🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLHTC-I Electra Glide Classic

Product Code Identifier:

FLHTC-I

Model Years Covered:

1996, 1997, 1998

👋 Introduction

Target Audience:

Harley-Davidson owners, independent motorcycle mechanics, and service departments seeking authoritative repair information.

Value Proposition:

Provides essential, detailed information to maintain, diagnose, and repair the FLHTC-I Electra Glide Classic, reducing reliance on costly dealership services and ensuring proper vehicle upkeep.

Manual Competitors:

Competes with other third-party service manuals and official Harley-Davidson service literature, offering a comprehensive and accessible digital alternative.

Completeness:

Encompasses all aspects of the motorcycle's operation, maintenance, and repair for the specified model years.

Accuracy:

Derived from authoritative sources, providing correct procedures and specifications crucial for correct repairs.

Digital Accessibility:

Downloadable format allows for immediate access and offline use on various devices.

📋 Manual Details

Manual Type:

Complete Workshop Service Repair Manual

Language:

English

Format:

Downloadable Digital Format (likely PDF)

📖 Manual Coverage

Engine:

Detailed diagnostics, repair, and overhaul of the Harley-Davidson Evolution V-Twin engine (likely 1340cc, 80 cubic inch, fuel-injected variant).

Fuel System:

Comprehensive coverage of the Electronic Sequential Port Fuel Injection (ESPFI) system, including fuel pump, injectors, sensors (MAP, IAT, TPS, O2), and ECU troubleshooting.

Ignition System:

Ignition module, crank position sensor, spark plugs, coils, and diagnostic procedures for ignition timing.

Transmission:

Service and repair of the 5-speed constant mesh gearbox, including clutch operation, internal components, and fluid maintenance.

Drivetrain:

Primary drive system (clutch, compensator, chain), final drive (belt drive system), and wheel bearing service.

Suspension:

Front telescopic forks (including oil change and seal replacement) and rear shock absorber assembly and adjustment.

Brakes:

Front and rear braking systems, including hydraulic lines, master cylinders, calipers, brake pads, rotors, and bleeding procedures.

Electrical System:

Wiring diagrams, battery service, charging system (alternator, regulator), lighting, starter system, and accessory circuits.

Bodywork And Trim:

Fairing removal and installation, saddlebag service, seat assembly, and interior trim components.

Wheels And Tires:

Wheel removal and installation, tire mounting and balancing, and spoke tensioning (if applicable).

Routine Maintenance:

Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, brake fluid flush, lubrication points.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting for common issues related to engine performance, electrical faults, and drivability.

Component Repair:

Step-by-step instructions for disassembling, inspecting, repairing, and reassembling major and minor motorcycle components.

Technical Specifications:

Detailed torque specifications, clearances, fluid capacities, and electrical system parameters.

Diagnostic Procedures:

Instructions for using diagnostic tools (e.g., Harley-Davidson Digital Technician) and interpreting fault codes for the fuel-injected engine.

Depth Of Coverage:

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

📊 Manual Specifications

Digital Format:

Likely PDF, optimized for digital viewing and printing.

Searchability:

Expected to be text-searchable, allowing for quick location of specific information.

Digital Reproduction:

High-resolution reproduction of original factory documentation, ensuring clarity of diagrams and text.

Physical Manual Analogue:

While digital, it emulates the completeness and organization of a professional workshop manual, typically spiral or perfect bound for ease of use in a workshop environment.

Digital Analogue:

Content is presented in a format suitable for printing on standard paper sizes (e.g., A4 or Letter).

⚙️ Engine Specifications

Engine Type:

Harley-Davidson Evolution V-Twin, Air-Cooled

Engine Displacement:

1339 cc (81.8 cubic inches)

Bore X Stroke:

3.4375 in x 4.25 in (87.3 mm x 108 mm)

Compression Ratio:

8.5:1 (typical for this era)

Horsepower:

Approximately 65-70 HP (actual figures vary slightly by source and tune)

Torque:

Approximately 82-86 ft-lbs @ 3200 RPM

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded Premium Gasoline, 91+ Octane

Fuel Tank Capacity:

5.0 US gallons (18.9 L)

Oil Capacity With Filter Change:

3.0 US quarts (2.8 L)

Recommended Oil Viscosity:

Harley-Davidson 20W-50 (or equivalent specification for air-cooled V-Twins)

Recommended Oil Spec:

API SG, SH, SJ, SL or higher; JASO MA

🔧 Transmission

Transmission Type:

5-Speed Constant Mesh Manual

Transmission Variants:

N/A for this specific model and year range; standard 5-speed.

