Brand Heritage:
Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903, known for its V-twin engines, distinctive styling, and strong rider community.
Model Segment:
The Touring line represents Harley-Davidson's flagship long-distance touring motorcycles, designed for comfort, cargo capacity, and highway cruising.
Competitors:
Competes with other large-displacement touring motorcycles from brands like Honda (Gold Wing), Indian (Roadmaster, Springfield), and BMW (K series touring).
Platform Design:
The 2000-2006 era Touring models are built on a common chassis and powertrain architecture, sharing many components and design philosophies across different model names.
Engine Technology:
Primarily features Harley-Davidson's Twin Cam 88 and later Twin Cam 96 (introduced later in the period for some models) engines, known for their torque delivery.
Covered Years:
2000, 2001, 2002, 2003, 2004, 2005, 2006
Covered Models:
Harley-Davidson Touring models including Electra Glide, Road Glide, Road King, Street Glide, and potentially CVO (Custom Vehicle Operations) variants within the specified years.
Estimated Page Count:
Typically 800-1200+ pages for comprehensive workshop manuals of this era and scope.
Manual Type:
Workshop Service Repair Manual
Engine:
Engine overhaul, top-end rebuild, bottom-end assembly, valve adjustments, timing, lubrication system, cooling system (air-cooled for most, specific oil cooling if applicable), fuel injection (EFI) and carburetor systems.
Transmission Drivetrain:
Gearbox disassembly, inspection, and assembly; clutch operation and adjustment; primary drive system; final drive (belt drive system components and maintenance).
Chassis Suspension:
Frame inspection and repair; front fork (including telescopic and potentially FLHT/FLTR fairing fork components) overhaul, seal replacement, fluid specifications; rear shock absorber and suspension linkage inspection and service.
Braking System:
Front and rear brake caliper overhaul, pad replacement, rotor inspection, hydraulic system bleeding, master cylinder service.
Electrical System:
Wiring diagrams, charging system (stator, regulator/rectifier), ignition system, lighting (headlight, taillight, turn signals), instrumentation, horn, starter system, battery maintenance and testing, fuse and relay identification.
Fuel System:
Fuel tank removal and installation, fuel pump operation, fuel filter replacement, fuel lines, EFI sensors (e.g., MAP, IAT, O2), carburetor adjustment and cleaning (for applicable models).
Body And Fairings:
Fairing removal and installation, saddlebag mounting and hardware, seat removal and maintenance, fenders, windshield, and associated trim.
Routine Maintenance:
Oil and filter changes, air filter service, spark plug replacement, drive belt inspection and adjustment, lubrication points, brake fluid checks.
Troubleshooting:
Diagnostic charts for common starting, running, electrical, and performance issues, with step-by-step diagnostic procedures.
Repair And Rebuild:
Detailed instructions for component disassembly, inspection, repair, and reassembly for major vehicle systems.
Technical Specifications And Tolerances:
Torque specifications for critical fasteners, engine component clearances, electrical system resistance values, fluid capacities.
Depth Of Coverage:
Comprehensive, covering everything from basic rider maintenance to full engine and transmission rebuilds, electrical system diagnostics, and chassis component overhauls.
Engine Type:
Air-cooled, 45-degree V-twin, pushrod overhead valves.
Engine Displacement:
Primarily 1450cc (88 cubic inches). Later models in this range might feature the 1550cc (96 cubic inches) Twin Cam.
Bore X Stroke:
For Twin Cam 88: 3.75 in. x 4.00 in. (95 mm x 101.6 mm).
Horsepower Est:
Approximately 65-70 HP (at crankshaft, varies by model year and tune).
Torque Est:
Approximately 80-90 lb-ft (at crankshaft, varies by model year and tune).
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI) or Carbureted (Keihin CV carburetor).
Fuel Type:
Unleaded gasoline, 91 octane or higher recommended.
Oil Type:
Harley-Davidson 20W-50 Synthetic Motorcycle Oil or equivalent.
Oil Capacity:
Approximately 4 quarts (3.8 liters) with filter change.
Transmission Type:
5-speed constant mesh manual transmission.
Optional Transmission:
None (5-speed was standard for this platform).
Primary Drive:
9-plate dry clutch, chain drive to transmission.
Final Drive:
Belt drive (32mm wide belt).
Transmission Oil Type:
Harley-Davidson Formula+, or suitable 80W-90 gear oil.
Transmission Oil Capacity:
Approximately 24 US fluid ounces (0.71 liters).
Safety Ratings:
Motorcycles typically do not receive official government safety ratings like cars. Emphasis is on rider control and roadworthiness.
Active Safety:
Disc brakes front and rear, linked braking systems may be present on some later models. Rider skill is the primary active safety feature.
Passive Safety:
Robust frame construction, fairings for rider protection from elements, large motorcycle presence for visibility. ABS was an optional feature on some models towards the end of this period.
Audio System:
Factory-installed AM/FM radio with cassette player and/or CD player, often with handlebar-mounted controls. Speakers integrated into the fairing.
Cruise Control:
Electronic cruise control was a common option or standard on many Touring models during this period, enhancing highway comfort.
ABS:
Anti-lock Braking System (ABS) was an optional feature on many models, particularly towards the later years of this range.
Connectivity Features:
Limited by modern standards; typically relied on auxiliary input for portable music devices. No integrated smartphone connectivity.
Oil Change Interval:
Typically every 5,000 miles (8,000 km) or annually, whichever comes first.
Primary Drive Oil Change:
Check and change as per manual recommendations, often at similar intervals to engine oil.
Spark Plug Replacement:
Around 10,000-15,000 miles (16,000-24,000 km).
Drive Belt Inspection:
Inspect for wear and tension at every 5,000-mile service; check belt tension specs.
Fork Oil Type:
Harley-Davidson fork oil or equivalent (e.g., Bel-Ray, Spectro) with specific weight (e.g., 10W or 15W depending on application and preference).
Brake Fluid Type:
DOT 4 brake fluid.
Common Wear Items:
Clutch plates, fork seals, wheel bearings, cam chain tensioners (early Twin Cam models had a known issue with wear), regulator/rectifier failures, exhaust system leaks.
Engine Specifics Tc88:
The early Twin Cam 88 engines were subject to cam chain tensioner wear, which could lead to engine damage if not addressed. Upgraded tensioners and oiling systems are common aftermarket fixes.
Touring Platform Introduction:
The modern Harley-Davidson Touring platform, with its frame-mounted fairing and integrated saddlebags, evolved significantly over the decades, with this 2000-2006 period representing a key phase of the Twin Cam era.
Manufacturing Location:
Primarily York, Pennsylvania, USA.
Key Engine Updates In Period:
The introduction of the Twin Cam 88 engine in 1999 marked a significant modernization, followed by the introduction of the Twin Cam 96 (1550cc) in some Touring models around 2007, just outside this manual's scope but representing the transition.
Model Accolades:
Harley-Davidson Touring models are consistently recognized for their comfort, long-distance capabilities, and iconic styling, often topping sales charts in their segment.
Customer Satisfaction:
Generally high, particularly among loyal Harley-Davidson owners who appreciate the brand's character and community.
Certification Type:
N/A (Motorcycle certification is primarily regulatory for road legality, not comparative 'awards' like cars).
