Positioning:
Essential resource for owners and independent repair shops maintaining Harley-Davidson Touring models, known for their comfort and long-distance capability.
Comparison:
Directly competes with factory service manuals (FSMs) and other reputable aftermarket repair guides, offering detailed procedures crucial for proper maintenance and repair of complex touring platforms.
Advantage:
Provides detailed step-by-step instructions, clear diagrams, and essential technical data that are often critical for performing complex repairs accurately and efficiently.
Audience:
Professional motorcycle technicians, experienced DIY mechanics, and Harley-Davidson enthusiasts focused on maintaining their Touring motorcycles.
Primary Coverage:
Harley-Davidson Touring motorcycles
Specific Models Covered:
Road King, Road Glide, Ultra Classic, Electra Glide
Estimated Page Count:
Refer to product description for exact count, typically 800+ pages for comprehensive manuals
Type:
Repair and Service Manual
Engine:
Twin Cam 88, Twin Cam 88B (including fuel injection and carbureted models)
Transmission:
5-speed Cruise Drive, clutch, primary drive
Chassis:
Frame, suspension (front forks, rear shocks), wheels, steering
Electrical:
Ignition, lighting, charging system, starting system, instrumentation, H-D security system
Brakes:
Front and rear disc brakes, hydraulic systems
Fuel System:
Fuel tank, fuel pump, injectors (EFI), carburetor service
Exhaust System:
Exhaust pipes, mufflers, catalytic converters (where applicable)
Bodywork And Trim:
Fairings, saddlebags, tour-paks, fenders, seat assembly
Cooling System:
Air cooling for Twin Cam engines
Maintenance:
Routine service checks, oil changes, filter replacements, spark plug service, brake fluid flush, drive belt adjustment
Troubleshooting:
Diagnostic flowcharts, common problem identification, symptom-based remedies
Repair:
Engine disassembly and reassembly, transmission overhaul, suspension component replacement, electrical component diagnosis and repair
Diagnostics:
Understanding DTC codes (Diagnostic Trouble Codes), using diagnostic tools (e.g., H-D Digital Technician)
Technical Specifications:
Torque values, clearances, fluid capacities, electrical specifications
Depth:
Comprehensive, covering basic maintenance to full engine and transmission rebuilds; intended for professional technicians but accessible to experienced DIY mechanics
File Format:
PDF (Portable Document Format)
Searchability:
Likely searchable text, allowing for quick location of information
Image Resolution:
High resolution for diagrams and illustrations
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Completeness:
Comprehensive coverage, designed to guide users through all aspects of servicing, maintenance, repair, and troubleshooting for the specified model year and variants.
Engine Type:
Harley-Davidson Twin Cam V-Twin
Displacement:
1450cc (88 cubic inches)
Engine Variants:
Twin Cam 88 (pushrod overhead valves) and Twin Cam 88B (with internal counterbalancer)
Horsepower Estimate:
Approx. 65-70 HP (figures vary slightly by specific model and tuning)
Torque Estimate:
Approx. 85-90 lb-ft @ 3000-3500 RPM (figures vary slightly by specific model and tuning)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI) or Keihin CV Carburetor
Fuel Type:
Unleaded Gasoline, 91 octane (RON+MON)/2) or higher recommended
Ignition Type:
Electronic ignition with single fire ignition coils
Cooling Method:
Air-cooled
Transmission Type:
5-speed Cruise Drive Manual Transmission
Gear Ratios:
Specific ratios detailed in the manual, typically with overdrive 5th gear
Clutch Type:
Wet, multi-plate, cable-actuated
Primary Drive:
43/64 gear ratio (primary drive gear/compensating sprocket)
Final Drive:
32/66 tooth final drive ratio (belt drive)
Transmission Oil:
Harley-Davidson Formula+ Transmission and Primary Chaincase Lubricant (or equivalent SAE 50 motorcycle gear oil)
Transmission Capacity:
Approximately 1 quart (0.95 L)
Wheelbase:
Approx. 63.5 inches (1613 mm) - Varies by model
Seat Height:
Approx. 29.5 inches (750 mm) - Varies by model
Dry Weight:
Approx. 700-750 lbs (317-340 kg) - Varies by model
Gross Vehicle Weight Rating Gvwr:
Typically around 1200 lbs (544 kg) - Consult specific model
Saddlebag Capacity:
Integrated hard saddlebags, capacity varies by design
Tour Pak Capacity:
Optional, with significant cargo volume
Crash Test Ratings:
N/A for motorcycles as they are not typically crash-tested by regulatory bodies like NHTSA.
Braking System:
Dual-disc front brakes, single-disc rear brake, hydraulic actuation
Lighting:
Halogen headlight, LED taillight and turn signals (depending on model and configuration)
Frame Construction:
Steel cradle frame
Security System:
Factory-installed H-D Smart Security System with proximity-based key fob, often with siren and immobilizer.
Audio System:
Factory-installed AM/FM/WB radio with CD player, integrated handlebar controls on most models.
Speaker System:
Integrated fairing speakers, often with optional rear speakers for some models.
Cruise Control:
Electronic cruise control was a common option and is detailed in the manual.
Diagnostic Port:
OBD-II compliant diagnostic connector for engine management and fault code retrieval.
First Service:
Typically at 1,000 miles (1,600 km) - includes engine oil and filter change, primary chain case oil, inspection of various components.
Subsequent Service:
Every 5,000 miles (8,000 km) or annually, whichever comes first, for major services (oil change, filter, spark plugs, inspection). Consult the manual for detailed intervals for all systems.
Engine Oil:
Harley-Davidson 20W50 SYN3 (synthetic) or similar premium V-twin motorcycle oil meeting Harley-Davidson specifications.
Engine Oil Capacity:
Approximately 4 quarts (3.8 L) with filter change
Brake Fluid:
DOT 4 hydraulic fluid
Cam Chain Tensioner:
Early Twin Cam models (including 2002) had hydraulic cam chain tensioners that could wear prematurely, potentially leading to noise or damage. Upgraded tensioners are available.
Crankcase Breather:
Some models may experience oil blow-by from the crankcase breather; proper ventilation and oil management are key.
Electrical Connections:
As with many vehicles of this era, checking and ensuring clean electrical connections is important for system reliability.
Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and touring capabilities.
Touring Platform:
The Touring platform has evolved significantly, with the 2002 models featuring the then-current Twin Cam engine architecture, a progression from the Evolution Big Twin era.
Production Era:
The 2002 model year falls within the early production years of the Twin Cam 88/88B engine, which debuted in 1999.
