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Harley Davidson FLHT Electra Glide Standard Motorcycle 2004 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHT Electra Glide Standard Year: 2004 Product Type: Service Repair Workshop Manual Format: Download PDF 👋 Introduction Market Position Segment: Full-dress touring motorcycle,...
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Tipo: Motorcycle
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SKU: 532663
Harley Davidson FLHT Electra Glide Standard Motorcycle 2004 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FLHT Electra Glide Standard
Year:
2004
Product Type:
Service Repair Workshop Manual
Format:
Download PDF
👋 Introduction
Market Position
Segment:
Full-dress touring motorcycle, flagship model for Harley-Davidson.
Competitive Analysis
Key Competitors:
Honda Gold Wing, Indian Roadmaster, Victory Vision Tour (during that era).
Key Features
Features Standard:
Large displacement V-twin engine, comfortable seating for rider and passenger, ample luggage capacity (saddlebags, tour-pak provision), fairing with windshield for weather protection, cruise control (often optional or part of specific packages).
Heritage
Model Lineage:
The Electra Glide nameplate has a long and storied history within Harley-Davidson's touring line, representing the pinnacle of comfort and long-distance capability.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Factory Service Repair Workshop Manual
Page Count
Estimated Page Count:
Refer to actual manual (typically 800-1200 pages for this model/era)
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English
Format Details
Access:
Instant Download
Licensing:
No Expiry Dates
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, overhaul of Twin Cam 88, Twin Cam 88B engines, including fuel injection, ignition, lubrication, cooling systems.
Transmission:
Service and repair of the 5-speed Cruise Drive transmission, including clutch, primary drive, final drive.
Chassis Suspension:
Front fork assembly, rear shock absorbers, wheel bearings, steering head bearings, swingarm.
Braking System:
Front and rear brake caliper service, hydraulic lines, master cylinders, rotor specifications, bleeding procedures.
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator), starter, lighting, ignition switch, horn, instruments, fuse block, diagnostic trouble codes (DTCs).
Fuel System:
Fuel injection system (EFI), fuel pump, fuel filter, fuel tank, throttle body, diagnostic procedures for fuel delivery.
Exhaust System:
Exhaust pipes, mufflers, mounting hardware, emissions controls.
Bodywork Fittings:
Fairing, saddlebags, fenders, seat, handlebars, controls, mounting hardware, cosmetic trim.
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, air filter service, spark plug replacement, lubrication points, brake fluid checks, tire pressure checks.
Troubleshooting:
Systematic diagnostic procedures for common and complex issues, fault code interpretation, component testing.
Component Rebuild:
Detailed instructions for engine, transmission, and brake caliper rebuilds, including torque specifications and clearances.
Assembly Disassembly:
Step-by-step guides for removing and installing major components and sub-assemblies.
Wiring Diagrams:
Comprehensive, color-coded electrical schematics for all systems.
Technical Depth
Depth:
Comprehensive coverage from basic maintenance to complete engine and transmission overhauls, including advanced diagnostics and electrical system repair.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text-based PDF for easy navigation.
Print Quality
Print Readability:
Designed for clear printing with high-resolution images and diagrams.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Family:
Harley-Davidson Twin Cam 88 (or 88B for Softail variants, but FLHT is touring chassis so likely Twin Cam 88).
