Harley Davidson FLHTC Electra Glide 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHTC Electra Glide Classic Year: 2004 Codes Model Code: FLHTC 👋 Introduction Market Position Segment: Full-dresser touring motorcycle segment Target Audience: Owners of...

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Type: Motorcycle

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Sku: 441388

Tags: 2004 Electra Glide FLHTC Harley Davidson Misc Motorcycle Motorcycles

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

FLHTC Electra Glide Classic

Year:

Codes

Model Code:

FLHTC

👋 Introduction

Market Position

Segment:

Full-dresser touring motorcycle segment

Target Audience:

Owners of the 2004 Harley-Davidson FLHTC Electra Glide Classic seeking to perform their own maintenance, repairs, or modifications; independent repair shops

Competitive Analysis

Positioning:

The FLHTC Electra Glide Classic was a benchmark in the American touring motorcycle market, known for its comfort, storage, and V-twin power. This manual supports the upkeep of a premium touring machine.

Key Features

Vehicle Highlight:

The 2004 FLHTC is characterized by its Batwing fairing, ample saddlebag storage, comfortable seating for rider and passenger, and the classic Harley-Davidson V-twin experience.

Manual Value Proposition:

Provides the authoritative information needed to maintain and repair the motorcycle to factory specifications, ensuring longevity and optimal performance.

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair, overhaul, maintenance, and troubleshooting of the 2004 Harley-Davidson FLHTC Electra Glide Classic

Secondary Coverage:

Diagnostics, electrical systems, engine, transmission, chassis, bodywork, and accessories

Page Count

Estimated Pages:

Approximately 600-800 pages (typical for this era of Harley service manuals)

Manual Type

Type:

Service Manual / Workshop Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, inspection, component tolerances, valve train, piston/cylinder, crankshaft, camshafts, timing, seals, gaskets

Engine Fuel System:

Carburetor (Keihin CV) overhaul and adjustment, fuel pump, fuel lines, fuel tank maintenance

Engine Ignition System:

Ignition module, spark plugs, ignition timing, coil testing and replacement

Engine Exhaust System:

Exhaust pipe and muffler removal, installation, and inspection

Transmission Drivetrain:

Primary drive, clutch operation and adjustment, transmission case disassembly/assembly, gear inspection, shift mechanism, final drive belt maintenance and adjustment

Electrical System:

Battery, charging system (alternator, regulator), starting system (starter motor, solenoid), lighting (headlight, taillight, signals), horn, instrumentation, wiring diagrams, fuses, relays

Brakes:

Front and rear brake caliper overhaul, hydraulic system bleeding, brake pad replacement, master cylinder service, brake line inspection

Suspension:

Front fork disassembly, seal replacement, fluid levels, rear shock absorber adjustment and replacement, swingarm service

Steering:

Handlebar, steering head bearing inspection and adjustment, fork tube alignment

Bodywork Chassis:

Frame inspection, fairing removal/installation, saddlebag mounting, fuel tank mounting, seat assembly, fenders

Wheels Tires:

Wheel bearing inspection and repacking, tire inspection and replacement, wheel balancing

Procedures Included

Routine Maintenance:

Oil and filter changes, primary chain adjustment, spark plug replacement, air filter cleaning/replacement, brake fluid checks, tire pressure checks

Diagnostic Troubleshooting:

Step-by-step diagnostic procedures for common faults and performance issues across all major systems, utilizing Harley-Davidson specific diagnostic information

Major Repairs:

Complete engine rebuilds, transmission overhauls, clutch replacement, suspension component replacements, electrical component diagnostics and repair

Component Overhaul:

Detailed procedures for disassembling, inspecting, servicing, and reassembling key components like carburetors, starters, alternators, and brake calipers

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, multimeter usage, and component testing

Technical Depth

Depth:

Comprehensive, covering everything from basic rider maintenance to complete engine and transmission rebuilds, suitable for both DIY enthusiasts and professional technicians

Detail Level:

Detailed specifications, torque values, clearances, troubleshooting flowcharts, and step-by-step instructions with accompanying diagrams and illustrations

📊 Manual Specifications

File Format

File Type:

Searchability:

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

Print Quality

Quality:

Digital reproduction of original factory service manual content, aiming for clarity in text and illustrations

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, Evolution (V-twin)

Displacement:

1450cc (88 cubic inches)

Bore X Stroke:

3.75 in. x 4.00 in. (95.3 mm x 101.6 mm)

Compression Ratio:

8.8:1 (typical for this engine)

