Segment:
Full-size touring motorcycle
Target Audience:
Long-distance touring riders, enthusiasts seeking comprehensive service information.
Competitors 2004:
Honda Gold Wing, Yamaha Royal Star Venture, Indian Chief.
Design Philosophy:
Comfort, long-distance capability, iconic Harley-Davidson styling.
Distinguishing Features:
Large fairing, ample luggage capacity (saddlebags and tour-pak), comfortable seating for rider and passenger, cruise control, advanced infotainment system for its era.
Engine:
Detailed diagnostics, repair, and overhaul for the Twin Cam 103 V-twin engine, including fuel injection system (EFI).
Transmission:
Service and repair of the 5-speed Cruise Drive transmission, including clutch, gearbox, and final drive.
Electrical System:
Comprehensive coverage of the electrical system, including ignition, lighting, charging system, battery, starter, wiring diagrams, and accessory circuits.
Chassis And Suspension:
Maintenance and repair of front forks, rear shock absorbers, frame components, steering, and wheel bearings.
Braking System:
Service procedures for hydraulic disc brakes (front and rear), including caliper, master cylinder, and brake line maintenance.
Fuel System:
Detailed information on the Electronic Fuel Injection (EFI) system, fuel pump, injectors, throttle body, and fuel tank.
Bodywork And Trim:
Disassembly, reassembly, and repair of fairings, saddlebags, tour-pak, and interior trim components.
Cooling System:
Information on engine cooling (if applicable, though typically air-cooled for this era's Twin Cam).
Exhaust System:
Details on exhaust components and installation.
Preventive Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, and inspections.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting guides, and common problem resolutions.
Engine Repair:
Complete engine disassembly, inspection, rebuilding, and reassembly procedures.
Transmission Repair:
Gearbox overhaul, clutch adjustment and replacement, and final drive servicing.
Electrical Diagnostics:
Wiring diagram interpretation, component testing, and fault diagnosis for electrical systems.
Brake Service:
Brake bleeding, pad replacement, rotor inspection, and master cylinder overhaul.
Suspension Adjustment:
Fork oil changes, fork seal replacement, and rear shock absorber adjustments/replacement.
Fuel System Calibration:
EFI system diagnostics and potential adjustments.
Bodywork Restoration:
Detailed guides for removing and reinstalling body panels, fairings, and luggage systems.
Diagnostic Capabilities:
Advanced diagnostics for engine management and electrical systems, including potential use of diagnostic tools (though specific tool recommendations might be sparse in PDF format).
Repair Scope:
Comprehensive repair procedures, from minor adjustments to major component overhauls and rebuilds.
Special Tools:
Identification and usage of specialized Harley-Davidson tools required for specific repair tasks.
Engine Type:
Air-cooled, Twin Cam 103 V-twin
Displacement:
1690 cc (103 cubic inches)
Bore X Stroke:
3.75 in. x 3.81 in. (95.25 mm x 96.82 mm)
Valvetrain:
Pushrod-actuated overhead valves with hydraulic lifters
Horsepower:
Approx. 65-70 HP (at crank, estimated for 2004 models)
Torque:
Approx. 85-90 ft-lbs (at crank, estimated for 2004 models)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane (AKI)
Length:
Approx. 103.0 in. (2616 mm)
Width:
Approx. 38.0 in. (965 mm)
Height:
Approx. 54.5 in. (1384 mm)
Wheelbase:
Approx. 63.5 in. (1613 mm)
Dry Weight:
Approx. 790 lbs (358 kg)
Gross Vehicle Weight Rating:
Approx. 1360 lbs (617 kg)
Saddlebag Capacity:
Integrated, lockable
Tour Pak Capacity:
Integrated, lockable, passenger backrest
Crash Test Ratings:
Not applicable to motorcycles in the same way as cars.
Braking:
Dual disc front brakes, single disc rear brake with linked functionality (depending on specific configuration).
Lighting:
Halogen headlight, integrated front and rear turn signals, passing lamps, auxiliary fog lamps (standard on Ultra Classic).
Chassis Design:
Sturdy steel frame providing stability.
Passenger Support:
Comfortable passenger seat with armrests and backrest.
First Service:
1,000 miles (1,600 km) or 6 months, whichever comes first (oil change, primary chain tension check, general inspection).
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months for general maintenance (oil, filter, inspections).
Major Service Intervals:
Refer to manual for specific component service intervals (e.g., spark plugs, transmission oil, brake fluid).
Engine Oil:
Harley-Davidson 20W-50 SYN3 or equivalent API SG rated oil.
Primary Chain Case Oil:
Harley-Davidson primary fluid or equivalent SE Performance Lubricant.
Transmission Oil:
Harley-Davidson Formula + Transmission and Primary Chaincase Lubricant (GL-4) or equivalent.
Brake Fluid:
DOT 4 Synthetic Brake Fluid.
Fork Oil:
Harley-Davidson Type 'E' or 'HD 10W' fork oil (check manual for specific weight).
Primary Chain Tensioner:
Early Twin Cam models were known for automatic primary chain tensioner wear, potentially leading to noise or damage if not addressed. Upgrade kits are available.
Cam Chain Tensioners:
Similar to the primary tensioner, cam chain tensioners can wear over time, especially on earlier models. Manual will detail inspection and replacement.
Carburetor Vs Efi:
While this is an EFI model, older EFI systems can sometimes have issues with sensors or fuel delivery, which this manual will help diagnose.
Founding:
1903, Milwaukee, Wisconsin, USA.
Legacy:
Iconic American motorcycle manufacturer known for V-twin engines and distinctive styling.
Electra Glide Lineage:
The Electra Glide line dates back to the 1960s, evolving into the premier touring platform for Harley-Davidson.
Ultra Classic Positioning:
Represents the top-tier, fully-equipped touring model, offering maximum comfort and amenities.
Twin Cam Introduction:
The Twin Cam engine platform was introduced in 1999, replacing the Evolution engine in many models.
2004 Updates:
For 2004, key updates often included refinements to the EFI system, potential styling tweaks, and the introduction of the 103 cubic inch motor as a significant option for touring models.
