🏷️ Basic Information

Make:

Harley-Davidson

Model:

Touring Series

Family:

Touring

Product Type:

Service Repair Manual

Applicable Model Years:

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

👋 Introduction

Target Audience:

DIY enthusiasts, professional mechanics, workshops, owners seeking to perform their own maintenance and repairs.

Segment:

Full-size touring motorcycles, often considered among the benchmark for long-distance comfort and rider amenities in the V-twin cruiser segment.

Value Proposition:

Offers significant cost savings compared to professional servicing, provides essential information for immediate problem-solving and comprehensive repairs.

Manual Benefits:

Instant download, detailed instructions, troubleshooting assistance, saves money, manufacturer-produced content, high-quality illustrations.

Troubleshooting Focus:

Emphasis on immediate problem-solving and how to fix issues quickly.

📋 Manual Details

Specific Models Covered:

FLHR/FLHRI Road King, FLHRCI Road King Classic, FLHRS/FLHRSI Road King Custom, FLHT/FLHTI Electra Glide Standard, FLHTC/FLHTCI Electra Glide Classic, FLHTCSE2 Screamin' Eagle Electra Glide 2, FLHTCUI Classic Electra Glide, FLTR/FLTRI Road Glide

Total Pages:

700+

Type:

Official Factory Service Manual / Workshop Manual

Content Origin:

Original manufacturer-produced manual.

Language:

English

Format:

PDF Download

File Size Indication:

Can be very large, up to 5 GB, due to comprehensive content.

📖 Manual Coverage

Major Systems:

Engine, Clutch and Primary Drive, Transmission, Fuel System, Exhaust and Emission Control, Electrical System, Wheels, Hubs and Tires, Front Suspension and Steering, Rear Suspension, Brakes, Cruise Control, Bodywork, Wiring Diagrams

Engine Details:

Complete engine overhaul, including disassembly, inspection, assembly, timing, ignition system, fuel delivery, lubrication, cooling (air-cooled), and specific components like pistons, cylinders, crankshaft, camshafts.

Braking And Wheel Systems:

Brake system bleeding and overhaul (master cylinders, calipers, lines), wheel removal and installation, hub service, and tire pressure recommendations.

Cruise Control System:

Diagnosis, adjustment, and troubleshooting of the electronic cruise control system.

Fuel And Emission Control:

Fuel tank, fuel lines, fuel pump (EFI), fuel injectors (EFI), carburetor service, emission control systems (if applicable).

Transmission Details:

Clutch adjustment, transmission disassembly, inspection, and reassembly, gear inspection, shift linkage adjustments.

Repair And Maintenance:

Troubleshooting, Lubrication, Maintenance, Tune-Up, Rebuild, Diagnosis, Servicing, Preventative Maintenance, Installation

Electrical Diagnostics:

Wiring diagrams, troubleshooting electrical faults, charging system (stator, regulator/rectifier), starting system (starter, solenoid, battery), lighting, ignition, instrumentation, and accessory circuits.

Body And Trim:

Fairing removal and installation, saddlebag service, seat removal, and other body panel procedures.

Engine Tuning:

Carburetor adjustment and tuning, ignition timing checks, fuel injection system diagnostics.

Level Of Detail:

Comprehensive, Step-by-step instructions, Detailed component breakdowns, Exploded views, Troubleshooting guides, Professional technician level

Chassis And Suspension:

Detailed procedures for front fork overhaul (including oil changes and seal replacement), rear shock absorber adjustment and replacement, steering head bearing service, wheel bearing replacement, and tire mounting/balancing.

Diagnostic Tools:

Information that supports the use of diagnostic tools and software for fault code retrieval and system analysis.

Completeness:

Complete step-by-step information for all servicing, repairing, and preventative maintenance procedures.