Valve Train:

Overhead valve (OHV), 2 valves per cylinder, pushrod actuated

Performance

Horsepower:

Approximately 65-70 HP (estimated at crankshaft)

Torque:

Approximately 76-82 ft-lbs (estimated at crankshaft)

Fuel System

Fuel Delivery:

Keihin CV (Constant Velocity) carburetor, 40mm

Fuel Type:

Unleaded gasoline, minimum 87 octane

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Primary Drive:

Duplex chain, 34/46 ratio

Final Drive:

Belt drive, 32/65 ratio

Features

Clutch Type:

Wet, multi-plate, manual operation

Transmission Fluid:

Harley-Davidson Formula + Transmission and Primary Chaincase Lubricant, or equivalent API GL-5 rated gear oil

📐 Dimensions

Exterior

Length:

Approximately 103.4 inches (2626 mm)

Width:

Approximately 36.0 inches (914 mm)

Height:

Approximately 57.5 inches (1461 mm)

Wheelbase:

Approximately 63.5 inches (1613 mm)

Weights

Dry Weight:

Approximately 785 lbs (356 kg)

Gross Vehicle Weight Rating:

Approximately 1200 lbs (544 kg)

Cargo

Saddlebag Capacity:

Integrated hard saddlebags with substantial storage volume

Tour Pak Capacity:

Optional Tour-Pak provided additional lockable storage

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not applicable in the same manner as automobiles; focus on rider safety features and build quality.

Active Features

Braking System:

Dual front disc brakes, single rear disc brake, hydraulic actuation

Lighting:

Halogen headlight, full lighting suite including turn signals, brake light, taillight, and running lights

Passive Features

Chassis Stability:

Sturdy frame construction, balanced weight distribution for stability

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM stereo with cassette player, often with CB radio and intercom capabilities (depending on specific options/package)

Speakers:

Integrated fairing speakers

Driver Assistance

Cruise Control:

Optional feature on FLHTC models, operated via handlebar controls

Connectivity

Intercom:

Available on models equipped with CB/intercom systems for rider-passenger communication

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 miles or 6 months, whichever comes first

Primary Chain Adjustment:

Every 5,000 miles or 6 months

Spark Plug Replacement:

Every 10,000 miles

Air Filter Cleaning:

Every 5,000 miles, or more frequently in dusty conditions

Brake Fluid Flush:

Every 2 years

Fluid Specifications

Engine Oil:

Harley-Davidson 20W50 V-Twin Motorcycle Oil, or equivalent SAE 20W-50 API SG or higher rated motorcycle oil

Primary Chaincase Fluid:

Harley-Davidson Formula + Transmission and Primary Chaincase Lubricant

Transmission Fluid:

Harley-Davidson Formula + Transmission and Primary Chaincase Lubricant or equivalent API GL-5 rated gear oil

Brake Fluid:

DOT 4 hydraulic brake fluid

Fork Oil:

Specify weight based on manual, typically a mid-weight fork oil like 10W or 15W

Known Issues

Common Wear Items:

Clutch plates, wheel bearings, steering head bearings, brake pads, primary chain wear

Engine Considerations:

Potential for oil leaks from seals (e.g., cam cover, transmission seals), exhaust system leaks, and general wear and tear on the Evolution engine. The CV carburetor may require occasional adjustment.

Electrical Considerations:

Aging wiring harnesses, potential for regulator/rectifier failure, and starter solenoid issues are not uncommon on motorcycles of this vintage.

📚 Vehicle History

Brand Heritage

Heritage Brand:

Harley-Davidson, founded in 1903, with a long history of producing V-twin motorcycles for utility, sport, and touring.

Model Evolution

Electra Glide Lineage:

The Electra Glide line dates back to the 1960s, evolving from the Duo-Glide and Servi-Car, becoming Harley-Davidson's premier touring platform.

2004 Updates:

The 2004 models incorporated the Twin Cam 88 engine (introduced in 1999) and continued the established Electra Glide platform with refinements in comfort and features.

Production

Manufacturing Location:

United States (York, Pennsylvania and Milwaukee, Wisconsin typically)

Model Production Years:

The Electra Glide Classic model has been in continuous production for decades, with various iterations and engine platforms.

🏆 Awards & Recognition

Recognitions

Market Reputation:

Harley-Davidson Electra Glide models are consistently recognized for their comfort, long-distance touring capability, and iconic status in motorcycling.

Brand Recognition:

Harley-Davidson is a globally recognized brand synonymous with American motorcycling culture.