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Harley Davidson FLHTCI Electra Glide Classic EFI Complete Workshop Service Repair Manual 2004
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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHTCI Electra Glide Classic EFI Year: 2004 Codes Model Code: FLHTCI Engine Code Suffix: EFI 👋 Introduction Market Position Segment: Full-size, premium touring...
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🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FLHTCI Electra Glide Classic EFI
Year:
2004
Codes
Model Code:
FLHTCI
Engine Code Suffix:
EFI
👋 Introduction
Market Position
Segment:
Full-size, premium touring motorcycle.
Target Audience:
Long-distance touring riders seeking comfort, style, and performance.
Competitive Analysis
Key Competitors:
Indian Chief Vintage, Honda Gold Wing, Yamaha Star Venture.
Key Features
Touring Amenities:
Full fairing, large windscreen, comfortable seating for rider and passenger, ample storage (saddlebags, tour pack).
Engine Platform:
Harley-Davidson Twin Cam 88 V-Twin engine.
Electronics:
Electronic Fuel Injection (EFI) for improved performance and emissions.
Manual Value Proposition
Value:
Essential resource for owners and technicians to maintain, diagnose, and repair the FLHTCI Electra Glide Classic EFI.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Workshop Service and Repair
Page Count
Estimated Pages:
High (typically 500+ pages for a full workshop manual)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, including disassembly, inspection, assembly, and tuning of the Twin Cam 88 engine.
Fuel System:
Detailed coverage of the Electronic Fuel Injection (EFI) system, including sensors, injectors, fuel pump, and ECU diagnostics.
Ignition System:
Spark plugs, coils, ignition module, timing adjustments, and troubleshooting.
Transmission:
5-speed Cruise Drive transmission service, maintenance, and repair, including clutch and primary drive components.
Drivetrain:
Belt drive system, rear wheel, and drive pulley maintenance and inspection.
Electrical System:
Full electrical system schematics, wiring diagrams, battery, charging system (alternator, regulator), starter, lighting, instrumentation, and accessories.
Brakes:
Front and rear brake system maintenance, including hydraulic components, calipers, rotors, pads, and bleeding procedures.
Suspension:
Front fork (Telescopic) and rear shock absorber service, adjustment, and replacement.
Frame And Bodywork:
Chassis, frame, fairing, saddlebags, fuel tank, seat, and body panel removal, installation, and repair.
Wheels And Tires:
Wheel bearing service, tire mounting and balancing, and spoke tension adjustment (if applicable).
Controls:
Handlebars, controls, cables, and linkages adjustment and replacement.
Procedures Included
Maintenance:
Scheduled maintenance, routine checks, lubrication, and fluid changes.
Troubleshooting:
Extensive diagnostic procedures for common and uncommon problems, with symptom-based troubleshooting guides.
Repair:
Step-by-step instructions for component repair and replacement.
Disassembly Assembly:
Detailed instructions for complete vehicle teardown and reassembly.
Diagnostics:
Includes diagnostic codes, sensor data interpretation, and electrical testing procedures.
Technical Depth
Depth:
Comprehensive, covering basic to advanced repair and overhaul procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (typically)
Print Quality
Quality:
High-resolution, suitable for printing.
Binding Type
Binding:
Not applicable (downloadable format)
Paper Type
Paper Type:
Not applicable (downloadable format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 45-degree V-Twin
Engine Family:
Twin Cam 88
Displacement:
1449 cc (88 cubic inches)
Bore X Stroke:
3.75 in x 3.37 in (95.25 mm x 85.5 mm)
Compression Ratio:
8.8:1
Performance
Horsepower:
Approx. 60-65 HP (at crankshaft, estimated for model year)
Torque:
Approx. 75-80 lb-ft @ 3500 RPM (at crankshaft, estimated for model year)
Fuel System
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, 91 octane or higher recommended
Lubrication
Oil Type:
Harley-Davidson Genuine V-Twin 20W-50 or equivalent synthetic
Oil Capacity:
3.5 quarts (3.3 liters) with filter change
🔧 Transmission
Standard
Type:
5-speed constant mesh, helical gears
Clutch:
Wet, multi-plate, hydraulic actuation
Features
Gear Ratios:
Detailed in manual, typically includes 1st: 9.312, 2nd: 6.422, 3rd: 4.774, 4th: 3.796, 5th: 3.119
Primary Drive:
Duplex chain, 1.450 ratio
Final Drive:
Belt drive, 32/66 tooth ratio (2.06:1)
Fluid Specifications
Transmission Oil Type:
Harley-Davidson Formula + Transmission and Primary Chaincase Lubricant or equivalent.
