2003 Harley Davidson FLT Touring Motorcycle Repair

Prix habituel: $16.99
Prix soldé: $16.99
Prix habituel
Prix unitaire: par

This manual covers the 2003 FL Touring series, including models such as the FLTRI Road Glide, FLHTPI Electra Glide Police, FLHTI Electra Glide Standard, FLHTCUI Ultra Classic Electra Glide, FLHTCI...

26 people are viewing this right now

Taper: Motorcycle

Distributeur:

UGS: 145196

Mots clés: 2003 FLT Harley Davidson Motorcycle Motorcycles Police Touring

Variantes de produits

Description

This manual covers the 2003 FL Touring series, including models such as the FLTRI Road Glide, FLHTPI Electra Glide Police, FLHTI Electra Glide Standard, FLHTCUI Ultra Classic Electra Glide, FLHTCI Electra Glide Classic, FLHTC Electra Glide Classic, FLHT Electra Glide Standard, FLHRSEI Screamin Eagle Road King, FLHRI Road King, FLHRCI Road King Classic, and FLHR Road King. These motorcycles are renowned for their classic American styling, comfortable ride, and capability for long-distance touring, powered by the robust 1450 cc (88 cubic inch) Twin Cam 88 or Twin Cam 88B V-twin engine. They feature advanced technology for their time, including optional Anti-lock Braking System (ABS) and cruise control, and offer substantial luggage capacity for extended journeys. This comprehensive shop repair and service manual provides detailed guidance for the repair, service, and maintenance of your 2003 FL Touring motorcycle. It covers all major systems, including the engine, fuel system, transmission, electrical system, steering, suspension, brakes, and bodywork. You will find extensive information on routine maintenance, engine overhaul procedures, transmission service, electrical diagnostics, and component-specific repairs. This manual is an indispensable resource for owners and technicians alike, offering the necessary specifications, troubleshooting steps, and procedures to ensure the optimal performance and longevity of your motorcycle.

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Year:

Family:

FL Touring

Models Covered:

FLTRI Road Glide, FLHTPI Electra Glide Police, FLHTI Electra Glide Standard, FLHTCUI Ultra Classic Electra Glide, FLHTCI Electra Glide Classic, FLHTC Electra Glide Classic, FLHT Electra Glide Standard, FLHRSEI Screamin Eagle Road King, FLHRI Road King, FLHRCI Road King Classic, FLHR Road King

Codes

Chassis Code Prefix:

👋 Introduction

Market Position

Positioning:

The 2003 Harley-Davidson FL Touring models represent the pinnacle of American cruiser touring, offering comfort, style, and long-distance capability. This manual serves owners and independent technicians maintaining these iconic motorcycles.

Competitive Analysis

Competitors:

Competes with other large-displacement touring motorcycles from brands like Honda (Gold Wing), Kawasaki (Voyager), Yamaha (Venture), and Indian (Chief).

Key Features

Vehicle Features:

Large fairings for weather protection, comfortable seating for rider and passenger, ample luggage capacity (saddlebags, optional Tour-Pak), powerful V-twin engines, cruise control (on some models), advanced infotainment systems (on some models).

Manual Value Proposition

Value:

Provides essential, detailed information for DIY maintenance, repairs, and diagnostics, saving owners time and money compared to dealership service. Enables on-the-go troubleshooting via smartphone.

📋 Manual Details

Coverage Areas

Primary Focus:

Repair, Service, and Maintenance

Secondary Focus:

Parts Lookup, Troubleshooting, Specifications

Page Count

Estimated Pages:

Extensive (typical for Harley-Davidson service manuals, often 600-1000+ pages depending on specific models and detail)

Manual Type

Type:

Shop Repair Manual / Service Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine:

Twin Cam 88, Twin Cam 88B (details on operation, disassembly, assembly, troubleshooting)

Fuel System:

Carburetor (Keihin CV40 or similar), Fuel Injection (EFI - Delphi Electronic Fuel Injection) systems, fuel pump, fuel lines, fuel filter

Lubrication And Cooling:

Oil pump, oil filter, oil passages, oil pressure, lubrication system diagnostics, oil cooler (where applicable)

Transmission:

5-speed Cruise Drive transmission, clutch operation, gear shifting mechanisms, transmission fluid

Electrical System:

Battery, charging system (alternator, regulator/rectifier), ignition system (ignition module, coil, spark plugs), lighting system (headlight, taillight, turn signals), starter system, instrument cluster, wiring diagrams, fault codes

Steering And Suspension:

Front forks (telescopic, cartridge types), rear shock absorbers, swingarm, bearings, steering head bearings, alignment

Brakes:

Front and rear brake systems (hydraulic disc brakes), brake pads, calipers, master cylinders, brake fluid, ABS (where equipped)

Bodywork And Trim:

Fairings, saddlebags, tour-pak, fenders, fuel tank, seat assembly, mounting hardware, cosmetic repairs

Intake And Exhaust:

Air cleaner assembly, intake manifold, exhaust pipes, mufflers, catalytic converters (where applicable)

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, air filter cleaning/replacement, spark plug checks, tire pressure, chain adjustment (if applicable to specific model variant, though most FLs are belt-driven), battery maintenance

