🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLHTC Electra Glide Classic

Year:

2004

Product Name:

Harley-Davidson FLHTC Electra Glide Classic 2004 Service Repair Manual PDF

👋 Introduction

Positioning:

The Harley-Davidson Electra Glide Classic is a flagship touring motorcycle, designed for long-distance comfort and carrying capacity, appealing to riders seeking a classic American V-twin touring experience.

Competitors:

Primarily competed with other large-displacement touring motorcycles from brands like Honda (Gold Wing), Indian, and to some extent, BMW (K-series touring models).

Features:

Iconic Batwing fairing with integrated audio, large comfortable seating for rider and passenger, spacious saddlebags and trunk for luggage, V-twin engine character, rider-focused ergonomics.

Value Proposition:

This service manual provides essential information for maintaining, troubleshooting, and repairing the 2004 Harley-Davidson FLHTC Electra Glide Classic, enabling owners and technicians to keep the motorcycle in optimal condition.

📋 Manual Details

Manual Type:

Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

V-Twin, air-cooled, pushrod OHV

Engine Details:

Twin Cam 88 (1450cc)

Fuel System:

Carbureted (Keihin CV 40mm) and Fuel Injection (EFI - Electronic Fuel Injection)

Transmission:

5-speed Cruise Drive manual transmission

Clutch:

Wet, multi-plate, diaphragm spring

Frame:

Steel, cradle type

Suspension Front:

Telescopic fork, 41.3 mm (1.63 in) diameter, air-assisted

Suspension Rear:

Swingarm with dual shock absorbers, adjustable preload

Brakes Front:

Dual 320 mm (12.6 in) discs, 4-piston calipers

Brakes Rear:

Single 320 mm (12.6 in) disc, 4-piston caliper

Wheels Front:

16 x 3.00 in (cast aluminum alloy or chrome laced)

Wheels Rear:

16 x 5.00 in (cast aluminum alloy or chrome laced)

Tires Front:

Dunlop D402F bias-ply, 130/90B16 M/C 67H

Tires Rear:

Dunlop D402 bias-ply, 150/80B16 M/C 77H

Electrical System:

12V, 30 Amp system

Battery:

YTX20L-BS, 12V, 18 Ah

Lighting:

Halogen headlight, auxiliary passing lamps, LED taillight/stoplight

Bodywork:

Full fairing, saddlebags, trunk, Batwing fairing

Routine Maintenance:

Oil change, filter replacement, air filter cleaning/replacement, spark plug inspection/replacement, brake fluid flush, clutch fluid flush, drivetrain lubrication.

Engine Repair:

Top-end overhaul (cylinder head, piston, rings), bottom-end overhaul (crankshaft, connecting rods, bearings), valve adjustment, cam chain tensioner replacement, oil pump service.

Fuel System Service:

Carburetor disassembly, cleaning, and adjustment; fuel injection system diagnosis and troubleshooting, sensor replacement.

Transmission And Drivetrain:

Clutch adjustment and replacement, transmission disassembly and reassembly, primary drive inspection, final belt drive inspection and adjustment.

Suspension And Steering:

Fork seal replacement, fork oil change, shock absorber replacement, steering head bearing adjustment and replacement.

Brake System:

Brake pad replacement, brake caliper service, master cylinder overhaul, brake line replacement, bleeding procedure.

Electrical System Diagnostics:

Wiring diagram interpretation, troubleshooting electrical faults, starter system, charging system (alternator, regulator/rectifier), ignition system, lighting system, accessory installation.

Bodywork And Trim:

Fairing removal and installation, saddlebag and trunk repair, seat removal and installation, windshield replacement.

Troubleshooting:

Diagnostic charts for common problems and solutions.

Depth:

Comprehensive: Covers everything from routine maintenance to full engine and transmission rebuilds, including detailed electrical system diagnostics.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution scans, suitable for printing.

Searchability:

Searchable text within the PDF for quick information retrieval.

Page Count Estimate:

Approximately 600-800 pages (typical for a comprehensive service manual of this era and model).

Binding Type:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Type:

Twin Cam 88

Displacement:

1450 cc (88 cubic inches)

Bore X Stroke:

95.25 mm x 101.6 mm (3.75 in x 4.00 in)

Compression Ratio:

8.8:1

Horsepower Estimate:

Approx. 67 HP @ 5200 RPM (stock configuration)

Torque Estimate:

Approx. 86 ft-lbs @ 3200 RPM (stock configuration)

Carburetor Model:

Keihin CV 40mm

Efi System:

Closed-loop EFI with oxygen sensors (on applicable models)

Oil Type:

Harley-Davidson Syn3 (synthetic) or SAE 20W50 motorcycle oil

Oil Capacity:

3.5 US quarts (3.3 liters) with filter change

Ignition Type:

