🏷️ Basic Information

Make:

Harley-Davidson

Model:

Touring Series (FLT Platform)

Year:

2003

Platform:

FLT

Vin Designation:

Generally '1HD' prefix for Harley-Davidson motorcycles.

👋 Introduction

Target Audience:

Harley-Davidson owners and independent repair shops specializing in touring motorcycles.

Value Proposition:

Provides detailed, model-specific repair and maintenance information for a significant range of 2003 Harley-Davidson touring models, including crucial electrical diagnostics, at a comprehensive page count.

Manual Utility:

Enables DIY maintenance, advanced troubleshooting, and complete rebuilds, saving owners significant costs on dealership services.

📋 Manual Details

Covered Models:

FLTRI Road Glide, FLHTPI Electra Glide Police, FLHTI Electra Glide Standard, FLHTCUI Ultra Classic Electra Glide, FLHTCI Electra Glide Classic, FLHTC Electra Glide Classic, FLHT Electra Glide Standard, FLHRSEI Screamin Eagle Road King, FLHRI Road King, FLHRCI Road King Classic, FLHR Road King

Total Pages:

1193

Type:

Service and Repair Manual (including Electrical Diagnostics)

Primary Language:

English

Digital Format:

PDF Download

📖 Manual Coverage

Powertrain:

Engine (V-Twin Evolution/Twin Cam 88), Transmission (5-speed Cruise Drive), Clutch, Final Drive (Belt Drive)

Chassis:

Frame, Suspension (Front Forks, Rear Shocks), Steering, Wheels, Tires, Brakes (Front & Rear)

Electrical:

Ignition System, Charging System (Alternator, Regulator), Starting System, Lighting (Headlight, Taillight, Turn Signals), Instrumentation, Battery, Wiring Diagrams, Electronic Fuel Injection (EFI) System, ECU

Bodywork:

Fairings, Saddlebags, Fenders, Fuel Tank, Seat, Handlebars, Control Levers, Footboards/Pegs

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel injectors, EFI control module (ECU), throttle body, sensors (MAP, IAT, TPS, O2).

Exhaust System:

Exhaust pipes, mufflers, catalytic converters (if applicable), oxygen sensors.

Frame And Suspension:

Frame inspection, front fork service (seals, oil, bushings), rear shock absorber replacement, swingarm and bearings.

Maintenance:

Oil Changes, Filter Replacements, Chain/Belt Adjustment, Tire Pressure Checks, Brake Fluid Flushes, Coolant Changes (if applicable), Spark Plug Replacement, Air Filter Service

Diagnostics:

Troubleshooting guides for common issues, diagnostic codes, electrical system testing, fuel system diagnostics, engine performance issues

Repairs:

Complete tear down and rebuild procedures for engine, transmission, suspension, brakes, electrical components, bodywork

Specifications:

Torque specifications for critical fasteners, fluid capacities, tire pressure recommendations, valve clearances, technical data for all major components

Engine Rebuild:

Piston and ring replacement, cylinder head removal/installation, valve inspection/adjustment, crankshaft and connecting rod checks.

Transmission Overhaul:

Gearbox disassembly, inspection, and reassembly, clutch component service.

Electrical Troubleshooting:

Wiring diagrams, component testing, fault code interpretation, starting/charging system diagnostics, ignition system analysis.

Wheel And Tire Service:

Tire replacement, wheel balancing, spoke adjustment (if applicable), axle and bearing maintenance.

Level Of Detail:

Comprehensive. Covers everything from basic maintenance to complete engine and transmission overhauls, including detailed electrical diagnostics.

Illustrations:

Includes pictures and part diagrams to aid in disassembly, assembly, and identification.

Diagnostic Tools:

May refer to specific Harley-Davidson diagnostic tools (e.g., Digital Technician) for advanced EFI diagnostics, but provides manual methods for component testing.

📊 Manual Specifications

Digital Format:

PDF

Printable:

Yes, no restrictions on printing.

Digital Features:

Searchable text, clickable chapters.

Storage Options:

Can be saved/burned to disc.

⚙️ Engine Specifications

Engine Family:

Harley-Davidson Twin Cam 88 (and Evolution Big Twin for some older platforms, though 2003 leans heavily into Twin Cam)

Displacement:

Typically 88 cubic inches (1450cc). Some Screamin' Eagle models might have higher displacement variants (e.g., 95ci, 103ci).

Configuration:

Air-cooled, 45-degree V-Twin

Valvetrain:

Overhead valve (OHV), 2 valves per cylinder

Cooling System:

Air-cooled. Some models may have oil coolers.

Horsepower:

Varies by model, typically in the 60-70 HP range for standard Twin Cam 88.

Torque:

Varies by model, typically in the 70-80 lb-ft range for standard Twin Cam 88.