📊 Manual Specifications

Compatibility:

Compatible with Windows, Linux, Mac OS; requires PDF reader; may require WinZip/WinRAR for extraction

Printability:

Printable on any computer and printer

Physical Format:

Digital Download (No physical copy, CD, or DVD)

Digital Quality:

High-quality digital reproduction with zoomable illustrations

⚙️ Engine Specifications

Engine Family:

Harley-Davidson Twin Cam 88 (and variants)

Displacement:

88 cubic inches (1450cc). Specific variants may have different configurations or enhancements (e.g., Screamin' Eagle).

Horsepower:

Typically in the range of 60-70 HP (estimated, actual varies by model and tuning).

Torque:

Peak torque typically around 80-90 ft-lbs (estimated).

Fuel Delivery:

Carbureted (CV-style) or Fuel Injection (EFI) depending on model and year.

🔧 Transmission

Transmission Type:

5-speed constant mesh, sequential manual transmission.

Clutch Type:

Wet, multi-plate, manually operated.

Drive System:

Primary drive via duplex chain; final drive via belt drive.

📐 Dimensions

General Styling:

Classic cruiser styling with large fairings, saddlebags, and comfortable seating for touring.

Wheelbase:

Varies by model, typically around 63.5 - 64.5 inches (1613 - 1638 mm).

Dry Weight Approximate:

Varies by model, typically between 700-850 lbs (318-385 kg).

🛡️ Safety Features

General Safety:

Focus on rider control and stability, braking performance. Specific crash ratings not applicable to motorcycles in the same way as cars.

Braking System:

Dual 32mm, 4-piston, fixed front calipers with 11.5-inch (292mm) floating rotors; Single 32mm, 4-piston, fixed rear caliper with 11.5-inch (292mm) rotor. Some models may feature ABS.

Lighting:

Halogen headlamp, auxiliary passing lamps (on some models), LED tail lamp and brake lamp.

💡 Technology Features

Audio System:

Many models feature a premium audio system with AM/FM radio, CD player (on some models), and speakers integrated into the fairing. CB radio and intercom options may be available.

Display Features:

Analog gauges for speedometer and tachometer, with integrated digital readouts for odometer, trip meter, and gear indication.

Cruise Control:

Electronic cruise control is a standard or optional feature on many Touring models during this period, enhancing long-distance comfort.

Diagnostic Ports:

Diagnostic connectors for engine management and other electronic systems are covered in the manual for fault finding.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 miles (8,000 km) or annually, whichever comes first. Primary chaincase oil and transmission oil also require separate service intervals.

Spark Plug Replacement:

Refer to manual for specific intervals, typically around 10,000-20,000 miles (16,000-32,000 km).

Engine Oil Type:

Harley-Davidson Genuine V-Twin 20W-50 SYN3 or equivalent API CI-4 rated synthetic motorcycle oil.

Primary Chaincase Oil Type:

Harley-Davidson Genuine Primary Chaincase Lubricant or Formula+ Transmission and Primary Chaincase Lubricant.

Transmission Oil Type:

Harley-Davidson Genuine Transmission Lubricant or Formula+ Transmission and Primary Chaincase Lubricant.

Brake Fluid Type:

DOT 4 hydraulic fluid.

Fork Oil Type:

Specific Harley-Davidson fork oil or equivalent SAE 15W fork oil is commonly used, consult manual for exact specification and quantity.

Common Wear Items:

Cam chain tensioners (early Twin Cam 88), primary compensator, wheel bearings, brake pads, clutch plates, battery.

Common Maintenance Tasks:

Regular checks of tire pressure, brake fluid level, chain tension (if applicable), clutch adjustment, and electrical connections.

📚 Vehicle History

Manufacturer:

Harley-Davidson Motor Company, a storied American motorcycle manufacturer with a rich history dating back to 1903.

Touring Lineage:

The Touring series represents Harley-Davidson's commitment to comfortable long-distance riding, evolving from earlier large touring motorcycles with continuous refinement of comfort, power, and technology.

Key Models Covered:

This period covers the transition and evolution of the Twin Cam 88 engine and its various configurations within the Touring platform.

Manufacturing Location:

Primarily manufactured in the United States.