HARLEY DAVIDSON TOURING ModelS 2004 Service Repair Manual

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Type: Motorcycle

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Sku: 121079

Tags: 2004 Harley Davidson Motorcycle Motorcycles Police Touring Models

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Description

This manual covers the 2004 Touring Models, featuring the powerful and reliable Twin Cam 88 1450cc engine. These motorcycles are engineered for long-distance comfort and performance, embodying renowned heritage and distinctive V-twin character. The 2004 lineup includes advancements such as the 5-speed Cruise Drive transmission and robust chassis components, designed to provide a superior riding experience for touring enthusiasts. This comprehensive service repair manual, identified by part number 99483-04, along with supplementary manuals for Police Service, Electrical Diagnostics, and the FLHTCSE, offers detailed guidance on maintenance, repair, and troubleshooting. It covers all essential mechanical and electrical systems, including the engine, fuel system, transmission, brakes, and ignition. This resource is invaluable for owners and technicians aiming to maintain the optimal performance and longevity of their 2004 Touring motorcycle.

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Touring Models

Year:

Product Name:

Harley-Davidson Touring Models 2004 Service Repair Manual

Primary Manual Part Number:

99483-04

Supplementary Manual Part Numbers:

• 99483-04SP (Police Service Supplement)

• 99497-04 (Electrical Diagnostics)

• 99500-04 (FLHTCSE Service Supplement)

Codes

Vehicle Platform:

Touring

👋 Introduction

Market Position

Target Audience:

Harley-Davidson owners performing their own maintenance and repairs, independent repair shops specializing in Harley-Davidson motorcycles, and enthusiasts seeking in-depth technical knowledge.

Competitive Analysis

Value Proposition:

Offers comprehensive technical coverage for 2004 Harley-Davidson Touring models at a highly competitive price point due to a known technical limitation in its digital format (non-functional menu system).

Key Features

Manual Strengths:

• Covers a broad range of Touring models from 2004.

• Includes specialized supplements for Police models and the FLHTCSE (Screamin' Eagle) variant.

• Dedicated electrical diagnostics manual provides deep insight into wiring and electronic systems.

• Detailed procedures for maintenance, repair, and troubleshooting.

• Provides essential technical specifications and service intervals.

📋 Manual Details

Coverage Areas

Primary Manual Coverage:

• Maintenance

• Chassis

• Engine

• Fuel System

• Starter

• Drive

• Transmission

• Electrical

• Fuel Injection

• Appendix

Police Supplement Coverage:

• Maintenance

• Chassis

• Electrical

Electrical Diagnostics Coverage:

• Starting & Charging

• Instruments

• TSM & TSSM (Turn Signal Module & Turn Signal Security Module)

• Engine Management

• Engine Management (EFI)

• Sound System

• Cruise Control

• Wiring

Flhtcse Supplement Coverage:

• Maintenance

• Chassis

• Engine

• Starter

• Drive

• Transmission

• Electrical

Page Count

Estimated Total Pages:

Likely several hundred pages across all included manuals, specific counts not provided but indicative of comprehensive coverage for the year.

Manual Type

Primary Manual:

Service Repair Manual

Supplementary Manuals:

• Service Supplement

• Electrical Diagnostics

Language

Language:

English

Format

Format:

Digital (indicated by menu system not working, pages viewed one by one, suggesting a PDF or similar format with navigation limitations)

📖 Manual Coverage

Systems Covered

Mechanical Systems:

• Engine (Twin Cam 88, Twin Cam 88B variations likely)

• Chassis components (frame, suspension, wheels, brakes)

• Drive belt/chain systems

• Transmission (5-speed Cruise Drive likely)

• Fuel system (carbureted and early EFI)

• Starter and charging systems

• Exhaust systems

Electrical Systems:

• Ignition system

• Lighting

• Instrumentation

• TSM/TSSM security and turn signal functions

• Engine management electronics (ECU, sensors)

• Sound systems

• Cruise control systems

• Wiring diagrams (comprehensive)