Induction:

Electronic Fuel Injection (EFI) with sequential port injection (SPI) or throttle body injection (TBI), depending on specific model variant. Some earlier models or specific custom variants might still utilize carburetors (e.g., Keihin CV).

Fuel Type:

Unleaded Gasoline

Fuel Management:

ECU controlled, with sensors for MAP, IAT, TPS, O2 (on some models)

Compression Ratio:

Typically around 8.9:1 for standard Twin Cam 88 engines.

🔧 Transmission

Type:

5-speed Manual (Cruise Drive)

Variants:

Not typically applicable for factory options in this year for touring models, but aftermarket kits exist.

Drive System:

Primary drive: Chain. Final drive: Belt drive (4th gear and 5th gear are overdrive).

Transmission Oil:

Harley-Davidson specified SYN3 (SAE 20W-50 Synthetic) or equivalent motorcycle-specific transmission oil. Check manual for exact capacity.

📐 Dimensions

Wheelbase:

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

Length:

Varies by model, generally between 95 - 99 inches (2413 - 2515 mm).

Width:

Varies by model, but generally includes handlebars and fairings, typically around 38-40 inches (965-1016 mm) at widest point.

Height:

Varies by model, typically around 55-60 inches (1397-1524 mm).

Dry Weight:

Varies by model, typically between 700 - 800 lbs (318 - 363 kg).

Fuel Capacity:

Typically 5.0 U.S. gallons (18.9 L).

🛡️ Safety Features

Crash Test Data:

Motorcycles are not typically subjected to standardized crash testing like automobiles. Safety relies on design and rider skill.

Braking System:

Dual disc front brakes, single disc rear brake. ABS was not standard on most touring models in 2003, but may have been an option on higher trims (e.g., FLHTPI).

Lighting:

Halogen headlight, LED taillight (on some models), amber front/rear turn signals.

Chassis Stability:

Stable touring chassis designed for highway cruising.

💡 Technology Features

Audio System:

Many touring models featured integrated audio systems with AM/FM radio, and CD players. Some may have CB radio or intercom capabilities.

Cruise Control:

Electronic cruise control was available on many touring models.

Diagnostic Ports:

Diagnostic connectors for reading fault codes and accessing engine data via specific tools.

🔧 Maintenance

Oil Change Interval:

Typically every 2,500 - 5,000 miles (4,000 - 8,000 km) or annually, depending on usage and oil type specified in the manual.

Primary Chain Tensioner:

Self-adjusting hydraulic tensioner on Twin Cam models, but inspection is recommended.

Spark Plugs:

Check at 5,000 miles, replace as needed. Specific interval may vary.

Engine Oil:

Harley-Davidson SYN3 (SAE 20W-50 Synthetic) or comparable motorcycle-specific 20W-50 oil. Check manual for specific capacity (usually around 3.5 US quarts for Twin Cam 88).

Primary Oil:

Harley-Davidson primary fluid or Formula+ transmission lubricant. Check manual for capacity (typically 1 quart).

Brake Fluid:

DOT 4 or DOT 5.1 (check manual for precise specification and color coding). Harley-Davidson typically specified DOT 5 Silicone Fluid for some years, but DOT 4/5.1 may be acceptable with proper flushing and system compatibility checks.

Coolant Type:

Not applicable, as these are air-cooled engines. Oil coolers may use engine oil.

Wheel Bearing Grease:

Specific wheel bearing grease type and lubrication intervals covered.

Fork Oil:

Specific type and capacity for front fork suspension oil.

Primary Chain Tensioner Wear:

Early Twin Cam models (pre-2007) are known for hydraulic primary chain tensioner shoe wear, which can lead to noise and eventual failure. Manual will detail inspection and replacement.

Crankcase Breather Emissions:

Proper venting and oil separation is crucial. Manual will cover system checks.

Efi Component Reliability:

While generally robust, issues with fuel injectors, throttle position sensors, or the ECU can occur. Electrical diagnostics section is key here.

Camchain Tensioner Noise:

Rattling noise from the cam chain tensioners on Twin Cam engines can indicate wear. The manual will detail inspection and replacement of tensioners and sprockets.

📚 Vehicle History

Legacy:

Harley-Davidson is an iconic American motorcycle manufacturer with a long history dating back to 1903, renowned for its V-twin engines and cruiser/touring motorcycles.

Touring Platform:

The FLT platform evolved significantly over the years, culminating in the introduction of the Twin Cam 88 engine in 1999 and the Cruise Drive transmission in 2001. The 2003 models represent a mature iteration of this platform.

Manufacturing Location:

Primarily York, Pennsylvania, USA.

🏆 Awards & Recognition

Model Awards:

Specific awards for individual models are not readily publicized in the same way as cars. However, Harley-Davidson touring models consistently receive recognition for comfort, style, and long-distance touring capability within the motorcycle community.

Customer Satisfaction:

Generally high among dedicated Harley-Davidson owners, focusing on brand loyalty, customization, and the riding experience.