Segment:
Full-size touring motorcycles, premium segment
Competitors:
Honda Gold Wing, Kawasaki Vulcan Voyager, Yamaha Royal Star Venture
Vehicle Appeal:
Comfort, long-distance touring capability, iconic styling, V-twin engine character, customization potential
Primary Coverage:
Harley-Davidson FLH Touring models equipped with Twin Cam 88 and Twin Cam 103 engines
Specific Models Covered:
FLHTC Electra Glide Classic, FLHTCI Electra Glide Classic EFI, FLHTCU Ultra Classic Electra Glide, FLHTCUI Ultra Classic Electra Glide EFI, FLHR Road King, FLHRI Road King EFI, FLHRS Road King Custom, FLHRSI Road King Custom EFI, FLHT Electra Glide Standard, FLHTI Electra Glide Standard EFI
Estimated Pages:
Approximately 700-900 pages (typical for comprehensive service manuals of this era)
Type:
Repair and Service Manual
Engine Mechanical:
Engine disassembly, assembly, inspection, repair, top-end, bottom-end, valve train, timing, lubrication system, cooling system (air-cooled)
Fuel System:
Carburetor (Keihin CV) and Fuel Injection (EFI) systems, fuel pump, fuel lines, fuel filter, throttle control
Ignition System:
Ignition module, spark plugs, ignition coils, troubleshooting
Electrical System:
Starting system (starter motor, solenoid), charging system (alternator, regulator/rectifier), battery, lighting (headlight, taillight, turn signals), horn, wiring diagrams, fuses, relays
Transmission Drivetrain:
5-speed gearbox, clutch operation and repair, primary drive, final drive (belt drive), lubrication
Suspension Steering:
Front fork (air-assisted on some models), rear shock absorbers, swingarm, steering head bearing adjustment and replacement
Braking System:
Front and rear disc brakes, brake calipers, master cylinders, brake lines, hydraulic system maintenance, bleeding procedures
Bodywork Chassis:
Frame, fairing, saddlebags, tour-pak, seats, body panel removal and installation, mounting hardware
Wheels Tires:
Wheel bearing inspection and replacement, tire mounting and balancing
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, air filter service, brake fluid checks, lubrication points
Troubleshooting:
Diagnostic procedures for common issues, fault codes (for EFI models)
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls
Component Disassembly Assembly:
Step-by-step instructions for major component removal and reinstallation
Wiring Diagrams:
Comprehensive electrical schematics for all systems
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including EFI diagnostics and tuning fundamentals.
Engine Type:
Air-cooled, 45-degree V-twin, pushrod activated, overhead valves
Displacement Cc:
1449 cc (Twin Cam 88), 1690 cc (Twin Cam 103 - typically via CVO or dealer upgrade)
Bore X Stroke In:
3.75 x 4.00 in (Twin Cam 88)
Compression Ratio:
8.8:1 (Twin Cam 88), 9.2:1 (Twin Cam 103)
Horsepower Hp:
Approx. 65-70 hp (stock Twin Cam 88), Approx. 75-80 hp (stock Twin Cam 103)
Torque Lb Ft:
Approx. 80-85 lb-ft (stock Twin Cam 88), Approx. 90-95 lb-ft (stock Twin Cam 103)
Fuel Delivery:
Keihin 40mm CV Carburetor (EFI models utilize Sequential Electronic Fuel Injection)
Fuel Type:
Unleaded gasoline, 87-91 octane recommended
Oil Capacity Qts:
Approx. 4.0 US quarts (with filter change)
Oil Type:
Harley-Davidson V-Twin 20W-50 Motorcycle Oil or equivalent API SG/SH/SJ rated synthetic or mineral oil
Transmission Type:
5-speed constant mesh, helical gears
Optional Transmissions:
N/A for this model year FLH platform
Primary Drive:
Multi-plate, wet clutch, chain drive
Transmission Fluid Type:
Harley-Davidson primary chaincase lubricant or equivalent; transmission fluid separate for gearbox
Crash Test Results:
N/A (Motorcycle safety ratings are not standardized in the same way as automobiles. Focus is on rider protection, handling, and braking capabilities.)
Braking System:
Dual disc front brakes, single disc rear brake. Optional ABS available on some EFI models.
Lighting:
Halogen headlight, LED taillight and brake light, incandescent turn signals
Chassis Stability:
Sturdy frame construction, balanced weight distribution
Audio System:
Factory AM/FM radio with cassette player and/or CD player (model dependent), often with fairing-mounted speakers.
Cruise Control:
Standard on most FLHTCU/FLHTCUI and optional/available on other FLH models.
ABS:
Optional on select EFI models (Anti-lock Braking System)
Communication:
Intercom system (on Ultra models), CB radio (on Ultra models), 12V accessory power outlet.
First Service Miles:
1000 miles (break-in service: oil change, filter change, primary chain adjustment, inspection)
Subsequent Service Miles:
Every 5000 miles or annually, whichever comes first (includes engine oil, primary oil, transmission oil checks/changes, inspection of various components)
Engine Oil:
Harley-Davidson V-Twin 20W-50 Motorcycle Oil or equivalent
Primary Chaincase Oil:
Harley-Davidson Primary Chaincase Lubricant or HD Formula+
Transmission Oil:
Harley-Davidson Hypoid Gear Oil SAE 75W-90 (or specified equivalent)
Common Wear Items:
Clutch wear, wheel bearings, fork seals, regulator/rectifier failure (especially earlier models), starter solenoid issues, timing chain tensioners (pre-2007).
Efi Considerations:
While generally reliable, EFI models can benefit from careful tuning. Check for intake manifold leaks and proper sensor function.
Heritage Summary:
Harley-Davidson boasts a long and rich history dating back to 1903, renowned for its iconic V-twin engines, custom culture, and the touring segment leadership.
Flh Lineage:
The FLH platform has evolved significantly over decades, with the introduction of the Twin Cam engine in 1999 marking a major technological advancement. The 2003 model represents a mature iteration of the Twin Cam era.
Manufacturing Location:
United States (York, Pennsylvania and Milwaukee, Wisconsin)
