🏷️ Basic Information

Make:

Harley-Davidson

Model:

Softail

Year:

2004

Platform Code:

2004 Softail models

👋 Introduction

Target Audience:

Harley-Davidson owners, independent repair shops, and professional motorcycle technicians.

Value Proposition:

Provides comprehensive OEM-level technical information, enabling accurate repairs and maintenance, surpassing generic repair guides in detail and accuracy.

Comprehensiveness:

1068 pages of detailed information covering all aspects of the 2004 Softail model line.

Digital Convenience:

Instant download eliminates shipping costs and delays, offering immediate access to critical repair data.

📋 Manual Details

Primary Coverage:

Workshop Service and Repair

Total Pages:

1068

Manual Classification:

Factory Service Manual (FSM)

Language:

English

Delivery Format:

Digital (PDF)

📖 Manual Coverage

Engine Systems:

Engine assembly, disassembly, tuning, lubrication, cooling, fuel delivery (carburetor and EFI), ignition system, exhaust system, oil pump operation, piston and cylinder service.

Transmission And Drivetrain:

Primary drive, transmission internal components, clutch operation and service, final drive belt inspection and replacement, shifter mechanism.

Electrical System:

Wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlight, taillight, indicators), ignition system components, instrumentation, battery maintenance, fuses, relays.

Chassis And Suspension:

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

Braking System:

Front and rear brake caliper service (disassembly, cleaning, rebuilding), brake pad replacement, brake fluid flush and replacement, master cylinder service, brake line inspection, rotor inspection.

Fuel System:

Carburetor overhaul (e.g., CV carburetor), fuel injection system components (sensors, injectors, fuel pump), fuel tank inspection and cleaning, fuel lines.

Bodywork And Frame:

Fender removal and installation, fuel tank mounting, seat removal, handlebars, basic frame inspection.

Preventive Maintenance:

Scheduled maintenance intervals, fluid changes (engine oil, primary oil, transmission oil, brake fluid), filter replacements (oil filter, air filter), spark plug service, drive belt adjustment and inspection, battery charging.

Diagnostic Troubleshooting:

System-specific diagnostic charts, symptom-based troubleshooting guides, identifying common faults and their remedies for engine performance, electrical issues, and braking problems.

Repair And Rebuild:

Step-by-step instructions for major component disassembly, repair, and reassembly, including engine teardown, transmission overhaul, fork rebuilds, and brake caliper servicing.

Adjustments And Settings:

Carburetor idle speed and mixture adjustment, ignition timing checks (where applicable), clutch cable free play adjustment, steering head bearing preload, brake lever adjustment.

Diagnostic Capability:

Advanced diagnostic procedures, including interpretation of electrical schematics and symptom analysis for complex issues.

Rebuild Scope:

Comprehensive rebuild procedures for major engine and transmission components, enabling complete overhauls.

Torque Specifications:

Detailed torque specifications for all critical fasteners across all systems, essential for correct assembly and safety.

Special Tool Requirements:

Identification of Harley-Davidson proprietary tools and essential specialized equipment required for specific service procedures.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Readability:

High-resolution scans ensuring clarity of text, diagrams, and illustrations.

Digital Access:

Instant download, no physical binding.

Digital Format Note:

Optimized for on-screen viewing and printing of individual pages or sections.

⚙️ Engine Specifications

Engine Family:

Evolution (V-Twin)

Engine Displacement:

Commonly 88 cubic inches (1450cc) for 2004 models (e.g., Twin Cam 88B).

Engine Configuration:

45-degree V-twin, air-cooled

Engine Construction:

Cast iron cylinders, aluminum heads

Horsepower Estimate:

Approximately 60-70 HP (model dependent).

Torque Estimate:

Approximately 75-85 ft-lbs (model dependent).

Fuel Delivery Type:

Carburetor (e.g., Keihin CV40) or Electronic Fuel Injection (EFI) depending on specific Softail model (e.g., Dyna models often had EFI).

Recommended Fuel Octane:

91 Octane Unleaded (check specific model recommendation).

Oil Type:

Harley-Davidson Genuine V-Twin 20W-50 (or equivalent API SG or higher).

Engine Oil Capacity:

Approximately 4 US quarts (3.8 liters) with filter change (verify with manual).

🔧 Transmission

Transmission Type:

5-speed constant mesh, manual

Gear Ratios:

Specific gear ratios for each of the 5 speeds will be detailed in the manual.

Clutch Type:

Wet, multi-plate

Primary Chain Case Oil Capacity:

Approximately 1 US quart (0.95 liters) (verify with manual).

Primary Chain Case Oil Specification:

Harley-Davidson Genuine Formula+ (or equivalent SAE 50).

Final Drive:

Belt drive

📐 Dimensions

Wheelbase Estimate:

Typically around 64.5 - 66.0 inches (1638 - 1676 mm) depending on specific Softail model.

Seat Height Estimate:

Around 25.5 - 26.5 inches (648 - 673 mm) unladen.

Dry Weight Estimate:

Approximately 650 - 700 lbs (295 - 318 kg) depending on model and equipment.

🛡️ Safety Features

Safety Standard:

N/A (Motorcycles typically do not receive the same standardized safety ratings as cars).

Braking System Type:

Dual-piston caliper front and rear disc brakes.

Lighting System:

Halogen headlight, LED taillight, incandescent turn signals.

💡 Technology Features

Audio System:

Optional factory radio/audio systems were available on some touring-oriented Softail models, but generally not standard on all Softail variants in 2004.

Electronic Aids:

Limited to no electronic driver aids like ABS or traction control standard on most 2004 Softail models. ABS was an option on some later models or touring variants.

Connectivity Features:

No integrated smartphone connectivity or Bluetooth found on this generation of Softails.

🔧 Maintenance

Engine Oil Change Interval:

Every 5,000 miles (8,000 km) or 12 months, whichever comes first (check manual for exact recommendation).

Primary Oil Change Interval:

Every 10,000 miles (16,000 km) or 24 months.

Transmission Oil Change Interval:

Every 20,000 miles (32,000 km) or 24 months (often shared with primary oil change for some models).

Drive Belt Check Interval:

Every 5,000 miles (8,000 km) for tension and condition.

Brake Fluid Type:

DOT 4 (check manual for specific Harley-Davidson recommendation).

Fork Oil Type:

Harley-Davidson Genuine Fork Oil (e.g., 15W) or equivalent (refer to manual for viscosity).

Common Softail Issues 2004:

Potential for oil leaks from engine/transmission seals, front fork seal leaks, occasional electrical connector corrosion, wear on primary drive components over time, carburetor tuning sensitivity (CV carb).

Oil Filter Part Number Example:

Harley-Davidson OEM: 63796-77B (common for many Evolution models, verify for specific 2004 Softail).

📚 Vehicle History

Manufacturer Origin:

United States

Platform Introduction:

The Softail platform, known for its hidden rear suspension, was introduced in 1984, evolving significantly over the years.

Assembly Location:

York, Pennsylvania and Milwaukee, Wisconsin, USA.

🏆 Awards & Recognition

Model Achievements:

Harley-Davidson motorcycles, including the Softail line, have consistently been recognized for their iconic styling, V-twin engine character, and contribution to motorcycle culture, though specific annual awards for the 2004 model are not typically detailed in service manuals.