Procedures Included

Maintenance Procedures:

• Scheduled maintenance intervals

• Fluid checks and changes (oil, primary, transmission)

• Filter replacements (oil, air)

• Spark plug service

• Brake system maintenance

• Tire pressure and wear checks

• Battery maintenance

Repair Procedures:

• Engine disassembly and reassembly

• Transmission overhaul

• Chassis component repair and replacement

• Fuel system diagnostics and repair (carburetor and EFI)

• Electrical component troubleshooting and replacement

• Brake system repair

• Suspension adjustments and repair

Diagnostic Procedures:

• Troubleshooting guides

• Diagnostic trouble codes (DTCs) for EFI models

• Wiring diagram analysis

• Component testing procedures

Technical Depth

Depth Of Coverage:

Comprehensive, covering from basic maintenance to advanced repair and electrical diagnostics. The inclusion of a dedicated Electrical Diagnostics manual and specific model supplements indicates a high level of technical detail.

📊 Manual Specifications

File Format

Digital Format Notes:

Likely PDF. Limitation noted: Menu system does not function, requiring sequential page viewing, which impacts user experience and is the reason for the 'cheap' pricing.

Print Quality

Print Quality Assumption:

As a digital product with navigation issues, print quality is assumed to be standard for technical manuals, focusing on clarity of diagrams and text over aesthetic finish. Original print quality of Harley-Davidson manuals is typically high.

Binding Type

Binding Type For Digital:

Not applicable (digital format).

Paper Type

Paper Type For Digital:

Not applicable (digital format).

⚙️ Engine Specifications

Primary Engine

Engine Family:

Harley-Davidson Twin Cam 88

Engine Variants Covered:

Twin Cam 88 (pushrod V-twin), likely including Twin Cam 88B (balanced version for Softail models, though less common in Touring).

Performance

Displacement:

1450cc (88 cubic inches)

Bore X Stroke:

3.75 in x 3.968 in (95.25 mm x 100.6 mm)

Compression Ratio:

8.8:1 (typical for Twin Cam 88)

Horsepower Est:

Approx. 70-75 HP (at crankshaft, varying slightly by model and tuning)

Torque Est:

Approx. 80-85 ft-lbs (at crankshaft, varying slightly by model and tuning)

Fuel System

Fuel Delivery:

• Carbureted (Keihin CV Carburetor likely)

• Electronic Fuel Injection (EFI - Sequential Port Injection)

Fuel Type:

Unleaded gasoline, minimum 87 octane

Lubrication

Oil Type Primary:

Harley-Davidson 20W50 motorcycle oil, or equivalent meeting Harley-Davidson specifications.

Oil Type Engine:

Harley-Davidson 20W50 motorcycle oil, or equivalent meeting Harley-Davidson specifications. (Separate oil from primary drive).

Oil Type Transmission:

Harley-Davidson primary chain lubricant, or equivalent. (Different from engine oil).

Ignition

Ignition System:

Electronic ignition with single fire coil or dual fire coil configurations, depending on model and specific setup.

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh, sequential transaxle

Gear Ratios:

Specific ratios provided in manual, typical for this era's Touring models (e.g., 1st: 9.339, 2nd: 6.545, 3rd: 4.780, 4th: 3.733, 5th: 3.150).

Optional

Optional Transmissions:

None standard for the 2004 Touring platform; variants might exist for specific police or custom applications but are unlikely to be factory options.

Features

Drive Type:

Belt drive (final drive)

Clutch Type:

Wet, multi-plate

📐 Dimensions

Exterior

Typical Wheelbase:

Approx. 63.5 inches (1613 mm) (varies by specific Touring model - e.g., FLHTPI, FLHRCI, FLHTCUI)

Typical Length:

Approx. 90-95 inches (2286-2413 mm)

Weights

Typical Dry Weight:

Approx. 700-750 lbs (317-340 kg) (varies by model)

Typical Gvwr:

Approx. 1200 lbs (544 kg)

🛡️ Safety Features

Ratings

Safety Ratings:

Motorcycle safety is not rated by agencies like NHTSA or IIHS in the same manner as automobiles. Focus is on rider awareness and adherence to safe riding practices, as detailed in the owner's manual (not provided here but implied for owners).

