Harley Davidson FLH Twin Cam 88 103 2004 All Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLH Year: 2004 Engine Variant: Twin Cam 88, Twin Cam 88 with 103 cubic inch upgrade Model Designation: FLH Series (Electra Glide, Road...

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Type: Motorcycle

Vendor:

Sku: 518572

Tags: 2004 FLH Twin Cam 103 FLH Twin Cam 88 Harley Davidson Misc Motorcycle Motorcycles

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Year:

Engine Variant:

Twin Cam 88, Twin Cam 88 with 103 cubic inch upgrade

Model Designation:

FLH Series (Electra Glide, Road Glide, Street Glide variations)

Codes

Engine Code Base:

Twin Cam 88

Engine Code Upgrade:

Twin Cam 88 (with 95 cu in displacement) to 103 cu in

👋 Introduction

Market Position

Segment:

Cruiser/Touring Motorcycle

Target Audience:

Harley-Davidson FLH owners and independent repair shops specializing in V-twin motorcycles.

Competitive Analysis

Alternatives:

Factory service manuals (FSM), other third-party repair manuals (Haynes, Clymer - though often less detailed for H-D).

Key Features

Diy Focus:

Empowers owners to perform maintenance and repairs, ensuring quality and cost savings.

Diagnostic Support:

Provides critical troubleshooting steps for common and complex issues.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive service and repair for all FLH Twin Cam models of the specified year.

Page Count

Estimated Pages:

500-700 (typical for this era and depth)

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Downloadable Digital Format (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, inspection, and repair of Twin Cam 88 and 103 cubic inch V-twin engines.

Fuel System:

Carburetor (Keihin CV 40) or Fuel Injection (EFI - Delphi Systems) diagnosis, service, and adjustments.

Ignition System:

Ignition module, spark plugs, coils, timing, and diagnostic procedures.

Transmission:

Primary drive, clutch, 5-speed gearbox (Trapezoidal Gear), and final drive servicing.

Electrical System:

Wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter, solenoid), lighting, instrumentation, and accessory circuits.

Suspension:

Front fork (telescopic) overhaul, fork oil replacement, rear shock absorber service and replacement.

Brakes:

Hydraulic brake system diagnosis, service, fluid replacement, caliper, master cylinder, and rotor maintenance.

Chassis Frame:

Frame inspection, steering head bearing service, and general chassis component maintenance.

Bodywork Fairings:

Touring fairings, saddlebags, luggage rack, and cosmetic component removal/installation.

Cooling System:

Oil cooler system maintenance and inspection (air-cooled, but oil circulation is key).

Diagnostics Troubleshooting:

Fault code retrieval (for EFI models), symptom-based troubleshooting guides, and diagnostic procedures.

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, spark plug replacement, air filter service, brake fluid flush.

Engine Overhaul:

Top-end rebuild (cylinders, pistons, heads), bottom-end rebuild (crankshaft, bearings), camshaft and lifter service.

Transmission Rebuild:

Gearbox disassembly, component inspection, and reassembly for the 5-speed unit.

Electrical Repairs:

Wiring harness repair, component testing, starter motor, alternator, and battery system service.

Suspension Overhaul:

Fork seal replacement, fork oil viscosity and level checks, rear shock adjustments and replacement.

Brake System Service:

Brake bleeding procedures, master cylinder overhaul, caliper service, pad replacement.

Fuel System Cleaning:

Carburetor cleaning and adjustment (jetting), fuel injector cleaning and testing (EFI).

Wheel Tire Service:

Wheel bearing replacement, tire mounting and balancing, spoke tension (if applicable to specific FLH variants).

Steering Alignment:

Steering head bearing adjustment and replacement.

Technical Depth

Depth:

Full mechanical and electrical repair, including in-depth diagnostics and component-level troubleshooting.

Special Tools:

Identification and use of specialized Harley-Davidson tools for specific procedures.

Torque Specifications:

Detailed torque values for all critical fasteners and engine components.

Schematics:

Comprehensive electrical wiring diagrams and vacuum/fuel line schematics.

📊 Manual Specifications

File Format

Digital Format:

Print Quality

Readability:

High-resolution images, clear text, and easily printable pages.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 45-degree V-twin, pushrod actuated overhead valves.

Engine Displacement Base:

88 cubic inches (1450cc)

Engine Displacement Upgrade:

103 cubic inches (1690cc) - typically achieved via big bore kits

Bore Stroke Base:

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

Bore Stroke 103:

4.00 in x 4.00 in (101.6 mm x 101.6 mm)

Compression Ratio Base:

8.8:1 (typical for Twin Cam 88)

Compression Ratio 103:

9.2:1 - 9.7:1 (depending on piston type in 103 kits)

Performance

Horsepower Base:

Approx. 60-65 HP at rear wheel (stock Twin Cam 88)

Torque Base:

Approx. 70-75 lb-ft at rear wheel (stock Twin Cam 88)

Horsepower 103:

Approx. 70-75 HP at rear wheel (typical 103 conversion)

Torque 103:

Approx. 85-95 lb-ft at rear wheel (typical 103 conversion)

Fuel System

Fuel Delivery Base:

Keihin CV 40mm Carburetor

Fuel Delivery Efi:

Delphi Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline, minimum 91 octane (RON+MON)/2 (or 87 AKI)

🔧 Transmission

Standard

Type:

5-speed constant mesh, helical cut gears.

