🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLHTC Electra Glide Classic

Year:

2004

Product Type:

Service Repair Workshop Manual

👋 Introduction

Segment:

Full-size Grand American Touring motorcycle.

Target Audience:

Owners seeking to perform their own maintenance and repairs, independent repair shops, aspiring mechanics.

Competitors 2004:

Primarily other large displacement V-twin touring motorcycles from American and European manufacturers, such as Indian, certain Victory models, and potentially some custom builds or modified Japanese touring bikes.

Model Features:

Large fairing with integrated windshield, comfortable seating for rider and passenger, ample luggage capacity (saddlebags, tour-pak), large V-twin engine, highway-oriented ergonomics, advanced (for its time) features like cruise control and premium audio systems.

📋 Manual Details

General Coverage:

Comprehensive service and repair instructions for the 2004 Harley-Davidson FLHTC Electra Glide Classic.

Estimated Pages:

Typically 700-1000+ pages for a full factory service manual of this era.

Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

Digital (likely PDF), sometimes available as physical print.

📖 Manual Coverage

Powertrain:

Engine, transmission, clutch, drivetrain (primary and secondary).

Chassis:

Frame, suspension (front and rear forks, shock absorbers), steering, wheels, tires, brakes (front and rear).

Electrical:

Ignition system, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlight, taillight, turn signals), instrumentation, battery, wiring diagrams, fuses, relays, horn, audio system.

Bodywork And Trim:

Fairing, saddlebags, tour-pak, seat, fenders, fuel tank, controls, mounting hardware.

Fuel System:

Carburetor (Keihin CV type), fuel pump, fuel lines, fuel filter, fuel tank servicing.

Exhaust System:

Exhaust pipes, mufflers, heat shields.

Maintenance:

Routine maintenance checks, lubrication, filter replacement, spark plug service, brake pad inspection, tire pressure checks, fluid level checks.

Repair And Rebuild:

Engine disassembly, inspection, and reassembly; transmission overhaul; clutch service; fork seal replacement; brake caliper service; starter motor replacement.

Troubleshooting:

Diagnostic charts and procedures for common malfunctions and performance issues across all systems.

Technical Data And Specs:

Torque specifications, clearances, fluid capacities, wiring diagrams, component identification.

Depth:

Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and troubleshooting.

📊 Manual Specifications

Digital Features:

Searchable text, hyperlinked sections, printable pages.

Print Quality:

High-resolution images and diagrams, clear text, durable binding (if physical).

Binding:

Spiral-bound or perfect-bound for physical copies to lay flat.

Paper Quality:

Durable, often glossy or semi-gloss paper suitable for workshop environments.

⚙️ Engine Specifications

Engine Family:

Harley-Davidson Twin Cam 88

Engine Type:

Air-cooled, 45-degree V-twin

Displacement:

1450 cc (88 cubic inches)

Bore X Stroke:

3.75 in x 4.00 in (95.25 mm x 101.6 mm)

Compression Ratio:

8.8:1 (typical for Twin Cam 88)

Valve Train:

Pushrod actuated overhead valves, 2 valves per cylinder

Horsepower Est:

Approximately 65-70 HP at rear wheel (crank figures higher)

Torque Est:

Approximately 86-90 lb-ft at ~3000 RPM

Fuel Delivery:

Carbureted, Keihin 40mm CV (Constant Velocity)

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON+MON)/2)

Fuel Capacity:

5.0 US gallons (18.9 Liters)

🔧 Transmission

Transmission Type:

5-speed constant mesh, sequential manual gearbox

Optional Transmission:

N/A for this model year and trim

Clutch Type:

Wet, multi-plate

Primary Drive:

Duplex chain, offset

Final Drive:

Belt drive, 32 mm wide

Transmission Fluid Spec:

Harley-Davidson SYN3 transmission lubricant or equivalent SAE 75W-90 synthetic gear lubricant meeting Harley-Davidson specifications.

