2003 FLT Touring Motorcycle Repair Manual

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UGS: 155488

Mots clés: 2003 FLT Touring Harley Davidson Motorcycle Motorcycles Police

Variantes de produits

Description

This manual covers the FLT Touring motorcycle family from the 2003 model year. These premium large-displacement touring motorcycles are renowned for their comfort, long-distance capability, and distinctive styling, offering riders a superior experience on extended journeys. Models covered include various iterations of the Electra Glide, Road Glide, and Road King, including specialized police variants. Powered by the iconic Twin Cam engine, available in 88 cubic inch (1450cc) and 95 cubic inch (1550cc) configurations for Screamin' Eagle models, these machines feature robust engineering and a legacy dating back to the brand's founding in 1903. This comprehensive service and repair manual provides detailed guidance for maintaining and repairing your FLT Touring motorcycle. It covers a wide range of systems, including the Twin Cam engine, 5-speed Cruise Drive transmission, fuel systems (carbureted and EFI), lubrication, electrical systems, suspension, brakes, steering, and bodywork. You will find step-by-step procedures for routine maintenance, engine and transmission overhauls, electrical diagnostics, and component servicing. The manual also addresses troubleshooting common issues and provides essential technical specifications, ensuring that owners, mechanics, and technicians have the necessary information to keep these iconic motorcycles in optimal condition.

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model Family:

FLT Touring

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Market Segment:

Premium Large-Displacement Touring Motorcycles

Competitive Analysis

Key Competitors 2003:

Honda Gold Wing, Kawasaki Vulcan Voyager, Yamaha Royal Star Venture, BMW K-Series Touring

Key Features Of Models

Touring Capabilities:

Large fairings, comfortable seating for rider and passenger, ample luggage capacity (saddlebags, Tour-Pak), cruise control, advanced sound systems.

Police Variants:

Reinforced components, specific electrical configurations for lights and sirens, often higher output charging systems.

📋 Manual Details

Coverage Areas

Primary 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

Page Count

Estimated Page Count:

Extensive (typical for comprehensive Harley-Davidson service manuals of this era, likely 500-800+ pages)

Manual Type

Type:

Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Twin Cam 88, Twin Cam 88B, Twin Cam 95 (SE models)

Fuel System:

Carbureted (Keihin CV), Fuel Injection (EFI - Delphi Electronic Fuel Injection)

Lubrication And Cooling:

Oil Pump, Oil Filter, Oil Cooler (if equipped), Oil Tank, Lubrication Diagrams

Transmission Drive:

5-speed Cruise Drive Transmission, Clutch, Primary Drive, Final Drive Belt

Electrical System:

Ignition, Lighting, Charging System (Stator, Regulator/Rectifier), Starter, Battery, Fuses, Relays, Wiring Diagrams, ECUs, Sensors

Suspension:

Front Forks (Telescopic), Rear Shock Absorbers, Swingarm

Brakes:

Front and Rear Hydraulic Disc Brakes, Master Cylinders, Calipers, Brake Lines, Brake Fluid

Steering:

Handlebar, Headset, Fork Stem, Steering Bearings

Bodywork And Trim:

Fairings (Batwing, Tour-Pak), Saddlebags, Fenders, Fuel Tank, Seat, Controls

Intake Exhaust:

Airbox, Carburetor/Fuel Injectors, Exhaust System Components

Procedures Included

Routine Maintenance:

Oil Changes, Filter Replacements, Chain/Belt Adjustment, Tire Pressure Checks, Brake Fluid Flushes, Spark Plug Replacement, Air Filter Cleaning/Replacement

Engine Repair:

Top End Rebuild (Cylinders, Pistons, Heads), Bottom End Assembly, Camshaft Installation, Timing Procedures, Crankshaft Balancing

Transmission Repair:

Clutch Assembly, Gearset Removal/Installation, Bearing Replacement, Shift Drum and Pawl Service

Electrical Diagnostics:

Troubleshooting common electrical faults using schematics, Component testing (stator, regulator, starter, ignition module), Sensor diagnosis

Suspension Service:

Fork Seal Replacement, Fork Oil Change, Shock Absorber Replacement, Swingarm Bearing Service

Brake System Service:

Brake Pad Replacement, Rotor Replacement, Bleeding the Brake System, Master Cylinder and Caliper Rebuild

Bodywork Repair:

Fairing Repair and Refinishing, Saddlebag Mounting and Repair, Fender Replacement, Fuel Tank Removal and Installation

Troubleshooting:

Systematic diagnostics for various operating issues, error codes (for EFI models), common performance problems

Technical Depth

Depth:

Comprehensive: Covers routine maintenance, in-depth repairs, component overhauls, and advanced troubleshooting.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality Recommendation:

High resolution for clear diagrams and text. Printable.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Searchability

Text Search:

Searchable PDF content for quick information retrieval.

