🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLT

Engine Family:

Twin Cam 103

Applicable Years:

1999, 2000, 2001, 2002, 2003, 2004, 2005

Manual Product Identifier:

Harley Davidson FLT Twin Cam 103 1999-2005 Service Repair Manual

👋 Introduction

Market Segment:

Touring Motorcycle Segment

Target Audience:

Harley-Davidson FLT owners, independent repair shops, motorcycle technicians.

Competitors:

Other touring motorcycles of the era (e.g., Honda Gold Wing, Indian Roadmaster).

Vehicle Platform:

Harley-Davidson FLT platform (Electra Glide, Ultra Classic, King of the Road variants).

Engine Significance:

Introduction and refinement of the Twin Cam 88 and its evolution to the Twin Cam 96, representing a significant technological shift from the Evolution engine.

Value For Owner:

Empowers owners to perform maintenance and repairs, saving on labor costs and ensuring proper upkeep of a valuable asset.

Value For Technician:

Provides essential technical data, diagrams, and procedures for accurate and efficient servicing.

📋 Manual Details

Primary Coverage:

Complete service, repair, and maintenance for Harley-Davidson FLT models equipped with the Twin Cam 103 engine from 1999-2005.

Page Count:

706

Manual Type:

Workshop Service Manual / Repair Manual

Language:

English

Format:

PDF (Digital Instant Download)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, inspection, troubleshooting, component specifications, cylinder heads, cylinders, pistons, crankshaft, camshaft, valve train, oil pump, oil cooling, lubrication system.

Fuel System:

Fuel injection (EFI) system, fuel pump, fuel injectors, throttle body, fuel pressure regulator, fuel tank, fuel lines, diagnostics.

Ignition System:

Ignition module, spark plugs, ignition coils, crankshaft position sensor, camshaft position sensor, troubleshooting.

Transmission:

5-speed Cruise Drive transmission, clutch assembly, gearbox disassembly and assembly, gear inspection, lubrication, troubleshooting.

Drivetrain:

Primary drive, clutch operation, belt drive, final drive, swingarm, drive belt inspection and replacement, wheel bearings, rear pulley.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlight, taillight, turn signals), instrumentation, wiring diagrams, fuses, relays, ECM (Engine Control Module).

Brakes:

Front and rear brake systems, hydraulic components, brake calipers, master cylinders, brake lines, pads, rotors, bleeding procedures, troubleshooting.

Suspension:

Front fork (showa or similar), rear shock absorbers, suspension adjustments, fork oil replacement, seal replacement, troubleshooting.

Steering:

Handlebars, steering head bearings, triple clamps, steering stem inspection and adjustment.

Chassis And Frame:

Frame inspection, component mounting, bodywork (fenders, fairings, fuel tank), seat assembly, exhaust system.

Wheels And Tires:

Wheel inspection, tire pressure, tire replacement, wheel balancing, spoke adjustment (if applicable).

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug service, drive belt inspection, brake fluid checks, battery maintenance, tire pressure checks.

Scheduled Maintenance:

Detailed service intervals and procedures for all major maintenance tasks.

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common and complex issues.

Engine Rebuild:

Complete disassembly, inspection, measurement, component replacement, and reassembly of the Twin Cam 103 engine.

Transmission Repair:

Clutch adjustment and replacement, gearbox internal repairs, bearing replacement.

Electrical Diagnostics:

Troubleshooting wiring issues, component testing (stator, regulator, starter), ECM diagnosis.

Brake System Service:

Brake pad replacement, caliper service, master cylinder overhaul, brake fluid flush and bleed.

Suspension Service:

Fork seal replacement, fork oil changes, shock absorber replacement.

Bodywork And Trim:

Fairing removal and installation, fender replacement, fuel tank mounting.

Torque Specifications:

Detailed torque values for all critical fasteners.

Depth Level:

Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including in-depth diagnostics and specifications.

📊 Manual Specifications

File Format:

PDF

Searchable Text:

Likely Yes (standard for professionally produced PDF manuals)

Print Quality:

High Resolution (typical for service manuals, allowing clear diagrams and text)

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Air-cooled, V-twin, 45-degree, 4-stroke

Engine Family:

Twin Cam 103

Displacement:

1690 cc (103 cubic inches)

Bore X Stroke:

3.875 in x 4.38 in (98.4 mm x 111.3 mm)

Compression Ratio:

Approximately 9.2:1 (varies slightly by year/variant)

Horsepower Estimate:

Estimated 70-75 HP (at crank, actual figures vary with tuning and year)

Torque Estimate:

Estimated 90-100 ft-lbs (at crank, actual figures vary with tuning and year)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON+MON)/2

Valvetrain:

Overhead valves (OHV), pushrod actuated, 2 valves per cylinder

Camshaft Type:

