🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLHTC Electra Glide Classic

Year:

2005

Chassis Code:

FLHTC

Oem Manual Part Number:

99480-05

👋 Introduction

Positioning:

The FLHTC Electra Glide Classic represents Harley-Davidson's flagship touring motorcycle, designed for long-distance comfort and convenience. This manual is targeted at owners and independent repair shops seeking to maintain and repair these iconic machines.

Competition:

Competes directly with other large displacement touring motorcycles from brands like Honda (Gold Wing), Indian (Roadmaster), and BMW (K1600 series) in terms of touring capability and luxury features.

Vehicle Features:

Full fairing with integrated windshield, comfortable rider and passenger seating, ample luggage capacity (saddlebags and tour-pak), cruise control (often standard or optional), advanced audio systems (often standard or optional).

📋 Manual Details

All Systems:

Yes

Specific Components:

Engine, Transmission, Drivetrain, Suspension, Brakes, Electrical System, Fuel System, Ignition System, Bodywork, Fairings, Controls, Instruments, Lighting, Chassis, Wheels, Tires

Estimated Pages:

Approximately 600+

Type:

Factory Service Repair Workshop Manual

Language:

English

Format:

Downloadable Digital File (PDF)

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, top-end and bottom-end assembly, valve timing, piston and ring installation, crankshaft and connecting rod service, oil pump and lubrication system diagnostics.

Fuel System:

Carburetor tuning and rebuilding (CV Carburetor), fuel injection system diagnostics (EFI models if applicable), fuel pump service, fuel filter replacement, fuel tank and lines.

Ignition System:

Ignition timing, spark plug specifications, coil testing, ignition module diagnostics, crankshaft position sensor (CKP) service.

Electrical System:

Comprehensive wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting systems (headlight, taillight, turn signals), battery maintenance and testing, fuse and circuit breaker identification and testing, instrumentation and accessory circuits.

Transmission Drivetrain:

Clutch service and adjustment, primary drive system inspection, transmission gear inspection and repair, final drive belt inspection and tensioning, wheel bearing service.

Brakes:

Hydraulic brake system bleeding, caliper service and rebuild, master cylinder service, brake pad replacement, rotor inspection and replacement, parking brake adjustment.

Suspension Steering:

Front fork service (oil change, seal replacement), rear shock absorber inspection and replacement, steering head bearing adjustment and replacement, swingarm pivot bearing service.

Bodywork Chassis:

Fairing removal and installation, fender service, seat removal, saddlebag mounting and repair, frame inspection, floorboard and footpeg service.

Maintenance:

Scheduled maintenance (oil changes, filter replacements, fluid checks), lubrication, tire pressure checks, brake adjustments, belt tensioning.

Troubleshooting:

Diagnostic charts for common problems, symptom-based troubleshooting guides, electrical system fault finding.

Repair:

Step-by-step instructions for virtually all mechanical and electrical repairs, including complete engine rebuilds, transmission overhauls, and component replacement.

Technical Specifications:

Torque specifications for all fasteners, clearance specifications, electrical resistance values, fluid capacities and types, engine specifications (bore, stroke, compression ratio).

Depth:

Comprehensive, covering everything from basic user maintenance to complete engine teardowns and rebuilds. Includes detailed diagnostic procedures and component testing.

📊 Manual Specifications

Format:

PDF

Searchability:

Fully searchable text content for quick information retrieval.

Image Resolution:

High-resolution images and diagrams for clarity.

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Family:

Evolution (Twin Cam 88/88B)

Displacement:

1450 cc (88 cubic inches)

Configuration:

Air-cooled, 45-degree V-twin

Bore X Stroke:

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

Compression Ratio:

8.8:1

Horsepower:

Approx. 65-70 HP (at crank, estimated)

Torque:

Approx. 85-90 lb-ft (at crank, estimated)

Fuel Delivery:

Electronic Fuel Injection (EFI) or Carbureted (Keihin CV 40mm) depending on specific sub-model/region. For 2005 FLHTC, typically EFI.

Fuel Type:

Unleaded gasoline, 91 octane (R+M)/2 minimum recommended

Oil Capacity:

4.0 US quarts (3.8 liters) with filter change

Oil Type:

Harley-Davidson Genuine V-Twin Motor Oil SAE 20W-50 or equivalent API CI-4/SL rated oil.