Electronic spark, distributorless

Cooling Method:

Air-cooled

🔧 Transmission

Transmission Type:

5-speed constant mesh, Cruise Drive

Gear Ratios:

1st: 9.19, 2nd: 6.20, 3rd: 4.70, 4th: 3.72, 5th: 3.20

Primary Drive:

Double-row, chain with wet clutch

Final Drive:

Belt drive, 140-tooth belt

Clutch Type:

Wet, multi-plate, diaphragm spring

Transmission Oil Type:

Harley-Davidson Formula+ or SAE 50 transmission oil

Transmission Oil Capacity:

2.7 US quarts (2.56 liters)

📐 Dimensions

Length:

2578 mm (101.5 in)

Width:

960 mm (37.8 in)

Height:

1458 mm (57.4 in)

Wheelbase:

1600 mm (63.0 in)

Ground Clearance:

135 mm (5.3 in)

Dry Weight:

375 kg (827 lbs)

Gross Vehicle Weight Rating:

657 kg (1450 lbs)

Saddlebag Capacity:

Approx. 2.1 cu ft per saddlebag

Trunk Capacity:

Approx. 2.4 cu ft

Fuel Tank Capacity:

5.0 US gallons (18.9 liters)

🛡️ Safety Features

Safety Ratings:

Not applicable in the same manner as automobiles. Focus is on mechanical integrity and rider control.

Active Safety:

Strong braking system, stable chassis, adjustable suspension for ride control, good visibility from rider position.

Passive Safety:

Sturdy frame, fairing providing wind protection, integrated lighting for visibility.

💡 Technology Features

Audio System:

AM/FM stereo with CB radio and intercom capabilities, cassette player (typically) or CD player depending on specific trim options. Likely 40-watt per channel.

Speakers:

Fairing-mounted speakers.

Driver Assistance Features:

No electronic driver assistance features common in modern vehicles (e.g., ABS, traction control, cruise control was often an option).

Connectivity Options:

Limited to the integrated audio system and optional CB/intercom.

🔧 Maintenance

Initial Service:

First service typically at 1,000 miles (1,600 km).

Regular Oil Change:

Every 5,000 miles (8,000 km) or annually, whichever comes first.

Air Filter Service:

Inspect every 5,000 miles (8,000 km), clean or replace as needed.

Spark Plug Replacement:

Replace every 10,000 - 15,000 miles (16,000 - 24,000 km) or as indicated by inspection.

Brake Fluid Flush:

Every 2 years or as recommended by Harley-Davidson.

Engine Oil:

Harley-Davidson Syn3 20W-50 or equivalent high-quality motorcycle oil.

Transmission Oil:

Harley-Davidson Formula+ or SAE 50 transmission oil.

Primary Chain Case Oil:

Harley-Davidson Formula+ or SAE 50 transmission oil (shared with transmission).

Brake Fluid:

DOT 4 hydraulic brake fluid (check manual for specific approval).

Fork Oil:

Harley-Davidson Suspension Fluid (Heavy) or equivalent, viscosity typically 15W.

Cam Chain Tensioner:

Early Twin Cam 88 models (including some earlier 2004 bikes) had hydraulic cam chain tensioners that could wear and fail, leading to noise and potential damage. Later models and upgrades use improved designs.

Starter Clutch:

Some models may experience starter clutch issues, characterized by a grinding noise when starting.

Rear Brake Caliper:

Occasional issues with rear brake caliper sticking or overheating can occur if not properly maintained.

Electrical Connections:

As with many motorcycles of this era, corrosion or loose electrical connections can lead to intermittent faults.

📚 Vehicle History

Heritage:

Harley-Davidson has a long and storied history, synonymous with American motorcycle culture and the V-twin engine. Founded in 1903, the brand is known for its iconic designs and rider community.

Electra Glide Evolution:

The Electra Glide line originated in the 1960s as Harley-Davidson's premier full-dress touring motorcycle. The FLHTC model represents the Classic touring variant, emphasizing comfort and amenities.

Production Era:

The Twin Cam 88 engine was introduced in 1999, and the FLHTC model continued to be a popular variant throughout the early 2000s, including the 2004 model year.

Key Updates 2004:

While specific major changes for 2004 might be incremental, it's part of the established Twin Cam 88 platform that offered reliable touring performance. The FLHTC typically received premium features for its year.

🏆 Awards & Recognition

Brand Accolades:

Harley-Davidson motorcycles, particularly the Electra Glide line, are consistently recognized for their iconic styling, comfort, and touring capabilities, often appearing on 'best touring bike' lists for their respective eras.

Owner Satisfaction:

High owner satisfaction typically reported for the comfort and long-distance performance of the Electra Glide Classic, despite potential maintenance considerations.