Hydraulic flat tappet or roller tappet (depending on specific model year and configuration)

Cooling Method:

Air-cooled, with oil cooling circuit

Oil Type:

Harley-Davidson 20W-50 SYN3 (or equivalent API SG or higher certified motorcycle oil)

Oil Capacity:

Approximately 4 quarts (3.8 liters) with filter change

🔧 Transmission

Transmission Type:

5-speed constant mesh, helical gear

Transmission Model:

T2 (Cruise Drive)

Clutch Type:

Wet, multi-plate, hydraulic actuation

Final Drive:

Belt drive, 32/66 tooth ratio (typical)

Transmission Oil Type:

Harley-Davidson Formula + (or equivalent SAE 75W-90 GL-5 gear oil)

Transmission Oil Capacity:

Approximately 1 quart (0.95 liters)

📐 Dimensions

Wheelbase:

Approximately 63.5 inches (1613 mm)

Length:

Approximately 97.3 inches (2471 mm)

Dry Weight:

Approximately 763 lbs (346 kg)

Gross Vehicle Weight Rating Gvwr:

Typically around 1260 lbs (572 kg)

Fuel Tank Capacity:

5.0 gallons (18.9 liters)

🛡️ Safety Features

Safety Standard:

Motorcycle safety standards of the era; focus on rider control and stability.

Braking System:

Dual 32mm front pistons and single 32mm rear piston calipers with dual 300mm (11.8 inch) front and 292mm (11.5 inch) rear brake discs (typical).

Lighting:

Halogen headlight, LED taillight, front and rear turn signals.

Frame Construction:

Steel tubing frame providing rigidity and stability.

Wind Protection:

Full fairing and windscreen (standard on most FLT models) for rider comfort and protection from elements.

💡 Technology Features

Audio System:

Factory-installed radio with AM/FM, CD player, and sometimes CB/intercom options on higher trims (e.g., Ultra Classic).

Speakers:

Fairing-mounted speakers, potentially saddlebag-mounted speakers on touring models.

Cruise Control:

Standard on most FLT models of this era, providing rider comfort on long journeys.

Diagnostic Port:

Incorporates a diagnostic port for connecting electronic diagnostic tools (like Harley-Davidson's Digital Technician) for engine and system diagnostics.

🔧 Maintenance

First Service:

1000 miles (1600 km) or 6 months (whichever comes first) - typically includes oil and filter change, primary chain tensioner inspection, clutch adjustment, inspection of all critical fasteners.

Subsequent Oil Changes:

Every 5000 miles (8000 km) or 12 months, or as recommended by Harley-Davidson based on usage.

Air Filter Service:

Inspect every 5000 miles (8000 km), replace as needed or at least every 10,000-15,000 miles (16,000-24,000 km).

Spark Plug Service:

Replace every 10,000 miles (16,000 km).

Drive Belt Inspection:

Inspect tension and condition every 5000 miles (8000 km).

Brake Fluid Change:

Flush and replace every 2 years (DOT 4 fluid).

Engine Oil:

Harley-Davidson 20W-50 SYN3 or equivalent SAE 20W-50 API SG or higher certified motorcycle oil.

Primary Chain Case Oil:

Harley-Davidson Primary Fluid or equivalent SAE 85W-140 gear oil.

Transmission Oil:

Harley-Davidson Formula + or equivalent SAE 75W-90 GL-5 gear oil.

Brake Fluid:

DOT 4 Hydraulic Brake Fluid.

Primary Chain Tensioner:

Early Twin Cam models (up to ~2006) used an automatic tensioner that could wear out, leading to noise and potential chain damage. Later models (and aftermarket upgrades) feature a hydraulic tensioner.

Cam Chain Tensioner Upgrade:

The manual will likely cover the procedures for inspecting and potentially replacing the stock tensioner with an upgraded unit.

Oil Leaks:

Common areas for potential leaks include crankcase seals, primary cover gasket, and rocker box gaskets.

Ignition Module Failure:

Less common but possible; troubleshooting would involve checking sensors and wiring.

📚 Vehicle History

Brand Origin:

Founded in 1903 in Milwaukee, Wisconsin, USA. Pioneer in motorcycle manufacturing.

Flt Introduction:

The FLT touring platform was introduced in 1979 as a significant departure, featuring a rubber-mounted frame and aerodynamic fairing, evolving from the earlier FLH models.

Twin Cam Introduction:

The Twin Cam engine family (starting with the Twin Cam 88) was introduced in 1999, replacing the long-running Evolution engine, offering improved performance, reliability, and thermal management.

Manufacturing Location:

Milwaukee, Wisconsin, USA and York, Pennsylvania, USA (Harley-Davidson assembly plants).