Positioning:
Essential resource for owners and technicians of Harley Davidson FLH motorcycles equipped with the Twin Cam 88 engine, offering complete service and repair information.
Comparison:
This manual is a direct competitor to official Harley Davidson service manuals and other aftermarket publications, providing a similarly comprehensive level of detail for the specified model years and engine configuration.
Features:
Extensive page count, detailed diagrams and illustrations, step-by-step procedures, troubleshooting guidance, instant digital access.
Applicable Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Type:
Workshop Service Repair Manual
Format:
PDF (Instant Download)
Engine:
Complete disassembly, inspection, assembly, troubleshooting, diagnostics for Twin Cam 88 engine.
Fuel System:
Carburetor and fuel injection systems, fuel pump, fuel filter, fuel tank servicing.
Ignition System:
Ignition coils, spark plugs, ignition modules, timing.
Transmission:
5-speed constant mesh transmission overhaul, clutch service, primary drive system.
Drivetrain:
Final drive, belt drive system, wheel bearings, swingarm, rear axle.
Brakes:
Front and rear brake system maintenance, caliper overhaul, master cylinder service, brake fluid replacement.
Suspension:
Front fork (including cartridge fork details) and rear shock absorber service, fork oil replacement, adjustments.
Electrical System:
Wiring diagrams, battery service, charging system (stator, regulator/rectifier), starter system, lighting, switches, gauges.
Frame And Bodywork:
Frame inspection, body panel removal and installation, fairing, saddlebag service.
Cooling System:
Air cooling system specific details and recommendations.
Maintenance:
Scheduled maintenance, oil changes, filter replacement, chain/belt adjustment, battery care.
Troubleshooting:
Diagnostic flowcharts for common and complex issues.
Repair:
Detailed step-by-step repair procedures for all major components and systems.
Rebuild:
Complete engine and transmission rebuild procedures.
Wiring Diagrams:
Comprehensive and detailed electrical system wiring schematics.
Torque Specifications:
Precise torque values for all fasteners.
Diagnostic Codes:
Trouble code (DTC) interpretation and troubleshooting guidance (where applicable for the era).
Depth:
Comprehensive, covering from basic rider maintenance to full engine and transmission overhauls.
Engine Type:
Air-cooled, 45-degree V-twin, pushrod-actuated overhead valves
Engine Displacement:
1449cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Compression Ratio:
Typically 8.8:1 or 9.0:1 depending on specific sub-model/year
Horsepower:
Estimated 70-75 HP (varies by year and specific tuning)
Torque:
Estimated 80-85 ft-lbs (varies by year and specific tuning)
Carburetion:
Keihin CV (Constant Velocity) Carburetor (e.g., Keihin 40mm) for earlier models
Fuel Injection:
Electronic Sequential Port Fuel Injection (ESPFI) for later models (e.g., 2001 onwards)
Oil Type Recommendation:
Refer to manual for specific Harley-Davidson recommendations, typically 20W-50 motorcycle oil.
Oil Capacity:
Refer to manual, typically around 4 quarts (3.8 liters) with filter change.
Valve Timing:
Refer to manual for specific valve lift and timing events.
Cylinder Head Design:
Two valves per cylinder, pushrod actuated.
Cooling Method:
Air-cooled via finned cylinders and heads.
Type:
5-speed, constant mesh, overdrive
Optional Transmissions:
N/A (Standard configuration for FLH models of this era)
Clutch Type:
Wet, multi-plate, diaphragm spring
Primary Drive:
Duplex chain, centrifugal clutch (pre-2000), or primary drive with wet clutch (2000+ models typically use a dry clutch, but this era often transitioned).
Fluid Type:
Refer to manual, typically Harley-Davidson Formula+ or compatible transmission fluid.
Fluid Capacity:
Refer to manual, typically around 1 quart (0.95 liters).
Wheelbase:
Refer to specific model year specifications, typically around 63.5 inches (1613 mm).
Length:
Refer to specific model year specifications, typically around 90-95 inches (2286-2413 mm).
Seat Height:
Refer to specific model year specifications, typically around 28-30 inches (711-762 mm).
Dry Weight:
Refer to specific model year specifications, typically around 700-750 lbs (318-340 kg).
Gross Vehicle Weight Rating:
Refer to specific model year specifications, typically around 1200 lbs (544 kg).
Saddlebag Capacity:
Integral, refer to owner's manual for specific volume estimates.
Crash Test Results:
N/A (Motorcycle safety is assessed differently than automobiles and typically not through standardized crash testing programs like NHTSA.
Braking:
Dual disc front brakes, single disc rear brake. ABS was an option on some later models within this range.
Lighting:
Halogen headlight, taillight, brake light, turn signals.
Frame Construction:
Steel frame construction.
Audio System:
Many FLH models of this era featured optional AM/FM radio, cassette player, or CB/Intercom systems. Manual covers their maintenance and basic troubleshooting.
ABS:
Anti-lock Braking System (ABS) was an option on select models during these years, which the manual will detail if applicable to the specific sub-model covered.
Cruise Control:
Electronic cruise control was often an option on FLH touring models; manual will cover its operation and service.
Diagnostic Tools:
Manual provides procedures for using Harley-Davidson diagnostic tools or common electronic multimeters for troubleshooting.
First Service:
Typically 1,000 miles (1600 km) or 6 months, whichever comes first.
Subsequent Services:
Generally every 5,000 miles (8,000 km) or 12 months for oil changes and routine checks. More in-depth services every 10,000-20,000 miles.
Engine Oil Grade:
Harley-Davidson 20W-50 Motorcycle Oil (or equivalent API SG or higher specification).
Transmission Oil Grade:
Harley-Davidson Formula+ Transmission Lubricant (or equivalent.
Primary Chain Case Oil:
Harley-Davidson Formula+ or suitable HD primary fluid.
Brake Fluid Type:
DOT 4 (for most models, confirm with manual)
Cam Chain Tensioners:
Early Twin Cam models (pre-2007) are known for hydraulic cam chain tensioner shoe wear, which can lead to engine damage if not addressed. Manual covers inspection and replacement.
Crankcase Bearings:
Potential for crankcase bearing failures; manual provides inspection procedures.
Oil Leaks:
Common areas for oil leaks include primary and transmission seals, rocker box gaskets. Manual details seal replacement.
Spark Plugs:
Refer to manual for correct spark plug type (e.g., NGK, Champion) and gap.
Air Filter:
Regular inspection and replacement of the air filter element.
Battery Maintenance:
Checking terminal connections, electrolyte levels (if applicable), and ensuring proper charging.
Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer known for its touring and cruiser motorcycles.
Evolution Of Flh:
The FLH designation has a long history within Harley-Davidson, representing their large-frame touring motorcycles. The introduction of the Twin Cam 88 engine in 1999 marked a significant modernization of their platform, replacing the Evolution (Evo) Big Twin.
Production Years:
1999-2005 for this specific manual coverage.
Engine Introduction:
The Twin Cam 88 engine was first introduced in 1999, designed to offer improved performance, durability, and rider comfort over its predecessor.
Harley Davidson Reputation:
Harley-Davidson motorcycles are consistently recognized for their classic styling, V-twin rumble, and rider community, often winning awards for cruiser and touring categories in rider polls.
Customer Satisfaction:
While specific awards vary, Harley-Davidson generally maintains high customer loyalty and satisfaction among its rider base.
