🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLT

Model Variant:

Touring

Year:

2002

Engine Code:

Twin Cam 88

Engine Displacement Code:

103

Manual Product Code:

Likely a specific service manual identifier, not explicitly provided

👋 Introduction

Category:

Cruiser Motorcycle

Segment:

Touring

Competitors 2002:

Honda Gold Wing, Indian Chief, Kawasaki Vulcan, Suzuki Marauder, Yamaha Road Star

Distinctive Features:

Iconic V-twin engine, rider comfort for long-distance travel, large storage capacity (saddlebags, trunk), classic Harley-Davidson styling

Manual Value Proposition:

Essential resource for maintaining and repairing the FLT Twin Cam 88/103, enabling owners and technicians to perform tasks accurately and efficiently.

📋 Manual Details

Primary Coverage:

Repair and Service Procedures

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics

Estimated Page Count:

Over 500 pages (typical for full service manuals)

Type:

Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Twin Cam 88 and 103 (Bore & Stroke, Compression Ratio, Valve Timing, Lubrication System, Cooling System, Fuel System, Ignition System, Exhaust System)

Transmission:

5-Speed Cruise Drive (Gearbox Internals, Clutch, Shifting Mechanism, Primary Drive)

Drivetrain:

Belt Drive System, Rear Wheel Drive, Final Drive Gearing

Chassis:

Frame, Swingarm, Suspension (Front & Rear), Steering System

Brakes:

Front & Rear Hydraulic Disc Brakes, Caliper Service, Master Cylinder Service, Brake Fluid Specifications

Electrical:

Battery, Charging System (Generator/Alternator, Regulator), Ignition System, Lighting System, Starter System, Wiring Diagrams, Diagnostic Trouble Codes (DTCs)

Fuel System:

Carburetor (CV 40mm), Fuel Pump, Fuel Lines, Fuel Tank Service

Bodywork:

Fairing, Saddlebags, Fenders, Seat, Handlebars, Instrument Panel

Comfort And Convenience:

Gauges, Controls, Audio System (if equipped)

Routine Maintenance:

Oil Changes, Filter Replacements, Tire Pressure Checks, Brake Pad Inspections, Chain/Belt Adjustment, Spark Plug Service

Engine Overhaul:

Top-End Rebuild, Bottom-End Rebuild, Piston & Ring Replacement, Cylinder Head Service, Camshaft Installation

Transmission Service:

Clutch Adjustment & Replacement, Gearbox Disassembly & Reassembly, Bearing Service

Electrical Diagnostics:

Troubleshooting electrical faults, Component testing, Wiring repair

Brake System Repair:

Bleeding procedures, Pad & Rotor Replacement, Seal Replacement

Suspension Service:

Fork Seal Replacement, Shock Absorber Service, Bushing Replacement

Fuel System Cleaning:

Carburetor Cleaning & Adjustment, Fuel Filter Replacement

Troubleshooting Guides:

Systematic diagnostic procedures for common and uncommon issues

Special Tool Requirements:

Identification and usage of Harley-Davidson specific tools

Depth:

Comprehensive (covering from basic maintenance to complete engine and transmission rebuilds)

Diagnostic Level:

Advanced (includes diagnostic codes, testing procedures, and troubleshooting charts)

Scope:

Factory-level repair and service information

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable (depending on scan quality)

Printability:

Printable (designed for user printing of relevant sections)

Binding:

Not applicable (digital download)

Paper:

Not applicable (digital download)

⚙️ Engine Specifications

Engine Type:

Air-cooled, 45-degree V-twin

Engine Family:

Twin Cam 88

Engine Displacement Cc:

1450 (88 cubic inches)

Engine Displacement Ci:

88

Bore X Stroke Mm:

95.25 mm x 101.6 mm (3.75 in x 4.00 in)

Compression Ratio:

8.8:1 (typical for Twin Cam 88)

Horsepower Hp:

Approx. 65-70 HP (at crankshaft, model specific)

Torque Ft Lbs:

Approx. 75-80 lb-ft (at crankshaft, model specific)

Valve Train:

Overhead Valve (OHV), 2 valves per cylinder

Valves:

Pushrod actuated

Oil Capacity Quarts:

4.0 (with filter change)

Oil Type Specification:

Harley-Davidson SYN3 Full Synthetic or equivalent motorcycle oil (e.g., SAE 20W-50, API SG or higher)

Oil Filter Part Number:

Harley-Davidson 63796-77A (or equivalent like 63731-99)

Cylinder Design:

Twin cylinder, 45-degree V

Ignition System:

Electronic Ignition, Single Fire (typical)

Spark Plugs:

Harley-Davidson SE-1 or equivalent (e.g., NGK DCPR7E)

Carburetor:

Keihin CV 40mm (Constant Velocity)

Fuel Type:

Unleaded Gasoline, 91 Octane (or higher recommended)

Fuel Tank Capacity Gallons:

5.0 (standard FLT)

Fuel Pump Type:

Mechanical (engine-driven)

103 Ci Upgrade Context:

The '103' designation typically refers to an engine upgrade kit (e.g., Screamin' Eagle 103ci kit) that increases displacement from 88ci to approximately 103 cubic inches. This manual would cover the procedures for servicing both the stock 88ci and potential 103ci configurations if the upgrade components are similar in installation.