Interactivity

Hyperlinks:

Likely includes hyperlinks for navigation within the PDF, especially for diagrams and schematics.

⚙️ Engine Specifications

Primary Engine

Engine Family:

Harley-Davidson Twin Cam

Displacement Standard:

88 cubic inches (1450cc)

Displacement Screamin Eagle:

95 cubic inches (1550cc) - FLHRSEI

Engine Configuration:

Air-cooled, 45-degree V-twin

Valvetrain:

Overhead valve (OHV), 2 valves per cylinder

Performance

Horsepower Est Twin Cam 88:

Approx. 60-70 HP (varies slightly by model and tuning)

Torque Est Twin Cam 88:

Approx. 70-80 lb-ft (varies slightly by model and tuning)

Fuel System

Carburetor Type:

Keihin CV (Constant Velocity) 40mm

Efi System Type:

Delphi Electronic Fuel Injection (Sequential Port Injection)

Fuel Type:

Unleaded Gasoline, 91-octane (95 RON) or higher recommended

🔧 Transmission

Standard

Transmission Type:

5-speed Constant Mesh (Cruise Drive)

Features

Clutch Type:

Hydraulic, multi-plate wet clutch

Final Drive:

Carbon reinforced belt drive

Fluid Spec

Transmission Fluid Type:

Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant (or equivalent)

📐 Dimensions

Exterior

Wheelbase Approx:

63.5 inches (varies slightly by model)

Seat Height Laden Approx:

27.1 inches (varies slightly by model and suspension)

Weights

Dry Weight Approx:

750 - 800+ lbs (varies significantly by model, e.g., Ultra Classic is heavier)

Gvwr Approx:

1260 lbs

🛡️ Safety Features

Active Features

Braking System:

Dual front disc brakes, single rear disc brake with hydraulic actuation.

Lighting:

Halogen headlamp, auxiliary passing lamps (most models), LED tail/stop lamp, turn signals.

Passive Features

Frame Construction:

Steel cradle frame

💡 Technology Features

Infotainment

Audio System:

Many touring models featured premium AM/FM/WB radios with CD players, CB radio, and intercom systems. Manual covers basic operation and troubleshooting.

Driver Assistance

Cruise Control:

Electronic cruise control was a common feature on touring models. Manual covers activation, deactivation, and basic diagnostics.

Connectivity

Charging Ports:

Accessory power outlets for charging devices were often integrated.

🔧 Maintenance

Service Intervals

First Service:

1,000 miles (1,600 km) - Oil change, primary chain tension check, clutch adjustment, inspection of all systems.

Subsequent Service:

Every 5,000 miles (8,000 km) or annually - Oil change, belt tension check, brake fluid check, lubrication of pivot points.

Spark Plugs:

Inspect every 5,000 miles, replace as needed.

Fluid Specifications

Engine Oil Type:

Harley-Davidson SYN3 Synthetic Motorcycle Oil (20W-50) or equivalent (e.g., Shell Rotella T6 5W-40 often used).

Engine Oil Capacity:

Approximately 4 quarts (3.8 L) with filter change.

Primary Chaincase Oil Capacity:

Approximately 2.4 quarts (2.3 L).

Brake Fluid Type:

DOT 4 Hydraulic Fluid (unless otherwise specified for specific ABS models).

Known Issues

Cam Chain Tensioners:

Early Twin Cam models (pre-2007) can have wear on the hydraulic cam chain tensioners, potentially leading to noise or failure. The manual will cover inspection and replacement procedures.

Crankshaft Runout:

While less common on stock engines, improper assembly or high mileage can lead to crankshaft runout issues. The manual will provide specifications for checking this.

Electrical Connector Corrosion:

Exposure to elements can lead to corrosion on electrical connectors, causing intermittent faults. The manual's electrical section is critical for diagnosis.

📚 Vehicle History

Brand Heritage

Brand Establishment:

Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer with a deep history in V-twin engines and touring motorcycles.

Model Evolution

Flt Introduction:

The FLT chassis was introduced in 1980, evolving through various engine and feature updates. The 2003 models represent the later iterations of the Twin Cam platform.

Production

Production Plant:

York, Pennsylvania, USA; Milwaukee, Wisconsin, USA (various components)

🏆 Awards & Recognition

Recognitions

Brand Recognition:

Harley-Davidson motorcycles, particularly the FLT touring models, are widely recognized for their comfort, long-distance capability, and distinctive styling.