Positioning:
Essential reference for Harley-Davidson owners and independent repair shops to maintain and repair the popular Touring models of the early 2000s.
Value Proposition:
Provides factory-level information, often surpassing aftermarket options in accuracy and detail for this specific period.
Essential Resource:
Indispensable for accurate part ordering, correct maintenance procedures, and efficient troubleshooting, saving time and money.
Diy Support:
Empowers owners to perform a wide range of maintenance and repair tasks themselves.
Engine Mechanical:
Complete overhaul, disassembly, assembly, and tuning of Twin Cam 88 and Twin Cam 96 engines (depending on specific model year and variant).
Fuel System:
Carbureted (Keihin CV) and Fuel Injection (EFI - Delphi/Vance & Hines) systems, including fuel pump, injectors, sensors, and ECU diagnostics.
Ignition System:
Ignition module, coils, spark plugs, crank position sensor, and troubleshooting.
Electrical System:
Wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), battery maintenance, lighting, and accessories.
Transmission Drivetrain:
Clutch operation, primary drive, transmission assembly (5-speed Cruise Drive), final drive belt, and related adjustments.
Brakes:
Front and rear brake systems, including master cylinders, calipers, rotors, hydraulic lines, fluid types, bleeding procedures, and ABS (where applicable).
Suspension:
Front fork (telescopic, possibly air-assisted) and rear shock absorber systems, including service, fluid changes, and adjustment.
Frame Chassis:
Frame construction, steering head bearing service, and general chassis inspection.
Bodywork Farkling:
Fairing removal and installation, saddlebags, tour-pak, seat, fenders, and associated trim.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain/belt inspection, brake fluid checks.
Troubleshooting:
Diagnostic charts for common problems, symptom-based troubleshooting guides, and diagnostic trouble codes (DTCs) for EFI models.
Component Overhaul:
Detailed step-by-step instructions for rebuilding engines, transmissions, carburetors/fuel injectors, and brake systems.
Adjustment Procedures:
Clutch adjustment, throttle cable adjustment, idle speed adjustment, and suspension adjustments.
Electrical Diagnostics:
Testing charging system components, starter motor, ignition system, and troubleshooting electrical faults using wiring diagrams.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Depth:
Comprehensive from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics and troubleshooting.
Engine Family:
Harley-Davidson Twin Cam
Engine Displacement 2000-2006:
Primarily 88 cubic inches (1450cc), with some later models (2007 onwards, but covering the end of this range) introducing the 96 cubic inch (1573cc) engine. This manual likely covers the transition and earlier 88ci variants extensively.
Engine Configuration:
V-twin, 45-degree cylinder angle, air-cooled
Valve Train:
Overhead valve (OHV), 2 valves per cylinder
Horsepower Approx:
Typically 60-70 HP (approximate, varies by specific model year and tuning)
Torque Approx:
Typically 70-85 ft-lbs (approximate, varies by specific model year and tuning)
Fuel Delivery Early:
Keihin CV (Constant Velocity) Carburetor (e.g., CV 40mm)
Fuel Delivery Later:
Electronic Fuel Injection (EFI) - Delphi system (often referred to as 'Sequential Port Injection' or SPI)
Oil Type Specification:
Harley-Davidson SYN3 (or equivalent API SG or higher, SAE 20W-50 recommended by many owners for Twin Cam).
Oil Capacity Approx:
Approximately 4 US quarts (3.8 liters) with filter change (check manual for exact spec).
Wheelbase Approx:
Approximately 63.5 inches (1613 mm), varies slightly by model (e.g., Electra Glide, Road King).
Seat Height Approx:
Approximately 27.3 inches (693 mm) unladen, varies by model and suspension.
Dry Weight Approx:
Approximately 700-800 lbs (317-363 kg), varies significantly by model and features.
Gross Vehicle Weight Rating Gvw:
Typically around 1300-1400 lbs (590-635 kg).
Crash Test Ratings:
Motorcycles are not subjected to standardized crash test ratings like automobiles; safety is assessed through design and rider aids.
Anti Lock Braking System ABS:
Available as an option on many Touring models during this period. The manual will detail its function and servicing.
Lighting:
Halogen headlight, auxiliary passing lamps (on some models), LED taillight and brake lights.
Chassis Stability:
Robust frame and well-balanced design contributing to rider confidence and stability.
Audio System:
Factory-installed AM/FM/Cassette or CD player with handlebar-mounted controls on many models. Upgrade options exist.
Cruise Control:
Electronic cruise control was available on many Touring models, controlled via handlebar switches.
ABS:
Anti-lock Braking System (ABS) became more prevalent and an option on many models in this era.
Diagnostic Ports:
EFI models feature diagnostic connectors for interfacing with Harley-Davidson's diagnostic tools (e.g., Digital Technician) or compatible aftermarket scanners. The manual details these ports.
First Service:
Typically at 1,000 miles (1600 km) for initial engine break-in and fluid change. Specifics are detailed in the manual.
Regular Oil Change:
Every 5,000 miles (8,000 km) or annually, whichever comes first. Engine oil and filter replacement.
Transmission Fluid Change:
Every 10,000 miles (16,000 km) or annually. Primary and transmission fluid checks and changes.
Brake Fluid Flush:
Every 2 years or as recommended based on fluid condition. DOT 4 brake fluid specified.
Engine Oil:
Harley-Davidson SYN3 or equivalent SAE 20W-50 (API SG or higher).
Transmission Oil:
Harley-Davidson Formula + or SAE 80W-90 Hypoid Gear Oil.
Brake Fluid:
DOT 4 (refer to manual for specific DOT type if variations exist).
Primary Chain Case Oil:
Harley-Davidson Formula + or equivalent.
Cam Chain Tensioners:
Early Twin Cam models (pre-2007) are known for hydraulic cam chain tensioner wear. The manual will provide inspection and replacement procedures.
Rocker Box Gaskets:
Occasional oil leaks from rocker box gaskets can occur. The manual details their replacement.
Electrical Connectors:
Corrosion or loose connections in electrical connectors can lead to various electrical gremlins. The manual aids in diagnosis.
Heritage:
Harley-Davidson is an iconic American motorcycle manufacturer with a long history dating back to 1903, renowned for its V-twin engines and touring capabilities.
Touring Lineage:
The Touring line has evolved from earlier models like the Electra Glide, representing the pinnacle of comfort and long-distance riding for the brand.
Twin Cam Introduction:
The Twin Cam engine platform, introduced in 1999, became the standard for Harley-Davidson's Big Twin models, including the Touring series, offering improved performance and reliability over the Evolution engine.
Manufacturing Location:
Primarily manufactured in the United States (e.g., York, Pennsylvania and Milwaukee, Wisconsin).