🔧 Transmission

Type:

5-Speed Manual Transmission

Gear Ratios:

1st: 10.110, 2nd: 6.915, 3rd: 4.906, 4th: 3.891, 5th: 3.307 (Typical for 5-speed Cruise Drive)

Clutch Type:

Wet, multi-plate

Primary Drive:

Duplex chain to dry clutch

Final Drive:

Belt drive

Transmission Fluid Capacity Quarts:

1.0 (approx.)

Transmission Fluid Type Specification:

Harley-Davidson Formula + Transmission Oil or equivalent SAE 80W-90 Gear Oil (API GL-5)

Clutch Activation:

Cable-actuated

📐 Dimensions

Wheelbase Inches:

63.5 (1613 mm)

Length Inches:

93.3 (2370 mm)

Seat Height Inches:

27.1 (688 mm) (unladen)

Ground Clearance Inches:

5.1 (130 mm)

Dry Weight Lbs:

Approx. 700 lbs (318 kg)

Gross Vehicle Weight Rating Gvwr Lbs:

Approx. 1200 lbs (544 kg)

Payload Capacity Lbs:

Approx. 500 lbs (227 kg)

Saddlebag Capacity Cu In:

Approx. 2,300 cubic inches (total)

🛡️ Safety Features

Crash Test Ratings:

Motorcycles are not typically rated by NHTSA or IIHS in the same way as cars. Safety is evaluated based on design and component integrity.

Braking System:

Dual hydraulic disc brakes (front and rear)

Lighting:

Halogen headlight, tail light, brake light, turn signals

Frame Construction:

Steel, cradle frame

Handling:

Stable handling characteristics due to wheelbase and rake/trail geometry

💡 Technology Features

Audio System:

Optional AM/FM/Cassette or CD player integrated into fairing

Speakers:

Fairing-mounted speakers

Cruise Control:

Optional electronic cruise control (typically on higher trim FLT models like FLHTCI)

Diagnostics:

OBD-II compatible diagnostic port for reading Diagnostic Trouble Codes (DTCs) via specialized Harley-Davidson diagnostic tools (e.g., Digital Technician).

🔧 Maintenance

Initial Service Miles:

1,000 miles (1,600 km)

Subsequent Service Miles:

5,000 miles (8,000 km) or 6 months (whichever comes first), for most routine checks and fluid changes.

Engine Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months

Transmission Oil Change Interval:

Every 10,000 miles (16,000 km) or 12 months

Primary Chain Case Oil Change Interval:

Every 10,000 miles (16,000 km) or 12 months

Spark Plug Replacement Miles:

10,000 miles (16,000 km) or as needed

Brake Fluid Flush Interval:

Every 24 months (regardless of mileage)

Engine Oil:

Harley-Davidson SYN3 Full Synthetic or equivalent SAE 20W-50 motorcycle oil

Transmission Oil:

Harley-Davidson Formula + Transmission Oil or equivalent SAE 80W-90 Gear Oil

Primary Chain Case Oil:

Harley-Davidson Formula + Transmission Oil or equivalent SAE 80W-90 Gear Oil

Brake Fluid:

DOT 4 (or DOT 5.1 if specified for older systems, though DOT 4 is more common for this era)

Common Complaints Twin Cam 88:

Leaking primary cover seals, clutch basket runout, starter drive issues, oil leaks (e.g., rear main seal), cam chain tensioner wear (especially early models with single tensioner shoe), carburetor performance variations.

Common Complaints Flt Touring:

Fairing vibration, electrical connector issues, rear suspension preload adjustment complexity.

Tip 1:

Regularly inspect and maintain the cam chain tensioners, as early Twin Cam 88s can experience wear. Consider upgrading to the '07-'11 style hydraulic tensioners if not already done.

Tip 2:

Ensure correct fluid levels in all three holes (engine, transmission, primary) as they are separate.

Tip 3:

Keep electrical connections clean and dielectric grease applied, especially in moisture-prone areas.

📚 Vehicle History

Brand Foundation:

Harley-Davidson Motor Company, founded in 1903, is an iconic American motorcycle manufacturer with a rich heritage of building V-twin powered motorcycles.

Flt Introduction:

The FLT model line, introduced in 1979, represented a significant shift for Harley-Davidson with its frame-mounted fairing and touring-focused amenities, distinguishing it from earlier fork-mounted fairings.

Twin Cam Introduction:

The Twin Cam 88 engine was introduced in 1999, replacing the Evolution (Evo) engine, and featured a redesigned engine architecture for improved performance and durability.

Production Period Twin Cam 88:

1999-2006 (for FLT models before Twin Cam 96 introduction)

Manufacturing Location:

Milwaukee, Wisconsin, USA (and other Harley-Davidson facilities)

🏆 Awards & Recognition

Brand Recognition:

Harley-Davidson is consistently recognized as a leader in the cruiser and touring motorcycle market for its distinctive styling and brand loyalty.

Customer Satisfaction:

Generally high customer satisfaction for owners who appreciate the Harley-Davidson experience, with a strong aftermarket support network.

Emission Standards:

Meets EPA emission standards for the model year.