Engine Type:
Air-cooled, 45-degree V-twin
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Compression Ratio:
8.9:1 (typical for Twin Cam 88)
Performance
Horsepower:
Approx. 65-70 HP (at crankshaft, unconfirmed without specific manual data)
Torque:
Approx. 80-85 ft-lbs (at crankshaft, unconfirmed without specific manual data)
Fuel System
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI) - Keihin
Ignition System
Ignition Type:
Electronic Ignition with knock sensor
Cooling System
Cooling Method:
Air-cooled
Lubrication
Oil Type:
Harley-Davidson SYN3 or equivalent V-twin motorcycle oil (SAE 20W-50)
Oil Capacity:
Approx. 4 quarts (3.8 liters) with filter change
Oil Filter Part Number:
63731-99 (or equivalent, e.g., 63731-99A)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh, helical gear
Features
Clutch Type:
Wet, multi-plate, diaphragm spring
Primary Drive:
Duplex chain
Final Drive:
Belt drive (8mm pitch, 1 1/8" wide)
Fluid Specifications
Transmission Fluid Type:
Harley-Davidson Formula + or equivalent (API GL-5, SAE 85W-140)
Fluid Capacities
Transmission Fluid Capacity:
Approx. 24 oz (0.7 liters)
📐 Dimensions
Exterior
Length:
Approx. 93.3 in. (2370 mm)
Width:
Approx. 38.0 in. (965 mm)
Height:
Approx. 53.1 in. (1350 mm)
Wheelbase:
Approx. 63.5 in. (1613 mm)
Weights
Dry Weight:
Approx. 700 lbs (318 kg)
Gvwr:
Approx. 1200 lbs (544 kg)
Fuel Capacity
Fuel Tank Capacity:
5.0 US gallons (18.9 L)
Wheels Tires
Front Tire Size:
130/90B16 67H
Rear Tire Size:
140/90B16 71H
Front Wheel Type:
16-inch, cast aluminum or chrome laced (model dependent)
Rear Wheel Type:
16-inch, cast aluminum or chrome laced (model dependent)
🛡️ Safety Features
Ratings
Safety Certifications:
Meets FMVSS standards for motorcycles.
Active Features
Braking System:
Dual front disc brakes, single rear disc brake with hydraulic actuation.
Passive Features
Lighting:
Halogen headlight, LED taillight, amber turn signals, marker lights.
Frame Construction:
Steel, cradle frame.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/WB radio with CB/Intercom (may be optional depending on specific trim package for 'Standard' model).
Speaker Configuration:
Fairing-mounted speakers.
Driver Assistance
Cruise Control:
Often an optional feature on the Standard model, but a key differentiator for touring bikes of this era.
Connectivity
Diagnostic Interface:
OBD-II compliant for diagnostic trouble code retrieval via H-D interface (e.g., Screamin' Eagle diagnostician).
🔧 Maintenance
Service Intervals
Initial Service:
First service typically at 1,000 miles (1,600 km) or 6 months, whichever comes first.
Regular Oil Change:
Every 5,000 miles (8,000 km) or 12 months for engine oil and filter.
Transmission Service:
Check and change transmission fluid every 10,000 miles (16,000 km) or 24 months.
Primary Drive Service:
Check and change primary chaincase lubricant every 10,000 miles (16,000 km) or 24 months.
Air Filter Service:
Inspect at 5,000 miles (8,000 km); replace as needed or at 10,000 miles (16,000 km).
Spark Plug Replacement:
Typically every 10,000 miles (16,000 km).
Fluid Specifications
Engine Oil Viscosity:
SAE 20W-50
Brake Fluid Type:
DOT 4 (for hydraulic brake systems)
Known Issues
Common Wear Items:
Clutch plates, primary chain tensioner (early Twin Cam had a known issue with the stock plastic tensioner, often upgraded to hydraulic), wheel bearings, fork seals.
Engine Specific:
Potential for oil leaks at rocker box gaskets, cam cover, and primary cover. Some early Twin Cams experienced cam chain tensioner wear. Valve guide wear can occur over high mileage.
Electrical Specific:
Battery charging issues (regulator/stator failure), starter solenoid failure. CDI module issues can manifest as intermittent spark.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and cruiser/touring motorcycles.
Model Evolution
Electra Glide Lineage:
The Electra Glide line originated in the 1960s and has consistently represented Harley-Davidson's top-tier touring platform, evolving through Shovelhead, Evolution, and Twin Cam eras.
Production
Model Introduction Year:
The Electra Glide line dates back to 1965. The FLHT Standard variant has been a staple offering for decades.
Manufacturing Location:
Milwaukee, Wisconsin, USA (primary assembly).
🏆 Awards & Recognition
Recognitions
Model Recognition:
The Electra Glide Standard is consistently recognized as a benchmark in the full-dress touring motorcycle segment for its blend of comfort, performance, and iconic styling.
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