Engine Overhaul:

Engine removal and installation, cylinder head removal/installation, piston and connecting rod service, crankshaft and camshaft inspection/replacement, internal engine component torque specifications

Transmission Service:

Transmission disassembly and reassembly, gear inspection, bearing replacement, clutch adjustment and replacement

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, testing components (sensors, actuators, modules), clearing diagnostic trouble codes (DTCs)

Suspension And Steering:

Fork seal replacement, fork oil changes, shock absorber replacement, steering head bearing adjustment and replacement

Brake System Maintenance:

Brake bleeding, pad replacement, caliper service, master cylinder overhaul

Bodywork Repair:

Saddlebag repair, fairing installation/removal, mounting hardware torque values, trim piece replacement

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds. Includes detailed troubleshooting guides and diagnostic procedures.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text content

Print Quality

Quality:

High-resolution, suitable for printing individual pages or sections.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 45-degree V-twin, pushrod overhead valves

Engine Family:

Twin Cam 88 / Twin Cam 88B

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:

8.3:1 or 8.8:1 (depending on specific model/tune)

Torque:

Approx. 78-85 ft-lbs @ 3000-3500 RPM (varies by model and tune)

Horsepower:

Approx. 65-70 HP @ 5000-5500 RPM (varies by model and tune)

Fuel System

Fuel Delivery:

Carbureted (Keihin CV40 for most models) or Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline, 91 octane (AKI) or higher recommended

🔧 Transmission

Standard

Type:

5-speed constant mesh, manual

Drive System:

Primary drive: Duplex chain; Final drive: Belt drive (70-tooth rear pulley, 32-tooth front pulley)

Features

Clutch:

Multi-plate, wet type, hydraulic actuation

Transmission Fluid:

Harley-Davidson Formula+ or equivalent (refer to manual for specific viscosity and type)

📐 Dimensions

Exterior

Wheelbase:

Approx. 63.5 - 64.5 inches (1613 - 1638 mm) depending on model

Weights

Dry Weight:

Approx. 700 - 800 lbs (318 - 363 kg) depending on model and equipment

Gross Vehicle Weight Rating:

Approx. 1200 - 1300 lbs (544 - 590 kg)

Fuel Capacity:

Approx. 5.0 gallons (18.9 liters)

🛡️ Safety Features

Ratings

Crash Testing:

Motorcycles are not typically subjected to standardized crash testing like automobiles. Safety is assessed through design features and regulatory compliance.

Active Features

Lighting:

Halogen headlight, LED taillight, amber front and rear turn signals

Braking System:

Dual front disc brakes, single rear disc brake. Some models may feature ABS (Anti-lock Braking System).

Passive Features

Chassis Design:

Sturdy steel frame, integrated bodywork for rider protection.

💡 Technology Features

Infotainment

Audio System:

CB radio, intercom, AM/FM radio, cassette player (optional/standard on higher trims like Ultra Classic).

Cruise Control:

Standard on select models (e.g., Ultra Classic, Electra Glide Standard/Classic), optional on others.

Driver Assistance

Anti-lock Braking System (ABS) was available as an option on many 2003 FL models.

Connectivity

Diagnostics:

On-board diagnostics for EFI models, allowing retrieval of diagnostic trouble codes (DTCs).

🔧 Maintenance

Service Intervals

First Service:

1,000 miles (1,600 km) or 12 months (whichever comes first): Oil and filter change, primary chain case check, belt alignment, chassis lubrication, general inspection.

Subsequent Service:

Every 5,000 miles (8,000 km) or 12 months: Similar to first service, plus transmission oil change, spark plug inspection/replacement, air filter service, brake fluid check.

Fluid Specifications

Engine Oil:

Harley-Davidson 20W50 SYN3 or equivalent (refer to manual for specific recommendations).

Transmission Fluid:

Harley-Davidson Formula+ or equivalent.

Primary Chain Case Fluid:

Harley-Davidson Formula+ or equivalent.

Brake Fluid:

DOT 4 (refer to manual for specific type and replacement intervals).

Known Issues

Cam Chain Tensioners:

Early Twin Cam models (pre-2007) had less robust cam chain tensioners which could wear out. The manual will detail inspection and replacement procedures.

Rear Main Seal:

Occasional leaks from the rear main seal can occur over time, requiring engine disassembly to replace.

Idle Speed Control:

EFI models may experience rough idle or stalling issues related to the idle air control (IAC) motor or throttle body cleaning.

📚 Vehicle History

Brand Heritage

Heritage:

Harley-Davidson has a long and storied history dating back to 1903, synonymous with American motorcycle culture, freedom, and V-twin engines.

Model Evolution

Fl Series Evolution:

The FL platform has evolved significantly since its introduction in the 1940s, with the 'Touring' designation becoming prominent in later decades. The 2003 models are part of the evolutionary step leading to modern touring bikes, featuring the Twin Cam engine.

Production

Manufacturing Location:

United States

🏆 Awards & Recognition

Recognitions

Industry Awards:

Harley-Davidson motorcycles, particularly the FL touring series, have historically received numerous accolades for their design, comfort, and enduring appeal in the motorcycle press and among riders.