Model Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Platform Codes:
Often referred to as the 'FL' platform for touring models, with specific sub-designations like FLHT, FLHTC, FLHR, FLHTCUI.
Positioning:
The go-to reference for owners and independent mechanics seeking to maintain and repair the iconic Harley-Davidson Touring platform.
Alternatives:
Official Harley-Davidson service manuals are the benchmark. This manual provides equivalent detail and is essential for DIY or independent shop work, often surpassing generic aftermarket guides in accuracy and completeness for this specific platform.
Features:
Detailed diagnostic procedures, complete wiring diagrams, step-by-step repair instructions, exploded views, and specification tables.
Primary Coverage:
Comprehensive service and repair for Harley-Davidson Touring motorcycles
Specific Models:
Electra Glide Standard (FLHT), Electra Glide Classic (FLHTC), Road King (FLHR), Road King Custom (FLHRSI), Street Glide (FLHX), Ultra Classic Electra Glide (FLHTCU), CVO Ultra Classic Electra Glide (FLHTCSE).
Estimated Pages:
700-900+ pages (typical for comprehensive service manuals of this era)
Type:
Factory Service Manual / Workshop Manual
Format:
Print (likely bound paperback or spiral-bound for shop use)
Powertrain:
Engine (Twin Cam 88, Twin Cam 88B), Transmission (5-speed Cruise Drive), Drivetrain (Clutch, Primary Drive, Belt Drive).
Chassis:
Frame, Suspension (Front Fork, Rear Shocks), Steering, Wheels, Tires, Brakes (Front and Rear).
Electrical:
Battery, Charging System (Alternator, Regulator), Ignition System, Starting System, Lighting, Gauges, Audio System, Cruise Control, Accessory Wiring.
Bodywork:
Fairings (Batwing), Saddlebags, Tour-Pak, Fenders, Fuel Tank, Seat.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication, brake fluid service, tire pressure checks.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides.
Repair:
Engine disassembly and reassembly, transmission repair, brake caliper service, electrical component replacement, suspension overhaul.
Installation:
Installation procedures for genuine Harley-Davidson accessories and common aftermarket upgrades.
Depth:
Comprehensive from basic adjustments to full engine and transmission rebuilds, including detailed torque specifications, clearances, and diagnostic charts.
Format:
Print (likely high-quality paper suitable for workshop environments)
Quality:
Professional print, clear diagrams and illustrations.
Binding:
Likely perfect bound or spiral-bound for ease of use while working.
Paper:
Durable, possibly coated paper to resist grease and workshop contaminants.
Engine Family:
Harley-Davidson Twin Cam 88 and Twin Cam 88B
Engine Type:
Air-cooled, 45-degree V-twin, pushrod-actuated overhead valves
Displacement:
88 cubic inches (1450cc)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Horsepower Estimate:
Approximately 60-65 HP (varies by model and tuning)
Torque Estimate:
Approximately 72-78 ft-lbs @ 3500 RPM (varies by model and tuning)
Fuel Delivery:
Carbureted (Keihin CV 40mm) for most models, Fuel Injection (EFI) for select models (e.g., FLHTCI, FLHRSI).
Fuel Type:
Unleaded gasoline, minimum 87 octane
Compression Ratio:
8.8:1 (stock for Twin Cam 88)
Type:
5-speed Cruise Drive (Constant Mesh)
Variant:
N/A for this generation of touring models; 5-speed was standard.
Gear Ratios:
Detailed gear ratios for each speed are provided in the manual, crucial for performance analysis and troubleshooting.
Clutch Type:
Wet, multi-plate
Primary Drive:
Multi-plate clutch, chain drive to transmission.
Final Drive:
Belt drive (32-tooth front pulley, 65-tooth rear pulley typically)
Transmission Fluid:
Harley-Davidson recommends specific Syn3 transmission fluid or equivalent (e.g., Spectro Heavy Duty ShockProof Gear Oil, or a quality 75W-90 synthetic gear oil meeting Harley specifications).