📐 Dimensions

Length:

98.5 inches (2502 mm)

Width:

38.0 inches (965 mm)

Height:

63.3 inches (1608 mm) (at windshield top)

Wheelbase:

63.5 inches (1613 mm)

Dry Weight Est:

Approximately 770 lbs (349 kg)

Gross Vehicle Weight Rating Gvw:

1300 lbs (590 kg)

Payload Capacity Est:

Approximately 530 lbs (240 kg)

Saddlebag Capacity:

Integrated, lockable, hard-shell saddlebags

Tour Pak Capacity:

Large removable or fixed Tour-Pak with integrated luggage rack

🛡️ Safety Features

Safety Ratings:

N/A (motorcycles are not typically rated by organizations like NHTSA or IIHS in the same way as cars).

Braking System:

Dual 32 mm 4-piston calipers with 11.5 in (292 mm) floating rotors front; Single 32 mm 4-piston caliper with 11.5 in (292 mm) rotor rear. Linked braking system (Batwing fairing models often featured linked brakes).

Suspension Features:

Adjustable front fork (preload), adjustable rear shock absorbers (preload, rebound damping).

Lighting:

Halogen headlight, multiple front and rear running lights and turn signals, integrated brake light in tour-pak.

Chassis Design:

Heavy-duty steel frame designed for stability and carrying load.

💡 Technology Features

Audio System:

Factory-installed AM/FM stereo radio with cassette player (and potentially CD player option). Likely 4 speakers (fairing and rear). Features like weather band, seek/scan, volume control.

Cruise Control:

Electronic cruise control system integrated into handlebar controls.

ABS:

Anti-lock Braking System (ABS) was often an option on Electra Glide models in this era, though not standard on all FLHTC models for 2004. Manual would specify if ABS is present.

Connectivity Features:

Limited by modern standards; primarily focused on audio input (cassette/CD) and handlebar-mounted controls. No Bluetooth or USB connectivity typical for this year.

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles (8,000 km) or 12 months, whichever comes first (for engine oil).

Primary Chain Tensioner Inspection:

Inspect and adjust every 10,000 miles (16,000 km) or as needed based on noise.

Spark Plug Replacement:

Typically every 10,000 miles (16,000 km).

Brake Fluid Flush:

Every 24 months, or as per manual recommendations.

Engine Oil Type:

Harley-Davidson SYN3 (20W50 synthetic) or equivalent SAE 20W50 motorcycle oil meeting Harley-Davidson performance criteria.

Engine Oil Capacity:

Approximately 4.0 US quarts (3.8 Liters) with filter change.

Transmission Oil Type:

Harley-Davidson SYN3 or SAE 75W-90 synthetic gear lubricant.

Primary Case Oil Type:

Harley-Davidson SYN3 or SAE 75W-90 synthetic gear lubricant.

Brake Fluid Type:

DOT 4 brake fluid.

Twin Cam Tensioner Shoes:

Early Twin Cam models (pre-2007) used plastic cam chain tensioner shoes that could wear out and cause engine noise or damage. Manual would detail inspection and replacement procedures.

Rear Main Seal Leaks:

Some Twin Cam engines experienced rear main seal leaks, particularly after higher mileage. Manual would cover diagnosis and replacement.

Idle Speed Fluctuations:

CV carburetors can be sensitive to altitude and tuning, sometimes leading to rough or unstable idle. Manual would cover carb adjustment and cleaning.

📚 Vehicle History

Harley Davidson Heritage:

Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer renowned for its V-twin engines and distinct styling, a cornerstone of American motorcycling culture.

Electra Glide Lineage:

The Electra Glide line dates back to the 1960s, evolving through various engine platforms (Shovelhead, Evolution, Twin Cam) and design updates, consistently representing Harley-Davidson's flagship touring machine.

Twin Cam Introduction:

The Twin Cam 88 engine was introduced in 1999, replacing the Evolution Big Twin, and became the core of Harley-Davidson's touring and cruiser lineup through the early 2000s.

Model Year 2004 Significance:

The 2004 model year saw continued refinement of the Twin Cam 88 platform, with the FLHTC Electra Glide Classic being a popular choice for long-distance comfort and amenities.

🏆 Awards & Recognition

Brand Recognition:

Harley-Davidson consistently receives recognition for its brand loyalty, iconic styling, and V-twin engine performance in the touring motorcycle segment.

Motorcycle Journal Reviews:

Motorcycle publications of the era often praised the Electra Glide Classic for its comfort, rider amenities, and stable handling on long rides, while sometimes noting its weight and the characteristic Harley-Davidson riding experience.