🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLSTC Heritage Softail Classic

Year:

2004

Sub Model:

ST

Chassis Code:

FLSTC

👋 Introduction

Positioning:

The FLSTC Heritage Softail Classic ST for 2004 represented Harley-Davidson's commitment to its iconic styling and touring comfort, blending classic looks with modern V-twin technology.

Competition:

Competed primarily within the cruiser and touring motorcycle segments, often against models from Indian Motorcycle (though less prevalent in this era) and other custom-styled American V-twins.

Styling:

Retro styling, white wall tires, laced wheels, chrome accents, teardrop fuel tank, stepped seat, detachable windscreen, and saddlebags.

Engine Technology:

Harley-Davidson's counter-balanced Evolution V-twin engine, known for its robust performance and iconic rumble.

📋 Manual Details

Engine:

Yes

Transmission:

Yes

Electrical System:

Yes

Chassis:

Yes

Suspension:

Yes

Brakes:

Yes

Fuel System:

Yes

Ignition System:

Yes

Exhaust System:

Yes

Cooling System:

N/A (Air-Cooled)

Bodywork:

Yes

Accessories:

Yes

Diagnostics:

Yes

Troubleshooting:

Yes

Wiring Diagrams:

Yes

Approximate Pages:

Hundreds

Type:

Factory Service Manual (FSM)

Subtype:

Repair Manual

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Powertrain:

Engine overhaul, clutch, primary drive, transmission, final drive

Chassis And Suspension:

Frame, swingarm, front fork (including telescopic type), rear shocks, steering head, wheel bearings

Braking System:

Front and rear brake calipers, master cylinders, brake lines, brake fluid specifications, bleeding procedures

Fuel And Exhaust:

Fuel tank, fuel pump, fuel injectors (EFI), carburetor (if applicable for earlier models, but 2004 is EFI), fuel lines, mufflers, catalytic converter (if equipped)

Electrical And Ignition:

Battery, charging system (stator, regulator/rectifier), ignition system (ECM, spark plugs, ignition coil), lighting (headlights, tail lights, turn signals), starter motor, horn, instrument cluster, wiring harnesses, troubleshooting electrical faults

Controls:

Throttle controls, clutch lever, brake lever, shifter mechanism, handlebar controls

Body And Trim:

Fenders, fuel tank emblem, seat, windshield, saddlebags, fairing components, chrome trim

Maintenance:

Scheduled maintenance, lubrication, cleaning, inspection, fluid changes, filter replacements

Repair:

Engine disassembly and reassembly, transmission overhaul, brake caliper rebuild, fork seal replacement, electrical component repair, body panel repair/replacement

Diagnostics:

Troubleshooting common issues, interpreting diagnostic trouble codes (DTCs), using diagnostic tools

Installation:

Installation of accessories, replacement of parts

Adjustment:

Clutch cable adjustment, throttle cable adjustment, primary chain tensioner adjustment, idle speed adjustment

Depth:

Comprehensive, covering from basic maintenance to full engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications.

📊 Manual Specifications

Quality:

High-resolution scans, ensuring clarity and readability of text and diagrams.

Searchability:

Likely text-searchable PDF, allowing for quick access to specific topics.

Printability:

Printable pages for workshop use.

Binding:

N/A (Digital PDF Download)

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-twin

Displacement:

1450cc (88 cubic inches)

Bore X Stroke:

3.50 in x 4.48 in (88.9 mm x 113.8 mm)

Compression Ratio:

8.9:1

Valve Train:

Overhead valves (OHV), two valves per cylinder, pushrod actuated

Horsepower:

Estimated 65-70 HP (at crankshaft, actual figures varied slightly by source/tuning)

Torque:

Estimated 77-82 ft-lbs @ 3500 RPM (actual figures varied slightly by source/tuning)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI) - Keihin

Fuel Type:

Unleaded gasoline, minimum 91 octane (AKI)

🔧 Transmission

Transmission Type:

5-speed constant mesh

Primary Drive:

Plated, wet-type clutch; chain drive

Final Drive:

Belt drive, 32mm

Clutch Type:

Hydraulic actuation

Gear Ratios:

1st: 9.312, 2nd: 6.454, 3rd: 4.743, 4th: 3.810, 5th: 3.160 (Typical Harley-Davidson 5-speed ratios)

📐 Dimensions

Length:

Approx. 94.7 in (2405 mm)

Width:

Approx. 36.7 in (932 mm)

Height:

Approx. 56.3 in (1430 mm) to top of windshield

Wheelbase:

Approx. 63.5 in (1613 mm)

Ground Clearance:

Approx. 4.7 in (119 mm)

Seat Height:

Approx. 26.0 in (660 mm) laden

Dry Weight:

Approx. 665 lbs (301 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 1075 lbs (488 kg)

Fuel Capacity:

4.0 gal (15.1 L)

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycles are not typically subjected to standardized crash test ratings like automobiles)

Braking System:

Dual front disc brakes, single rear disc brake. ABS was not standard on all 2004 models, check specific VIN.