Gear Ratios:

1st: 10.110, 2nd: 6.857, 3rd: 4.847, 4th: 3.807, 5th: 3.158 (typical for 5-speed gearbox)

Primary Drive:

Duplex chain

Final Drive:

Belt drive, 29/65 tooth sprockets (typical)

Optional

Clutch Type:

Wet, multi-plate, diaphragm spring

Features

Clutch Actuation:

Hydraulic

📐 Dimensions

Exterior

Wheelbase:

63.5 inches (1613 mm) - typical

Length:

93.5 inches (2375 mm) - typical

Width:

36.5 inches (927 mm) - typical

Height:

53.0 inches (1346 mm) - typical

Weights

Dry Weight:

Approx. 750-800 lbs (340-363 kg) - varies by FLH model

Gross Vehicle Weight Rating Gvwr:

Approx. 1200 lbs (544 kg) - typical

Fuel Capacity:

5.0 US gallons (18.9 L)

Oil Capacity:

4.0 US quarts (3.8 L) (with filter change)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles are not subjected to standardized crash testing like automobiles).

Active Features

Braking System:

Dual 32mm piston front caliper and 32mm piston rear caliper, hydraulic actuation.

Lighting:

Halogen headlamp, LED taillight/brake light, turn signals.

Passive Features

Frame Construction:

Steel, cradle-type frame for stability and rigidity.

Tire Construction:

Tubeless, radial construction recommended for optimal handling.

💡 Technology Features

Infotainment

Audio System:

Optional premium audio systems with AM/FM radio, CB, intercom, and CD player (depending on FLH variant, e.g., Electra Glide).

Instrumentation:

Analog speedometer, tachometer, voltmeter, oil pressure, and engine temperature gauges.

Driver Assistance

Cruise Control:

Electronically controlled cruise control often standard on FLH models.

Connectivity

Accessories:

Accessory power outlets for charging electronic devices.

🔧 Maintenance

Service Intervals

Initial Service:

2,500 miles or 6 months (whichever comes first).

Subsequent Service:

Every 5,000 miles or 12 months (whichever comes first).

Engine Oil Change:

Every 2,500 - 5,000 miles depending on oil type and riding conditions, as per manual recommendations.

Primary Chain Tensioner Inspection:

Recommended inspection at 5,000-10,000 mile intervals, as it's a known wear item for this era.

Fluid Specifications

Engine Oil:

Harley-Davidson 20W-50 motorcycle oil or equivalent (e.g., SYN3, Mobil 1 V-Twin).

Primary Oil:

Harley-Davidson primary chain case lubricant or SAE 90W gear oil.

Transmission Oil:

Harley-Davidson Syn3 or SAE 80W-90 gear oil.

Brake Fluid:

DOT 4 hydraulic fluid.

Fork Oil:

Typically Harley-Davidson 10W fork oil (viscosity can be adjusted).

Known Issues

Primary Chain Tensioner:

The automatic chain tensioner is a common wear item and can fail, leading to noise and potential damage if not replaced.

Cam Chain Tensioners:

Early Twin Cam models (pre-2007) use hydraulic tensioners that can wear out, especially the inner cam chain tensioner.

Harley Rocker Box Gaskets:

Leaking rocker box gaskets can occur over time, requiring replacement.

Charging System Issues:

Stator or regulator/rectifier failure can lead to charging problems.

Carburetor Issues:

Keihin CV carburetors can require periodic adjustment or cleaning, especially if fuel quality is inconsistent.

📚 Vehicle History

Brand Heritage

Legacy:

Harley-Davidson, a storied American motorcycle manufacturer with a history dating back to 1903.

Model Evolution

Twin Cam Introduction:

The Twin Cam engine platform was introduced in 1999, replacing the Evolution (Evo) engine.

Flh Heritage:

The FLH designation has a long lineage within Harley-Davidson's touring models, evolving significantly over decades.

2004 Updates:

The 2004 model year saw continued refinement of the Twin Cam platform and FLH series, often incorporating improvements in comfort, handling, and electronics.

Production

Manufacturing Location:

United States (York, Pennsylvania and Milwaukee, Wisconsin)

🏆 Awards & Recognition

Recognitions

Brand Recognition:

Harley-Davidson is consistently recognized as a leader in the cruiser and touring motorcycle market, known for its iconic styling and V-twin performance.

Ratings

Reliability:

While known for character, Twin Cam engines require diligent maintenance to ensure optimal reliability; this manual is key to that.