Positioning:
Essential resource for Harley-Davidson Touring motorcycle owners and independent repair shops seeking in-depth technical guidance for models from 2004-2006.
Value Proposition:
Offers comprehensive coverage exceeding basic owner's manuals, providing professional-level repair and maintenance information for a significant period of Harley-Davidson's popular Touring line.
Instant Download:
Immediate access to critical service information without shipping delays or physical media.
Page Volume:
Over 1000 pages indicate a high level of detail and thoroughness in coverage.
Engine:
Engine mechanical, engine management, fuel system, ignition system, cooling system, lubrication system, exhaust system, emissions control
Transmission:
Clutch, gearbox, primary drive, final drive, transmission controls
Chassis:
Frame, suspension (front and rear), steering, wheels, tires, brakes (front and rear), bodywork, fairings, luggage systems
Electrical:
Battery, charging system, starting system, lighting system, instrumentation, ignition, wiring diagrams, diagnostic codes, accessory circuits
Maintenance:
Scheduled maintenance, lubrication, fluid changes, filter replacements, inspections, adjustments
Repair:
Component removal, disassembly, inspection, repair, reassembly, installation, troubleshooting, diagnostics
Diagnostics:
Fault finding, error code interpretation, component testing, diagnostic procedures
Depth:
Comprehensive, covering from basic maintenance to advanced engine and electrical diagnostics and rebuild procedures.
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable PDF, enabling quick access to specific information.
Print Readability:
Designed for clear printing of text, diagrams, and schematics.
Binding For Digital:
N/A (Digital download)
Paper For Printed:
N/A (Digital download, assumes standard paper if printed by user)
Engine Family:
Harley-Davidson Twin Cam 88, Twin Cam 95, and potentially Twin Cam 103 (depending on specific Touring model variants within these years)
Engine Configuration:
V-Twin, Air-Cooled, Pushrod-Actuated Overhead Valves
Bore Stroke Twin Cam 88:
3.75 in x 4.00 in (95.25 mm x 101.6 mm)
Displacement Twin Cam 88:
88 cubic inches (1450cc)
Bore Stroke Twin Cam 95:
3.75 in x 4.25 in (95.25 mm x 107.95 mm)
Displacement Twin Cam 95:
95 cubic inches (1550cc)
Horsepower Approx Twin Cam 88:
Approx. 65-70 HP (varies by model and tuning)
Torque Approx Twin Cam 88:
Approx. 80-85 ft-lbs (varies by model and tuning)
Horsepower Approx Twin Cam 95:
Approx. 70-75 HP (varies by model and tuning)
Torque Approx Twin Cam 95:
Approx. 85-90 ft-lbs (varies by model and tuning)
Fuel Delivery 2004:
Carburetor (Keihin CV 40mm) or Electronic Fuel Injection (EFI) depending on model and emissions regulations.
Fuel Delivery 2005 2006:
Primarily Electronic Fuel Injection (EFI) with sequential port injection.
Fuel Type:
Unleaded gasoline, minimum 91 octane (AKI)
Ignition System:
Electronic Ignition Module (EIM) with single spark per cylinder.
Type:
5-speed constant mesh, constant torque transmission
Primary Drive:
Multi-plate, wet-type clutch, chain drive (up to 2005, some may have belt drive variants), or enclosed primary belt drive (2006+ models typically)
Clutch Actuation:
Cable-actuated
Gear Ratios:
Specific ratios for each gear are detailed in the manual, critical for performance and diagnostics.
Transmission Fluid:
Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant (or equivalent spec oil)
Wheelbase:
Varies by model (e.g., FLHTPI Electra Glide Police: ~63.5 inches)
Length:
Varies by model (e.g., FLHTPI Electra Glide Police: ~93.1 inches)
Dry Weight:
Varies by model (e.g., FLHT Electra Glide Standard: ~770 lbs)
Gross Vehicle Weight Rating Gvwr:
Varies by model (e.g., ~1300 lbs)
Fuel Capacity:
4.9 US gallons (18.5 L)
Luggage Capacity:
Includes saddlebags and potentially a tour-pak, specific volumes detailed in manual.
Crash Test Ratings:
Motorcycle safety is not typically rated by agencies like NHTSA in the same manner as automobiles; safety relies heavily on rider skill and vehicle design.
Brakes:
Dual-disc front brakes, single-disc rear brake. Specific caliper types and rotor sizes detailed in manual.
Suspension:
Adjustable front forks and rear shock absorbers, providing stability and ride comfort.
Lighting:
Halogen headlight, taillight, brake light, turn signals, passing lamps (model dependent).
Fairing:
Aerodynamic fairings provide rider protection from wind and elements.
Audio System:
Many Touring models of this era featured integrated audio systems with AM/FM radio and CD players. Handlebar-mounted controls are common.
Cruise Control:
Electronic cruise control was a popular option on many Touring models, detailed in the manual for operation and troubleshooting.
ABS Brakes:
Anti-lock Braking System (ABS) was available on some models, a crucial safety feature the manual covers for diagnostics and maintenance.
Communications:
Intercom systems and CB radio capabilities were often integrated into higher-end Touring models (e.g., Ultra Classic Electra Glide) and covered by the manual.
Initial Service:
Typically at 1,000 miles (1600 km) for first service, including oil change, filter replacement, and comprehensive inspection.
Regular Maintenance:
Subsequent services typically scheduled every 5,000 miles (8000 km), with specific checks and fluid changes at intervals detailed in the manual.
Engine Oil:
Harley-Davidson 20W-50 SYN3 (Synthetic) or equivalent Harley-Davidson approved motorcycle oil. Capacity approximately 4 US quarts (3.8 L).
Transmission Fluid:
Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant or equivalent.
Brake Fluid:
DOT 5 Silicone-based fluid (Harley-Davidson recommends their own brand). DO NOT mix with DOT 3 or DOT 4.
Primary Chaincase Fluid:
Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant or equivalent.
Cam Chain Tensioners:
Early Twin Cam models (prior to 2007) had plastic hydraulic cam chain tensioners that could wear prematurely. This manual will detail inspection and replacement procedures.
Crankcase Bearings:
Potential for output shaft bearing or inner primary bearing issues requiring specific inspection and replacement techniques detailed in the manual.
Electrical Connectors:
Corrosion or loose connections can cause intermittent electrical issues, which the manual's wiring diagrams and troubleshooting sections will address.
Suspension Seals:
Fork seal leaks or rear shock absorber issues are common maintenance items, covered in the manual's suspension section.
Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and cruiser/touring motorcycles.
Touring Lineage:
The Touring line evolved from earlier large displacement Harley-Davidson models, emphasizing comfort, luggage capacity, and long-distance riding capability.
Twin Cam Introduction:
The Twin Cam engine family, introduced in 1999, represented a significant update and became the powerplant for most Harley-Davidson models, including the Touring series.
Manufacturing Location:
Primarily manufactured in York, Pennsylvania, and Milwaukee, Wisconsin, USA.
Sales Performance:
Harley-Davidson Touring models are consistently popular within their segment, representing a significant portion of the brand's sales.
Brand Recognition:
Harley-Davidson is a globally recognized brand synonymous with the American motorcycle lifestyle and a leader in the touring segment.
Owner Satisfaction:
Harley-Davidson motorcycles generally receive high owner satisfaction ratings for their character, comfort, and performance in the touring segment.
Manual Completeness:
This manual is certified as a comprehensive workshop service manual by its extensive page count and detailed coverage of all major vehicle systems.
