🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLHTC Electra Glide Classic

Year:

2004

Vehicle Type:

Motorcycle

Chassis Code:

FLHTC

👋 Introduction

Market Segment:

Full-size touring motorcycle, premium segment

Primary Competitors:

Honda Gold Wing, Indian Chief, Yamaha Royal Star Tour Deluxe

Defining Features:

Comfortable rider and passenger seating, extensive fairing for weather protection, large integrated luggage capacity (saddlebags and Tour-Pak), powerful V-twin engine, long-distance touring capability.

Manual Value:

Provides essential information for owners and technicians to maintain, diagnose, and repair the 2004 Harley-Davidson FLHTC Electra Glide Classic, ensuring optimal performance and longevity.

📋 Manual Details

Covered Systems:

Engine, Fuel System, Ignition System, Transmission, Drivetrain, Chassis, Suspension, Brakes, Electrical System, Lighting, Instruments, Bodywork, Fairing, Luggage, Tools, Diagnostic Procedures, Troubleshooting

Page Count:

Approximately 800+

Manual Type:

Factory Service Repair Workshop Manual

Language:

English

Format:

Download PDF

📖 Manual Coverage

Engine Systems:

Twin Cam 88 Engine, Engine Mechanical, Lubrication System, Cooling System (Air), Fuel Delivery (Injection/Carburetion, depending on specific model variant), Exhaust System

Transmission Drivetrain Systems:

5-Speed Cruise Drive Transmission, Clutch, Primary Drive, Final Drive (Belt Drive)

Electrical Systems:

Ignition System, Starting System, Charging System, Battery, Lighting (Headlight, Taillight, Turn Signals), Instrumentation, Audio System, Cruise Control, Security System

Chassis Suspension Brakes:

Frame, Front Fork (Telescopic), Rear Suspension (Air Adjustable), Wheels, Tires, Front and Rear Braking Systems (Hydraulic Disc)

Bodywork Accessories:

Fairing (Batwing), Saddlebags, Tour-Pak, Windshield, Seat, Handlebars, Controls

Maintenance Procedures:

Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug Replacement, Tire Pressure Checks, Brake Fluid Checks, Chain/Belt Adjustment (if applicable to specific model), Battery Maintenance

Repair Procedures:

Engine Disassembly and Reassembly, Transmission Overhaul, Clutch Replacement, Brake System Servicing, Suspension Component Replacement, Electrical Component Troubleshooting and Replacement, Bodywork Repair and Replacement

Troubleshooting:

Diagnostic Flowcharts, Symptom-Based Troubleshooting Guides, Electrical Schematics, Component Testing Procedures

Depth Of Coverage:

Comprehensive from basic maintenance to complete engine rebuilds and electrical system diagnostics. Includes torque specifications, clearances, and detailed assembly instructions.

📊 Manual Specifications

File Format:

PDF

Searchability:

Searchable text for quick information retrieval

Print Quality:

High-resolution, suitable for printing individual pages or the entire manual

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Air-cooled, 45-degree V-twin, pushrod OHV

Engine Family:

Twin Cam 88

Displacement:

1450 cc (88 cubic inches)

Bore X Stroke:

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

Compression Ratio:

8.8:1

Horsepower:

Approx. 65-70 HP (Varies by tuning and dyno)

Torque:

Approx. 86-90 ft-lbs @ 3200 RPM (Varies by tuning and dyno)

Fuel Delivery:

Electronic Fuel Injection (EFI) - Sequential Port Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline, minimum 87 octane

Fuel Tank Capacity:

5.0 US gallons (18.9 liters)

Oil Capacity:

3.0 US quarts (2.8 liters) with filter change

Oil Type Specification:

Harley-Davidson SYN3 (SAE 20W-50) or equivalent API CG-4 or higher rated motorcycle oil

🔧 Transmission

Transmission Type:

5-Speed Cruise Drive

Gear Ratios:

1st: 9.312, 2nd: 6.445, 3rd: 4.745, 4th: 3.779, 5th: 3.154

Clutch Type:

Wet, multi-plate, diaphragm spring

Primary Drive:

Clutch input shaft drives primary chain to transmission input shaft

Final Drive:

Belt drive, 32/66 tooth ratio (replaces chain drive on earlier models)

Transmission Fluid Type:

Harley-Davidson Formula+ Transmission/Primary Chaincase Lubricant (or equivalent SAE 80W-90 API GL-5 gear oil)

Transmission Fluid Capacity:

28-30 US fluid ounces (0.83 - 0.89 liters)

📐 Dimensions

Length:

93.3 in. (2370 mm)

Width:

37.4 in. (950 mm)

Height:

61.4 in. (1560 mm)

Wheelbase:

63.5 in. (1613 mm)

Ground Clearance:

5.1 in. (130 mm)

Dry Weight:

747 lbs. (339 kg)

Gross Vehicle Weight Rating:

1200 lbs. (544 kg)

Saddlebag Capacity:

Approx. 2.3 cu. ft. each

Tour Pak Capacity:

Approx. 2.2 cu. ft.

