements making it more powerful, reliable and smoother.

"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 Twin Cam 96. 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, crank cases, transmission cases and all the transmission parts are new. We think this next-generation Twin Cam will set the standard for the industry."

The Twin Cam 96 displaces 1584cc, compared to 1450cc for the Twin Cam 88 engine it replaces. The added displacement was achieved by increasing stroke from 4.00 inches to 4.38 inches (10.2cm to 11.1cm). The Twin Cam 96 cylinder bore is 3.75 inches (9.5cm), the same as that of the Twin Cam 88. The Twin Cam 96B is designed to be rigid-mounted in Harley-Davidson Softail models, and is equipped with internal counter-balance shafts to provide a smooth and powerful ride.
The Twin Cam 96 produces up to 93 ft. lbs of peak torque at 3500 rpm, compared to the Twin Cam 88 at up to 82 ft. lbs. at 3500 rpm.

The 6-speed Cruise Drive transmission, which was introduced on the Dyna family in 2006, features gear ratios optimised to match the torque curve of the new Twin Cam 96/96B engines. The addition of a higher-ratio sixth gear reduces top gear rpm by 11 percent, compared to the previous 5-speed Big Twin transmission. At 75 mph, engine speed is reduced by 368 rpm, from 3227 rpm to 2859 rpm. Second through fourth gears have helical cut teeth for quieter operation, and load carrying capacity has been increased significantly.

Twin Cam 96 highlights
Traditional V-Twin Styling: The Twin Cam 96/96B remains the styling centrepiece of each Harley-Davidson Big Twin model, and it retains the look, sound and feel that has always been part of the Big Twin character.
New Crankcase Design: The starter is now bolted directly to the inner primary housing, eliminating the starter jackshaft for improved starter performance. An integral oil filter adapter eliminates gaskets and hardware. Internal oil passages between the engine and transmission on the Twin Cam 96 eliminate external oil lines and fittings.

Reduced Reciprocating Mass: Lighter pistons and lighter, shorter connecting rods increase performance and reduce vibration.

Improved Camshaft Design: The new cams are lighter and use improved materials for enhanced durability. New hydrostatic, plain cam bearings replace the previous roller bearings and offer increased durability, reduced complexity, and quieter operation. New multi-piece assembled camshafts replace the previous forged, single-piece cams. A new, hydraulic automatic cam chain tensioner replaces the previous spring-loaded mechanical tensioner.

Improved Oil Pump: A new oil pump assembly provides 10 percent more flow and 23 percent more scavenging capacity than the previous design. There is also an integrated oil cooler adapter.

Improved EFI: New 25-degree fuel injector nozzles offer better fuel atomisation and spray targeting than the previous 8-degree injectors, and help reduce exhaust emissions and improve driveability.

New Primary Chain Tensioner: A new automatic primary chain tensioner eliminates the manual service adjustment of the primary chain. The inner and outer primary drive covers are redesigned to improve the appearance of the painted, polished or chromed surface.

New Exhaust Tuning: Muffler tuning has been changed to both improve exhaust flow for increased performance, and to improve the sound quality of the exhaust. Low frequencies have been enhanced to give the Twin Cam 96 a new, commanding exhaust tone that preserves the legendary Harley-Davidson sound.

Bolt-On 103 Big Bore Kit: An increase in displacement to 103 cid can be achieved by adding a bolt-on Big Bore Kit with 3.875-inch (9.85cm) bore cylinders and matching pistons from Harley-Davidson Genuine Motor Accessories. It is no longer necessary to add a stroker kit to get to 103 cid.