Transmission Oil Capacity:
24-26 fluid ounces (0.71 - 0.77 liters)
📐 Dimensions
Exterior
Length:
97.4 inches (2474 mm)
Width:
38.2 inches (970 mm)
Height:
53.7 inches (1364 mm)
Wheelbase:
63.5 inches (1613 mm)
Ground Clearance:
5.1 inches (130 mm)
Weights
Dry Weight:
765 lbs (347 kg)
Gross Vehicle Weight Rating Gvwr:
1260 lbs (572 kg)
Payload Capacity:
495 lbs (225 kg)
Cargo
Saddlebag Capacity:
Approx. 2.2 cubic feet per saddlebag
Tour Pak Capacity:
Optional, adds significant storage
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not applicable to motorcycles in the same way as automobiles.
Active Features
Braking System:
Dual disc front brakes, single disc rear brake with linked braking on some configurations.
Lighting:
Halogen headlight, LED taillight, turn signals.
Passive Features
Frame Construction:
Steel cradle frame designed for stability.
Rider Aid:
Reflex™ II Anti-lock Braking System (ABS) potentially available as an option, check specific VIN.
💡 Technology Features
Infotainment
Audio System:
AM/FM/WB stereo with CB and intercom, four speakers. May have CD player functionality depending on exact configuration.
Cruise Control:
Standard electronic cruise control.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was often an optional feature for this model; manual will cover its diagnostics if equipped.
Connectivity
Diagnostic Ports:
Includes diagnostic connectors for interface with Harley-Davidson diagnostic tools (e.g., Digital Technician).
Instrumentation
Gauge Cluster:
Analog speedometer, tachometer, fuel gauge, voltmeter, oil pressure gauge, and indicator lights. Digital odometer.
🔧 Maintenance
Service Intervals
First Service:
1,000 miles (1,600 km) or 6 months (whichever comes first) - oil change, primary chain adjustment, inspection of all fasteners and controls.
Subsequent Services:
Every 5,000 miles (8,000 km) or 12 months for regular service including engine oil and filter change, inspection of critical components.
Major Service Intervals:
Refer to manual for specific intervals for transmission oil, spark plugs, drive belt inspection/replacement, and suspension service.
Fluid Specifications
Engine Oil Part Number:
Harley-Davidson Genuine 20W-50 V-Twin Motor Oil (e.g., 62600031) or equivalent
Transmission Oil Part Number:
Harley-Davidson Formula + Transmission and Primary Chaincase Lubricant (e.g., 99811-05)
Brake Fluid Type:
DOT 4 hydraulic fluid (Harley-Davidson recommends their own brand or equivalent)
Known Issues
Common Wear Items:
Clutch plates, brake pads, tires, drive belt, wheel bearings.
Twin Cam Specific:
Potential for oil leaks at base gaskets, cam chain tensioner wear (though later models addressed this). Idle issues related to EFI sensors are possible.
Maintenance Tips
Belt Tension:
Proper drive belt tension is crucial for longevity and performance.
Charging System:
Regularly check battery voltage and alternator output. A failing voltage regulator is a common electrical failure point.
📚 Vehicle History
Brand Heritage
Manufacturer:
Harley-Davidson Motor Company, founded 1903.
Heritage Focus:
Long-standing tradition of V-twin engines and classic styling.
Model Evolution
Electra Glide Lineage:
The Electra Glide line has been a flagship touring model for Harley-Davidson since the 1960s, evolving with technological advancements while retaining its iconic identity.
Twin Cam Introduction:
The Twin Cam 88 engine platform was introduced in 1999, representing a significant upgrade in performance and reliability over the Evolution Big Twin.
Production
Production Years:
FLHTCI model produced across multiple years, with 2004 being a specific model year variant.
Manufacturing Location:
York, Pennsylvania, USA and Milwaukee, Wisconsin, USA
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the 2004 model are not commonly documented, the Electra Glide platform consistently receives accolades for its touring comfort and capabilities from motorcycle publications.