🛡️ Safety Features

Safety Ratings:

Motorcycles are not typically assigned NCAP or IIHS safety ratings in the same manner as passenger cars. Safety is primarily achieved through design, engineering, and rider responsibility.

Braking System:

Dual 32mm, 4-piston caliper front brakes; Single 32mm, 4-piston caliper rear brake. Linked braking system (LBS) may be present on some variants.

Lighting:

Halogen headlight, LED taillight, incandescent turn signals

Tires:

Tubeless tires with tread patterns designed for stability and grip.

Frame Construction:

Steel frame designed for rigidity and stability

Wind Protection:

Full fairing and windshield to deflect wind and debris from the rider.

Ergonomics:

Comfortable seating position for rider and passenger, designed for long-distance comfort and control.

💡 Technology Features

Audio System:

Factory-installed AM/FM stereo with cassette player (CD optional or aftermarket upgrades common).

Speakers:

Fairing-mounted speakers, often with rear speaker pods available.

Cruise Control:

Electronic cruise control integrated into handlebar controls.

Security System:

Factory-installed H-D Smart Security System (alarms, immobilizer) with key fob.

Original Connectivity:

Limited original connectivity; primarily focused on analog and early digital dashboard displays. Modern upgrades often add Bluetooth and smartphone integration.

🔧 Maintenance

First Service Mileage:

1000 miles (1600 km)

Subsequent Service Mileage:

Every 5000 miles (8000 km) or 6 months, whichever comes first

Specific Item Intervals:

Engine oil and filter change: every 5,000 miles or 6 months. Primary chaincase oil: every 10,000 miles or 12 months. Spark plugs: every 10,000 miles. Brake fluid flush: every 2 years.

Engine Oil Spec:

Harley-Davidson SYN3 SAE 20W-50 (API CG-4 or higher)

Primary Chaincase Oil Spec:

Harley-Davidson Formula+ or SAE 80W-90 API GL-5 gear oil

Brake Fluid Spec:

DOT 4 (refer to manual for specific Harley-Davidson branded fluid recommendations)

Rear Suspension Air Pressure:

Adjustable, typically 0-50 PSI (refer to manual for specific load conditions)

Common Wear Items:

Clutch wear, primary chain tensioner wear, wheel bearings, steering head bearings, exhaust pipe gaskets.

Electrical Common Points:

Wiring harness chafing, starter solenoid failure, battery charging issues (if not maintained properly).

Engine Specific Notes:

Some early Twin Cam 88 models experienced oil pressure issues or cam chain tensioner wear. Later revisions addressed these concerns.

Example Torque Spec:

Cylinder head bolts: Refer to specific sequence and torque values in the manual (multi-stage torquing required).

📚 Vehicle History

Brand Legacy:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its cruiser and touring motorcycles with a distinctive V-twin engine sound and heritage.

Electra Glide Lineage:

The Electra Glide line dates back to the 1960s, evolving into the premier touring platform for Harley-Davidson. The FLHTC represents a modern iteration of this classic touring concept.

Twin Cam 88 Introduction:

The Twin Cam 88 engine was introduced in 1999, replacing the Evolution engine, offering increased displacement, power, and improved internal balance.

Manufacturing Location:

United States (primarily York, Pennsylvania and Milwaukee, Wisconsin)

Model Year Significance:

The 2004 model year represented an ongoing refinement of the Twin Cam platform, with features like the Cruise Drive transmission becoming standard.

🏆 Awards & Recognition

Model Awards:

While specific awards for the 2004 model year are difficult to pinpoint universally, the Electra Glide line consistently receives accolades for its comfort, touring capability, and iconic status within the motorcycle community.

Owner Satisfaction:

Generally high owner satisfaction for long-distance touring, comfort, and the classic Harley-Davidson riding experience.