Category:
Heavyweight touring motorcycles
Target Audience:
Harley-Davidson owners, independent repair shops, DIY mechanics.
Competitors:
V-twin touring motorcycles from brands like Indian.
Vehicle Philosophy:
Comfortable long-distance touring with classic styling and a powerful V-twin engine.
Manual Value Proposition:
Empowers owners and technicians with the knowledge to maintain and repair their specific Harley-Davidson model, saving time and money.
Coverage:
All mechanical and electrical systems, routine maintenance to major overhauls, troubleshooting, diagnostics, and repair procedures.
Page Count:
Estimated 800-1000+ pages (typical for complete factory service manuals of this era)
Manual Type:
Workshop Service Repair Manual
Format:
Downloadable (Digital PDF)
Engine Systems:
Twin Cam 88, Twin Cam 88B (balance shaft), fuel injection (EFI), carburetion (CV carb), ignition, cooling, lubrication, exhaust, engine diagnostics.
Transmission Drivetrain:
5-speed Cruise Drive transmission, clutch, primary drive, final drive, clutch adjustment, transmission overhaul.
Chassis Suspension:
Frame, front fork (leading-link or conventional telescopic depending on specific model variant), rear shock absorbers, steering, wheel bearings, swingarm.
Braking System:
Front and rear disc brakes, hydraulic system, brake pad replacement, caliper service, bleeding procedures.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starting system, lighting (headlights, taillights, turn signals), horn, instrumentation, wiring diagrams, ECM (Electronic Control Module).
Bodywork Trim:
Fairings, saddlebags, fuel tank, fenders, seat, handlebars, controls, fairing removal and installation, component replacement.
Maintenance Procedures:
Oil changes, filter replacements, spark plug service, air filter service, chain/belt adjustment (if applicable), brake fluid flush, battery maintenance, tire pressure checks.
Diagnostic Procedures:
Troubleshooting common problems, diagnostic trouble codes (DTCs), electrical system fault finding, engine performance issues.
Repair Overhaul:
Engine disassembly and reassembly, transmission overhaul, fork seal replacement, brake caliper rebuild, electrical component replacement.
Calibration Adjustment:
Clutch adjustment, throttle cable adjustment, idle speed adjustment, ignition timing checks (if applicable).
Depth:
Comprehensive, covering routine maintenance, component-level diagnostics, detailed repair procedures, and complete engine/transmission rebuilds. Includes specifications, tolerances, and torque values.
Engine Type:
Air-cooled, 45-degree V-twin (Twin Cam 88 / Twin Cam 88B)
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.75 in x 4.00 in (95.25 mm x 101.6 mm)
Horsepower Est:
Approx. 65-70 HP (at crankshaft)
Torque Est:
Approx. 80-85 ft-lbs (at crankshaft)
Fuel Delivery:
Multi-point Fuel Injection (EFI) or Keihin 40mm CV Carburetor (depending on specific model variant)
Fuel Type:
Unleaded gasoline, 91 octane (or higher)
Fuel Tank Capacity:
5.0 US gallons (18.9 L)
Transmission Type:
5-speed constant mesh, helical cut gears
Primary Drive:
Duplex chain, 1.464:1 ratio
Final Drive:
Belt drive, 32/66 ratio (3.15:1)
Clutch Type:
Hydraulic assist, multi-plate wet clutch
Transmission Fluid Type:
Harley-Davidson Formula+ (or equivalent syntheric primary lubricant)
Transmission Fluid Capacity:
22 US fluid ounces (0.65 L)
Length:
Approx. 93.9 in (2385 mm)
Width:
Approx. 36.2 in (919 mm)
Height:
Approx. 57.5 in (1461 mm)
Wheelbase:
Approx. 63.5 in (1613 mm)
Dry Weight:
Approx. 722 lbs (327 kg)
Gross Vehicle Weight Rating:
Approx. 1160 lbs (526 kg)
Payload Capacity:
Approx. 438 lbs (199 kg)
Saddlebag Capacity:
Integrated hard saddlebags
Crash Test Ratings:
Motorcycles are not typically subject to standardized crash test ratings like automobiles.
Braking System:
Dual front disc brakes, single rear disc brake with hydraulic actuation.
Lighting:
Halogen headlight, taillight, stoplight, front and rear turn signals.
Chassis Stability:
Sturdy frame and balanced suspension contribute to rider stability.
Engine Oil Change:
Every 2,500 miles or 4 months (whichever comes first)
Primary Fluid Change:
Every 5,000 miles or 8 months (whichever comes first)
Transmission Fluid Change:
Every 10,000 miles or 12 months (whichever comes first)
Spark Plug Replacement:
Every 10,000 miles
Engine Oil Spec:
Harley-Davidson 20W-50 SYN3 or V-Twin 20W-50 (specific part numbers vary, consult manual)
Cam Chain Tensioners:
Early Twin Cam models are known for wear on the cam chain tensioners, which can lead to engine damage if not inspected and replaced.
Harley Diagnostics:
EFI models may require specialized diagnostic tools (like Harley-Davidson's Digital Technician) for advanced troubleshooting, covered in the manual.
Electrical Gremlins:
Older electrical systems can be prone to corrosion or loose connections; the manual's wiring diagrams are crucial for diagnosis.
Manufacturer:
Harley-Davidson Motor Company, founded in 1903.
Electra Glide Lineage:
The Electra Glide line has a long history as Harley-Davidson's flagship touring motorcycle, evolving significantly over decades.
Road King Introduction:
The Road King was introduced in 1994, offering a more classic, stripped-down touring look compared to the fully-faired Electra Glide models.
Twin Cam Era:
2002 marked a significant period for Harley-Davidson with the widespread adoption of the Twin Cam engine family.
Manufacturing Location:
United States (primarily York, Pennsylvania and Milwaukee, Wisconsin)
Industry Acclaim:
Harley-Davidson touring motorcycles are consistently recognized for their iconic style, comfort, and long-distance capability.
Customer Satisfaction:
While specific awards are rare for individual model years, Harley-Davidson touring bikes typically receive high marks for rider satisfaction and brand loyalty.
Manual Standard:
Adheres to industry standards for service manual clarity and technical accuracy, mirroring factory service publications.
