Model Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006
Manual Product Name:
Harley Davidson Touring 2000-2006 Service Repair Manual
Vehicle Platform:
FLHT/FLHR/FLHX/FLTR (Touring Chassis)
Segment:
Luxury Touring Motorcycles
Target Audience:
Long-distance riders, touring enthusiasts, customizers
Competitors:
Honda Gold Wing, Indian Roadmaster, BMW K1600GTL, Kawasaki Vulcan Vaquero
Vehicle Appeal:
Comfort, cargo capacity, rider amenities, V-twin engine character, iconic Harley-Davidson styling
Manual Value Proposition:
Enables owners and technicians to maintain, diagnose, and repair their Harley-Davidson Touring motorcycles effectively, preserving performance and value.
Engine:
V-Twin Evolution (Twin Cam 88, Twin Cam 96 for later years), Engine mechanics, cylinder heads, cylinders, pistons, crankshaft, camshafts, timing, lubrication, cooling (air-cooled), fuel injection, ignition system, exhaust system
Transmission:
5-speed Cruise Drive (for Twin Cam 96), 5-speed manual transmission, clutch, gearshift mechanism, primary drive, final drive (belt drive)
Brakes:
Hydraulic disc brakes (front and rear), brake system components, bleeding procedures, fluid specifications
Electrical:
Battery, charging system (alternator, regulator), starting system (starter, solenoid), lighting, ignition, instrumentation, fuel injection control module (ECM), anti-theft systems, wiring diagrams, diagnostic trouble codes (DTCs)
Chassis Suspension:
Frame, front suspension (forks, triple clamps), rear suspension (shock absorbers, swingarm), steering system, wheel bearings
Bodywork:
Fairings, saddlebags, tour-pak, fuel tank, seat, fenders, trim components, body panel removal and installation
Maintenance:
Routine scheduled maintenance, oil changes, filter replacements, spark plug checks, lubrication, tire pressure checks, brake pad inspections
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault finding based on symptoms, use of diagnostic tools
Repair:
Component-level repair and replacement, engine rebuilds, transmission overhauls, suspension work, electrical system repairs
Assembly Disassembly:
Detailed step-by-step instructions for disassembling and reassembling all major vehicle systems and components
Depth:
Comprehensive (Factory level detail, suitable for professional technicians and advanced DIY enthusiasts)
Engine Family:
Harley-Davidson V-Twin
Engine Type:
Air-cooled, 45-degree V-twin
Engine Displacement 2000-2005:
1450cc (88 cubic inches)
Engine Displacement 2007-Onwards:
1584cc (96 cubic inches) - Some late 2006 models might have the 96ci as an option
Engine Code Common:
Twin Cam 88
Horsepower Approx Twin Cam 88:
60-70 HP (at crankshaft, varies by year and tune)
Torque Approx Twin Cam 88:
75-85 ft-lbs (at crankshaft, varies by year and tune)
Fuel Delivery:
Electronic Fuel Injection (EFI) - Sequential Port Fuel Injection (SPFI)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Bore X Stroke Twin Cam 88:
3.75 in x 4.00 in (95.25 mm x 101.6 mm)
Transmission Type:
5-speed constant mesh, manual
Transmission Type Later Models:
6-speed Cruise Drive (introduced for some models starting around 2006-2007)
Clutch Type:
Hydraulic, multi-plate wet clutch
Final Drive:
Enclosed, single-strand, offset chain drive (5/8" x 1/2")
Transmission Fluid Type:
Harley-Davidson Formula+ Transmission & Primary Chaincase Lube (or equivalent)
Transmission Fluid Capacity:
Approximately 20-24 US fl oz (600-700 ml)
Wheelbase Approx:
63.5 - 64.5 inches (1613 - 1638 mm)
Length Overall Approx:
95.0 - 98.0 inches (2413 - 2489 mm)
Dry Weight Approx:
700 - 750 lbs (317 - 340 kg), varies by model variant
Gross Vehicle Weight Rating Gvwr Approx:
1300 - 1350 lbs (590 - 612 kg)
Saddlebag Capacity Approx:
2.25 cubic feet combined (63.7 liters)
Tour Pak Capacity Approx:
2.3 - 2.5 cubic feet (65 - 70 liters)
Crash Test Ratings:
N/A (Motorcycles are not subjected to the same crash testing protocols as automobiles)
Braking System:
Dual disc front, single disc rear; Optional ABS (Anti-lock Braking System) on some higher trims/later years.
Lighting:
Halogen headlight, auxiliary driving lights (on most models), LED tail/brake lights
Chassis Design:
Robust steel frame designed for stability and load carrying
Engine Guard Crash Bars:
Often equipped with or available as an accessory for leg and engine protection.
Audio System:
Factory-installed AM/FM/WB radios with cassette or CD players were common. Higher-end models offered premium sound systems with fairing-mounted speakers and handlebar controls.
Cruise Control:
Electronic cruise control was available on many Touring models during this period.
ABS:
Anti-lock Braking System (ABS) became an option or standard on many models in the later years of this range.
Intercom:
Some models featured an intercom system for rider-passenger communication, and connectivity for CB radio.
First Service:
Typically at 1,000 miles (1,600 km): Includes engine oil and filter change, inspection of critical fasteners, chain adjustment, brake inspection, clutch adjustment.
Subsequent Oil Change:
Every 5,000 miles (8,000 km) or annually, whichever comes first.
Spark Plug Replacement:
Typically every 10,000 - 15,000 miles (16,000 - 24,000 km), depending on spark plug type and model year.
Drive Belt Inspection:
Inspect tension and condition at every service interval.
Engine Oil Type:
Harley-Davidson V-Twin 20W-50 SYN3 or recommended 20W-50 motorcycle specific oil.
Engine Oil Capacity:
Approximately 4 US quarts (3.8 liters) with filter change.
Primary Chaincase Fluid:
Harley-Davidson Formula+ Transmission & Primary Chaincase Lube.
Brake Fluid Type:
DOT 4 compatible fluid (check specific model year recommendations for potential DOT 5.1 if specified).
Twin Cam 88 Cam Chain Tensioner:
Early Twin Cam 88s (pre-2007) used plastic cam chain tensioner shoes that could wear prematurely, potentially leading to chain slap or failure. Upgraded hydraulic tensioners are a common aftermarket modification.
Rear Cylinder Overheating:
Common on Harley-Davidson V-twins, especially in hot weather or stop-and-go traffic. Proper air cooling and maintenance are key.
Regulator Rectifier Failure:
Can lead to charging system issues. Replacement with improved aftermarket units is common.
Saddlebag Latch Issues:
May require adjustment or lubrication over time.
Brand Origin:
Founded in Milwaukee, Wisconsin in 1903, Harley-Davidson is an iconic American motorcycle manufacturer.
Touring Lineage:
The Touring line evolved from earlier large displacement V-twins, with the FL platform being a long-standing staple. The 2000-2006 era represents the development and refinement of the Twin Cam 88 engine and chassis.
Manufacturing Location:
Primarily Milwaukee, Wisconsin, USA; York, Pennsylvania, USA; Kansas City, Missouri, USA.
Model Cycle:
These years mark a significant period for the Twin Cam 88 engine, a departure from the previous Evolution engine, and saw incremental updates to styling, features, and engine performance leading up to the introduction of the Twin Cam 96 and 6-speed transmission.
Brand Acclaim:
Harley-Davidson motorcycles, particularly the Touring series, are consistently recognized for their iconic styling, rider comfort, and long-distance touring capabilities.
Owner Satisfaction:
Generally high owner satisfaction, especially among dedicated Harley-Davidson enthusiasts.
