Market Position:
The 2002 Harley-Davidson Touring models represented a significant evolution in the brand's long-distance touring capabilities, combining classic styling with modern performance and comfort features, catering to riders seeking the ultimate touring experience.
Competitors:
Competed against other large-displacement touring motorcycles from brands like Honda (Gold Wing), BMW (R series), and Victory.
Key Features 2002 Touring:
Introduction of the Twin Cam 88 engine across most touring models, advanced suspension systems, integrated fairings with audio options, spacious luggage capacity (saddlebags, tour-paks), comfortable seating for rider and passenger.
Applicable Models:
2002 Harley-Davidson Touring Models (e.g., Electra Glide, Road King, Street Glide, Heritage Softail)
Page Count:
Estimated 700+ pages (typical for comprehensive service manuals)
Manual Type:
Service and Repair Manual
Format:
Downloadable Digital File (PDF)
Engine Service:
All engine systems, including Twin Cam 88, Twin Cam 88B, carburetion and fuel injection servicing, ignition, lubrication, cooling (air-cooled), and exhaust.
Transmission Service:
Servicing of the 5-speed Cruise Drive transmission, including clutch, primary drive, gearbox, and final drive maintenance and repair.
Electrical System:
Comprehensive coverage of the entire electrical system, including battery, charging system (alternator, regulator), starting system, lighting (headlight, taillight, signals), instrumentation, ignition system, and accessory circuits.
Braking System:
Front and rear brake systems, including hydraulic lines, master cylinders, calipers, rotors, and brake fluid service.
Suspension And Steering:
Front fork (telescopic), rear shock absorbers, swingarm, steering head bearings, and related components.
Fuel System:
Carburetor (CV carburetor) or Electronic Fuel Injection (EFI) system servicing, fuel pump, fuel lines, and fuel tank maintenance.
Frame And Body:
Frame inspection, body panel removal and installation, fairings, saddlebags, and related trim.
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, air filter service, lubrication points, and general inspection procedures.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides for common issues.
Component Overhaul:
Detailed step-by-step instructions for engine disassembly and reassembly, transmission overhaul, brake caliper rebuild, and fork service.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all model variations.
Depth:
Covers everything from basic maintenance and adjustments to complete engine and transmission rebuilds, including diagnostic procedures and specifications.
Engine Type:
Air-cooled, 45-degree V-twin, OHV (Overhead Valve)
Engine Family:
Twin Cam 88 / Twin Cam 88B (B denotes counter-balanced for specific models like the Road King)
Displacement:
1450 cc (88 cubic inches)
Bore X Stroke:
3.75 in x 4.00 in (95.25 mm x 101.6 mm)
Horsepower Est:
Approx. 65-70 HP @ 5200 RPM (Varies slightly by model and tuning)
Torque Est:
Approx. 75-80 lb-ft @ 3500 RPM (Varies slightly by model and tuning)
Fuel Delivery:
Multi-point Fuel Injection (ESPFI) or Keihin 40mm CV Carburetor (depending on model variant)
Fuel Type:
Unleaded Gasoline, 87-91 Octane
Fuel Capacity:
Approx. 5.0 gallons (19 liters)
Transmission Type:
5-speed Constant Mesh, Sequential Gearbox
Optional Transmission:
N/A for 2002 Touring models (standard 5-speed)
Clutch Type:
Wet, Multi-plate
Primary Drive:
Duplex Chain, 1.407:1 Ratio
Final Drive:
Belt Drive, 32/66 Tooth, 3.15:1 Ratio
Transmission Fluid:
Harley-Davidson Formula+ Transmission and Primary Chaincase Lubricant or equivalent (e.g., SAE 50Wt)
Length Est:
Approx. 93.3 inches (2370 mm) - Varies by model
Width Est:
Approx. 37.0 inches (940 mm) - Varies by model
Height Est:
Approx. 54.0 inches (1370 mm) - Varies by model
Dry Weight Est:
Approx. 700-750 lbs (318-340 kg) - Varies by model
Gross Vehicle Weight Rating Est:
Approx. 1200-1300 lbs (544-590 kg) - Varies by model
Saddlebag Capacity Est:
Approx. 2.2 cubic feet per saddlebag
Tour Pak Capacity Est:
Approx. 2.4 cubic feet (optional)
Safety Ratings:
N/A (Motorcycles typically do not receive NHTSA star ratings)
Brakes:
Dual 32mm piston calipers with 11.5-inch (292mm) floating rotors (front), Single 32mm piston caliper with 11.5-inch (292mm) rotor (rear)
Tires:
Tubeless tires; typical sizes: Front 130/90B16, Rear 150/80B16 (check specific model for variations)
Lighting:
Halogen headlight, LED taillight, amber incandescent front/rear turn signals.
Frame Construction:
Steel, mild cradle frame with two-piece side plates.
Audio System:
Many 2002 Touring models offered factory-installed AM/FM radio with CB and Intercom functionality, often with handlebar-mounted controls and speakers integrated into the fairing.
Display:
Analog gauges for speedometer, tachometer, oil pressure, voltage, and fuel level, with indicator lights for various systems.
Cruise Control:
Electronic cruise control was a common option or standard on higher trim levels, managed via handlebar switches.
Auxiliary Power:
12V accessory outlet for charging devices.
Engine Oil Change:
Every 2,500 miles or 6 months
Transmission Primary Fluid Change:
Every 5,000 miles or 12 months
Drive Belt Inspection:
Every 5,000 miles
Spark Plug Replacement:
Every 10,000 miles
Air Filter Service:
Every 5,000 miles (or more frequently in dusty conditions)
Engine Oil Type:
Harley-Davidson 20W-50 SYN3 or equivalent motorcycle specific synthetic oil
Engine Oil Capacity:
3.8 US quarts (3.6 liters) with filter change
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Twin Cam 88 Cam Chain Tensioner:
Early Twin Cam models (pre-2007) are known for wear on the cam chain tensioner shoes, which can lead to engine noise and potential failure. This manual will detail inspection and replacement procedures.
Crankcase Breather System:
Potential for oil blow-by, especially with performance modifications. The manual provides guidance on proper breather setup and maintenance.
Electrical Connections:
As with any motorcycle of this era, corrosion or loose connections in electrical harnesses can cause intermittent issues. Detailed wiring diagrams are crucial for diagnosis.
Brand Heritage:
Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer renowned for its V-twin engines, distinctive styling, and enduring legacy in motorsports and popular culture.
Touring Evolution:
The 2002 Touring line built upon decades of Harley-Davidson's touring development, with the 2002 model year being a key transition period with the widespread adoption of the Twin Cam 88 engine and evolving chassis designs.
Manufacturing Location:
United States (primarily York, Pennsylvania and Milwaukee, Wisconsin)