Lighting:

Halogen headlight, auxiliary passing lamps, full LED tail lamp and brake light assembly (often an aftermarket upgrade for older models but standard on some newer ones - check original specs), amber turn signals.

Frame Construction:

Steel frame and swingarm providing a stable platform.

Engine Counterbalance:

Internal counterbalancer in the Evolution engine reduces vibration for rider comfort and control.

💡 Technology Features

Audio System:

Factory-installed radio and speaker systems were optional or part of specific packages on some FLSTC models. Typically AM/FM and sometimes cassette or CD player depending on the trim and options.

Display:

Analog speedometer and tachometer, fuel gauge, oil pressure light, and indicator lights on the instrument cluster.

ABS:

Anti-lock Braking System (ABS) was an optional feature for the 2004 FLSTC, not standard on all units. The manual would detail its operation and maintenance if equipped.

Connectivity Features:

Limited by modern standards. No integrated smartphone connectivity or Bluetooth. Aftermarket solutions are available for audio.

ECU:

Engine Control Unit (ECU) manages fuel injection and ignition timing based on sensor inputs.

🔧 Maintenance

First Service:

1,000 miles (1,600 km) - Oil change, primary chain case inspection, filter change, general inspection.

Subsequent Oil Change:

Every 5,000 miles (8,000 km) or annually, whichever comes first.

Primary Chain Tensioner:

Inspect and adjust every 5,000 miles (8,000 km) or as needed.

Spark Plugs:

Replace every 10,000-15,000 miles (16,000-24,000 km) depending on plug type and wear.

Belt Drive Tension:

Check and adjust according to manual specifications at regular intervals (e.g., every 5,000 miles).

Engine Oil:

Harley-Davidson V-Twin 20W-50 (API CG-4 or higher recommended) or equivalent SAE 20W-50 motorcycle-specific oil.

Primary Chain Case Fluid:

Harley-Davidson Primary Chain Case Oil or SAE 80W-90 Hypoid Gear Oil.

Transmission Fluid:

Harley-Davidson transmission fluid (e.g., SYN3 or HD 360) or SAE 85W-140 Hypoid Gear Oil.

Brake Fluid:

DOT 4 brake fluid.

Fork Oil:

Refer to manual for specific weight and type; typically a specialized fork oil is used.

Cam Chain Tensioners:

Early Twin Cam engines (pre-2006) were known to have plastic cam chain tensioners that could wear out, leading to potential engine damage. The 2004 model falls into this category and may benefit from an upgrade to hydraulic tensioners.

Primary Chain Tensioner:

Can require adjustment or replacement over time due to wear.

Electrical Gremlins:

As with many motorcycles of this era, aging wiring harnesses and connectors can lead to intermittent electrical issues. Thorough inspection and maintenance of the electrical system is crucial.

Paint And Chrome Flaking:

Some owners report issues with chrome pitting or flaking on certain components, and paint chipping over time, especially on fenders or tank.

📚 Vehicle History

Heritage:

Harley-Davidson, founded in 1903, has a long-standing legacy of producing V-twin motorcycles, synonymous with American freedom and iconic design.

Heritage Softail Line:

The Softail platform was introduced in 1984, designed to mimic the rigid frame look of classic Harley's while incorporating hidden rear suspension. The Heritage Softail models have consistently represented the brand's retro styling and touring capabilities.

Manufacturing Location:

United States (York, Pennsylvania and Milwaukee, Wisconsin assembly plants were primary)

Model Year Significance:

The 2004 model year continued the evolution of the FLSTC, featuring the Twin Cam 88 engine and Electronic Sequential Port Fuel Injection (ESPFI), a significant upgrade from carburetors in earlier models for improved emissions and performance.

🏆 Awards & Recognition

Model Awards:

While specific 'awards' for the 2004 FLSTC are not widely documented as distinct accolades, the Heritage Softail line consistently received praise from motorcycle journalists and owners for its blend of iconic styling, touring comfort, and the reliable performance of the Evolution engine.

Owner Satisfaction:

Generally high owner satisfaction ratings for its classic appeal and comfortable ride, often considered a flagship model for those appreciating traditional Harley-Davidson aesthetics.