🔧 Transmission

Type:

5-speed constant mesh

Primary Drive:

Multi-plate wet clutch, chain drive

Final Drive:

Belt drive

Gear Ratios:

1st: 9.375, 2nd: 6.516, 3rd: 4.783, 4th: 3.715, 5th: 3.150

Transmission Fluid:

Harley-Davidson Transmission Lubricant or equivalent SAE 80W-90

Capacity:

24 US fl oz (0.71 Liters)

📐 Dimensions

Length:

93.3 in (2370 mm)

Width:

37.0 in (940 mm)

Height:

63.4 in (1610 mm)

Wheelbase:

63.5 in (1613 mm)

Dry Weight:

732 lbs (332 kg)

Gross Vehicle Weight Rating:

1260 lbs (571 kg)

Payload Capacity:

Approx. 528 lbs (239 kg)

Saddlebag Capacity:

Approximately 2.2 cu ft each

Tour Pak Capacity:

Approximately 2.4 cu ft (optional, but common)

🛡️ Safety Features

Crash Test Ratings:

N/A for motorcycles in standard automotive ratings.

Braking System:

Dual-action front disc brakes, single disc rear brake with integrated parking brake.

Lighting:

Halogen headlight, LED taillight and brake light, incandescent turn signals.

Frame Construction:

Steel frame designed for stability and rider comfort.

Wind Protection:

Full fairing and windscreen provide significant wind and weather protection.

💡 Technology Features

Audio System:

AM/FM stereo with CB and intercom capabilities (typically optional or part of premium packages), cassette player or CD player depending on exact trim.

Speakers:

Fairing-mounted speakers.

Cruise Control:

Electronic cruise control was a key feature for long-distance touring, often standard on Classic models.

Accessories:

Provisions for CB radio, intercom, and CB antenna for communication.

🔧 Maintenance

Engine Oil Change:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first.

Transmission Oil Change:

Every 10,000 miles (16,000 km) or 12 months.

Primary Chain Tensioner:

Inspect every 5,000 miles (8,000 km), replace if necessary (hydraulic tensioner is known to wear).

Spark Plugs:

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

Drive Belt Tension:

Check and adjust every 5,000 miles (8,000 km).

Brake Fluid:

DOT 4 Synthetic

Fork Oil:

Harley-Davidson genuine front fork oil or SAE 15W

Primary Chain Tensioner:

Hydraulic chain tensioner can wear out, leading to knocking or rattling noises. Replacement with updated automatic tensioner is common.

Cam Chain Tensioner:

Early Twin Cam models (pre-2007) used cam chain tensioners that could wear prematurely, leading to noise and potential engine damage. Upgrading to hydraulic tensioners is a common modification.

Crankshaft Runout:

Some early Twin Cam engines had issues with crankshaft runout. The manual would detail how to measure this.

Rear Cylinder Overheating:

Characteristic of air-cooled V-twins, especially in hot weather or stop-and-go traffic. The manual provides guidance on fuel mixture and timing to optimize cooling.

📚 Vehicle History

Heritage:

Harley-Davidson has a long and storied history dating back to 1903, known for its iconic cruiser and touring motorcycles, strong brand loyalty, and distinct V-twin engine sound.

Electra Glide Evolution:

The Electra Glide line originated in the 1960s, evolving from simpler models to the fully-faired, touring-oriented machines of today. The introduction of the Evolution engine in the late 1980s and then the Twin Cam engine in 1999 marked significant advancements in performance and reliability.

Manufacturing Location:

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

Model Year Significance:

The 2005 model year featured the Twin Cam 88 engine, a robust and reliable platform that was a significant improvement over its predecessor. This year also saw refinements in electronics and chassis components.

🏆 Awards & Recognition

Brand Awards:

Harley-Davidson motorcycles, including the Electra Glide line, are often recognized for their enduring style, rider comfort, and cultural impact.

Rider Reviews:

Generally highly rated by owners for long-distance comfort, iconic styling, and the V-twin experience. Criticisms sometimes relate to the age of the platform (e.g., cam chain tensioner), but the manual helps address these.

Manual Quality:

Factory certified manual, ensuring accuracy and completeness of technical data and repair procedures.