Target Audience:
Harley-Davidson owners, independent repair shops, and professional motorcycle technicians working on 2004 Touring models
Manual Value Proposition:
Provides factory-level technical information essential for accurate diagnosis, maintenance, and repair, saving time and money compared to dealership service.
Digital Format Advantage:
Easy to store, access, and search; allows for printing of specific pages as needed.
Technical Accuracy:
Directly sourced from Harley-Davidson, ensuring adherence to factory specifications and procedures.
Engine Systems:
Engine assembly, disassembly, inspection, tuning, lubrication, cooling system (air-cooled), fuel system (carbureted and EFI), ignition system, exhaust system
Drivetrain Systems:
Clutch (wet multi-plate), primary drive, transmission (5-speed constant mesh), final drive (belt drive), wheel bearings
Chassis Systems:
Frame, suspension (forks, rear shocks), steering system, wheels, tires, brakes (hydraulic disc front and rear), swingarm
Electrical Systems:
Battery, charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), ignition system, lighting (headlamp, tail lamp, turn signals), instrumentation, audio system, wiring diagrams, fault diagnosis
Bodywork And Trim:
Fairings, saddlebags, tour-pak, seat, fuel tank, fenders, mirrors, controls
Maintenance:
Routine servicing, oil changes, filter replacements, brake fluid changes, spark plug replacement, belt tension adjustment, battery maintenance, chassis lubrication
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault codes (if applicable), electrical troubleshooting charts
Repair And Rebuild:
Detailed step-by-step instructions for component disassembly, inspection, repair, and reassembly of engine, transmission, suspension, brakes, and electrical components
Technical Specifications:
Torque specifications, clearances, fluid capacities, part numbers, wiring schematics, service limits
Depth:
Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications for professional technicians and advanced DIY mechanics.
Engine Family:
Twin Cam 88 / Twin Cam 88B (depending on specific Touring model)
Engine Type:
Air-cooled V-twin, pushrod activated overhead valves
Displacement:
1450cc (88 cubic inches)
Horsepower Estimate:
Approx. 65-70 HP (stock, may vary by model/tuning)
Torque Estimate:
Approx. 75-80 lb-ft @ 3500 RPM (stock, may vary by model/tuning)
Fuel Delivery:
Carburetor (e.g., Keihin CV40) or Electronic Sequential Port Fuel Injection (ESPFI) depending on sub-model
Fuel Type:
Unleaded gasoline, minimum 87 octane recommended
Oil Type:
Harley-Davidson SYN3 Full Synthetic SAE 20W-50 or equivalent motorcycle-specific oil
Oil Capacity:
Approx. 4 US quarts (3.8 liters) with filter change
Transmission Type:
5-speed, constant mesh, sequential manual
Primary Drive:
Multi-plate, wet clutch, chain drive
Final Drive:
Enclosed O-ring chain or Belt drive (depending on specific Touring model variant)
Transmission Fluid:
Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant or equivalent
Transmission Fluid Capacity:
Approx. 24 US fluid ounces (0.71 liters)
Wheelbase:
Approx. 63.5 inches (1613 mm) (varies slightly by model)
Seat Height Laden:
Approx. 28.0 inches (711 mm) (varies by model and suspension)
Dry Weight:
Approx. 700-800 lbs (318-363 kg) (varies by model)
Gross Vehicle Weight Rating Gvwr:
Approx. 1260 lbs (572 kg) (typical)
Safety Standards:
Complies with all applicable federal motor vehicle safety standards (FMVSS) for motorcycles.
Braking System:
Dual front disc brakes with 4-piston calipers, single rear disc brake with 4-piston caliper; hydraulic actuation.
Lighting:
Halogen headlamp, LED tail lamp and brake lamp, amber incandescent front and rear turn signals.
Frame Construction:
Steel, rigid backbone and downtube frame construction.
Audio System:
Many 2004 Touring models featured an integrated AM/FM radio with CD player or cassette player, often with handlebar-mounted controls. Some models offered upgraded audio systems.
Instrumentation:
Analog speedometer, tachometer, fuel gauge, voltmeter, oil pressure indicator, and warning lights. Some models may have a trip odometer.
ABS:
Anti-lock Braking System (ABS) was an optional feature on some 2004 Touring models. The manual will cover its components and service.
Cruise Control:
Electronic cruise control was a common option or standard on higher trim levels, managed via handlebar controls.
First Service:
Typically at 1,000 miles (1,600 km) or 6 months, whichever comes first. Includes engine oil and filter change, primary chaincase oil check, chassis lubrication, and general inspection.
Subsequent Service:
Generally every 5,000 miles (8,000 km) or 12 months for routine checks, with more comprehensive services required at higher mileage intervals (e.g., 10,000, 20,000 miles).
Engine Oil Grade:
SAE 20W-50
Transmission Primary Fluid:
Harley-Davidson Formula+ or equivalent
Brake Fluid:
DOT 4 hydraulic brake fluid
Common Wear Items:
Clutch plates, brake pads, wheel bearings, spark plugs, drive belts (if applicable).
Potential Twin Cam Considerations:
While generally robust, Twin Cam 88 engines can experience issues related to cam chain tensioners (especially earlier versions), potential oil leaks from seals, and regulator/rectifier failures. The manual will detail inspection and replacement procedures for these.
Electrical Considerations:
Wiring harness integrity, battery charging system performance, and starter solenoid reliability are areas to monitor.
Heritage:
Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903, known for its distinctive V-twin engines and cruiser/touring motorcycles.
Touring Lineage:
The Touring line has evolved from earlier large-displacement V-twin models designed for long-distance comfort and luggage carrying, becoming a flagship segment for the brand.
Twin Cam Era:
2004 models feature the Twin Cam 88 engine, which replaced the Evolution (Evo) engine, offering improved performance, reliability, and thermal management.
Manufacturing Origin:
Primarily manufactured in the United States.
Motorcycle Awards:
Harley-Davidson Touring motorcycles of this era are consistently recognized for their comfort, capability for long-distance touring, and iconic styling. Specific awards for the 2004 model year would typically be consumer-driven or through motorcycle enthusiast publications.
Build Quality Perception:
Generally regarded as having robust construction for touring duty, with emphasis on reliable powertrain and durable chassis components.