Active Features

Active Safety Features:

• Disc Brakes (Front and Rear)

• Hazard Warning Lights (covered in Electrical section)

• Tire Pressure Monitoring (Not standard on most 2004 models, check specific sub-models)

Passive Features

Passive Safety Features:

• Robust Frame Construction

• Integrated Lighting Systems

• TSSM (Turn Signal Security Module) for anti-theft functionality

💡 Technology Features

Infotainment

Audio Systems:

Many 2004 Touring models featured factory-installed audio systems (AM/FM, CB, Intercom) which are covered in the Electrical Diagnostics manual. These were typically analog systems with limited functionality compared to modern units.

Driver Assistance

Cruise Control:

Electronic cruise control was available on many 2004 Touring models and is covered in the Electrical Diagnostics manual, including its operation and troubleshooting.

Connectivity

Connectivity Features:

Limited by modern standards. Primarily focused on internal vehicle systems. CB radio and intercom provided basic rider-to-rider or rider-to-passenger communication. No Bluetooth or smartphone integration on factory systems.

🔧 Maintenance

Service Intervals

Initial Service:

Typically at 1,000 miles (1600 km) for initial break-in service, including oil and filter change.

Subsequent Maintenance:

Generally every 5,000 miles (8,000 km) or annually, whichever comes first, for routine checks and fluid changes. Specific intervals for clutch adjustment, brake service, belt inspection, etc., are detailed in the manual.

Engine Oil Change Interval:

Every 5,000 miles (8,000 km) or annually, or more frequently under severe service conditions.

Transmission Oil Change Interval:

Every 10,000 miles (16,000 km) or annually.

Primary Chain Case Oil Change Interval:

Every 5,000 miles (8,000 km) or annually.

Fluid Specifications

Engine Oil Capacity:

Approx. 4 US quarts (3.8 liters) with filter change.

Transmission Oil Capacity:

Approx. 1 US quart (0.95 liters).

Primary Chain Case Oil Capacity:

Approx. 32 US fluid ounces (0.95 liters).

Brake Fluid Type:

DOT 4 High Performance DOT 4 Motorcycle Brake Fluid (ensure compatibility with ABS if equipped).

Known Issues

Common Wear Items:

• Cam chain tensioner wear (especially earlier Twin Cam 88 models, though improvements were made)

• Clutch wear

• Wheel bearings

• Fork seals

• Drive belt wear/damage

Common Technical Issues:

• Fuel system issues (carburetor tuning, EFI sensor failures)

• Electrical connector corrosion or loose connections

• Starter clutch wear

• Exhaust system leaks

📚 Vehicle History

Brand Heritage

Brand Legacy:

Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903, known for its distinctive V-twin engines and cruiser/touring motorcycles.

Model Evolution

Touring Platform Evolution:

The 2004 Touring models represent a mature phase of Harley-Davidson's touring platform, which evolved from earlier Shovelhead and Evolution Big Twin engines. The Twin Cam 88 engine was introduced in 1999, significantly updating the platform with increased power and reliability. The 2004 models featured advancements like the 5-speed Cruise Drive transmission and refinements in chassis and electronics.

Production

Production Era:

The Twin Cam 88 engine platform was produced from 1999 to 2006 before the introduction of the Twin Cam 96.

Manufacturing Location:

United States (primarily York, Pennsylvania, and Milwaukee, Wisconsin assembly plants).

🏆 Awards & Recognition

Recognitions

Harley Davidson Brand Awards:

Harley-Davidson as a brand has received numerous accolades over its history for its iconic status, build quality, and rider community. Specific awards for the 2004 models are not typically highlighted individually in the same way consumer vehicles are, but the models were generally well-regarded for their touring comfort and performance within their segment.