Length Approx:
95.5 in. (2426 mm)
Width Approx:
37.2 in. (945 mm)
Height Approx:
52.0 in. (1320 mm)
Wheelbase Approx:
63.5 in. (1613 mm)
Saddlebag Capacity:
Integrated hard saddlebags with significant storage volume (specific liters not typically cited in general specs but detailed in manual).
Tour Pak Capacity:
Optional Tour-Pak provides additional lockable storage (specific liters available in manual).
Dry Weight Approx:
700-750 lbs (318-340 kg) depending on model
Gvwr Estimate:
Approx. 1160 lbs (526 kg)
Crash Test Info:
Motorcycles are not typically subject to standardized crash testing in the same manner as automobiles. Safety focuses on rider protection and system integrity.
Braking System:
Dual front disc brakes, single rear disc brake. ABS was optional on some models starting late in this period or for specific configurations.
Lighting:
Halogen headlight, dual taillights, front and rear turn signals, marker lights.
Chassis Stability:
Long wheelbase and low center of gravity contribute to stability.
Tire Considerations:
Proper tire inflation and condition are critical safety factors, detailed extensively in the manual.
Audio System:
Factory-installed Clarion or similar AM/FM/Cassette/CD stereo systems were common, often with handlebar controls.
Cruise Control:
Electronic cruise control was an available feature on many Touring models during this period, controlled by handlebar switches.
ABS Availability:
Anti-lock Braking System (ABS) was an optional feature, particularly on higher-trim models or as a late addition to the model run.
Accessory Ports:
Accessory power outlets (e.g., cigarette lighter style) for charging electronics were typically included.
Oil Change Interval:
Typically every 5,000 miles or 6 months, whichever comes first. The manual will detail specific oil and filter part numbers.
Primary Chain Tensioner:
A known wear item on early Twin Cam 88 engines. The manual provides inspection and replacement procedures for the automatic tensioner, which was later updated by Harley-Davidson.
Spark Plug Replacement:
Check and replace as per service schedule, often around 10,000-20,000 miles.
Brake Fluid Flush:
Recommended annually or every 2 years, depending on conditions.
Engine Oil:
Harley-Davidson 20W-50 SYN3 or equivalent (e.g., Screamin' Eagle synthetic or a high-quality motorcycle-specific 20W-50 mineral or synthetic oil meeting Harley-Davidson specifications).
Primary Chain Case Oil:
Harley-Davidson Primary Chain Case Lubricant or a suitable transmission fluid (e.g., Spectro Primary Fluid or a quality wet-clutch compatible motorcycle oil).
Brake Fluid:
DOT 4 recommended for most Harley-Davidson models of this era.
Fork Oil:
Specific weight and volume depend on the fork model and desired performance, detailed in the manual (often 10W or 15W).
Primary Chain Tensioner:
Early models (pre-2006) with the automatic cam chain tensioner are known for potential wear and failure, leading to noise and potential damage. The manual covers inspection and replacement with updated components.
Crankshaft Runout:
While less common, excessive crankshaft runout can be an issue on Twin Cam engines. The manual details measurement procedures.
Cam Chain Tensioner Audible Noise:
Often described as a 'marbles in a can' sound, indicating wear on the primary chain tensioner pads.
Heritage:
Harley-Davidson's legacy in building large-displacement V-twin motorcycles for touring and cruising stretches back over a century.
Evolution To Twin Cam:
The 1999 model year marked a significant transition with the introduction of the Twin Cam 88 engine, replacing the Evolution (Evo) Big Twin. This engine brought improved performance, reliability, and emissions compliance.
Touring Platform Development:
The 'Touring' designation solidified a line of motorcycles specifically designed for long-distance riding, characterized by fairings, ample storage, comfortable seating, and advanced features for the era.
Manufacturing Location:
Primarily York, Pennsylvania, USA, and Milwaukee, Wisconsin, USA.
Sales Impact:
This era of Harley-Davidson Touring bikes was highly successful, solidifying the brand's dominance in the large-displacement cruiser and touring market segment.