Clutch Type:

Wet, multi-plate

Final Drive:

Belt Drive

Transmission Fluid:

Harley-Davidson Transmission Fluid, SAE 75W-90 (or equivalent API GL-4)

Transmission Oil Capacity:

Approximately 24 US fluid ounces (0.71 L)

📐 Dimensions

Length:

Approximately 93.3 inches (2370 mm)

Width:

Approximately 36.0 inches (914 mm)

Height:

Approximately 57.0 inches (1448 mm)

Dry Weight:

Approximately 762 lbs (346 kg)

Gross Vehicle Weight Rating Gvwr:

Not explicitly specified, but typically in the 1100-1200 lb range for touring bikes.

Wheelbase:

Approximately 63.5 inches (1613 mm)

🛡️ Safety Features

Crash Test Results:

Motorcycles are not typically subjected to standardized crash testing in the same manner as passenger cars; safety is inherent in design and rider operation.

Braking System:

Dual front disc brakes and single rear disc brake with hydraulic actuation.

Lighting:

Halogen headlight, taillight, brake lights, and turn signals.

Chassis Design:

Sturdy steel frame providing stability and rider support.

Fairing:

Provides wind protection for the rider, contributing to comfort and reducing fatigue on long rides.

💡 Technology Features

Audio System:

Often equipped with a factory-installed AM/FM radio with cassette player or early CD player, linked to fairing-mounted speakers. Features may include weather band and CB radio.

Cruise Control:

Electronic cruise control was a common feature on Electra Glide models of this era, managed by the ECU.

Parking Brake:

Manual parking brake lever, typically integrated with the rear brake caliper.

Diagnostic Port:

A diagnostic connector (often 4-pin) is present for connecting diagnostic tools to read engine data and fault codes.

🔧 Maintenance

First Service:

Typically at 1,000 miles (1,600 km) for initial break-in service.

Subsequent Oil Changes:

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

Spark Plug Replacement:

Every 10,000 - 15,000 miles (16,000 - 24,000 km), depending on plug type and condition.

Brake Fluid Flush:

Recommended every 2 years or per manufacturer's guidelines.

Belt Drive Tension:

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

Engine Oil Filter Part Number:

Commonly Harley-Davidson part numbers such as 63796-77A, 63805-80A, or 63731-98 (verify specific fitment).

Transmission Fluid Part Number:

Harley-Davidson Genuine Formula Plus or equivalent SAE 75W-90 GL-4.

Brake Fluid:

DOT 4 High-Performance Synthetic Brake Fluid (non-silicone based).

Cam Chain Tensioner Wear:

Early Evolution engines (prior to hydraulic tensioners) were known to have wear issues with the spring-loaded cam chain tensioners. The manual will likely cover inspection and replacement procedures.

Rocker Box Gaskets:

Potential for minor oil leaks from rocker box gaskets, requiring periodic inspection and tightening or replacement.

Fuel System Component Wear:

Like any fuel-injected system, components such as fuel pumps, injectors, and sensors can wear over time and require diagnostics or replacement.

📚 Vehicle History

Harley Davidson Legacy:

Founded in 1903, Harley-Davidson has a long and storied history in motorcycle manufacturing, synonymous with American culture and freedom.

Electra Glide Lineage:

The Electra Glide is a foundational model in Harley-Davidson's touring lineup, evolving significantly over decades. The FLHTC-I variant represents the integration of fuel injection in the late 1990s, enhancing performance and drivability.

Evolution Engine Era:

The Evolution engine, introduced in the mid-1980s, was a significant advancement for Harley-Davidson, replacing the Shovelhead and Ironhead engines. The 'I' suffix denotes fuel injection.

Manufacturing Location:

Typically manufactured in York, Pennsylvania, and Milwaukee, Wisconsin, USA.

🏆 Awards & Recognition

Model Recognition:

The Electra Glide series has consistently been recognized as a benchmark in the touring motorcycle segment for its comfort, capability, and iconic status.

Motorcycle Publications:

While specific awards for the 1996-1998 models are not individually cataloged here, the Electra Glide platform has received numerous positive reviews and ratings from motorcycle publications throughout its production run for its touring prowess.