2004 Harley Davidson Touring FLT Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Touring FLT Year: 2004 Codes Model Code: FLT 👋 Introduction Market Position Target Audience: Harley-Davidson owners and independent motorcycle mechanics seeking to perform...

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类型: Motorcycle

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标签: 2004 Harley Davidson Misc Motorcycle Motorcycles Touring FLT

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Touring FLT

Year:

Codes

Model Code:

👋 Introduction

Market Position

Target Audience:

Harley-Davidson owners and independent motorcycle mechanics seeking to perform comprehensive maintenance and repairs.

Value Proposition:

Empowers owners to maintain their investment, save on dealership service costs, and understand their motorcycle's intricacies.

Competitive Analysis

Manual Comparison:

Offers significantly more detail and accuracy than generic aftermarket repair guides, aligning with factory specifications.

Key Features

Original Equipment:

Directly sourced from or based on Harley-Davidson's official factory service documentation.

Illustrated Guidance:

Features detailed diagrams, exploded views, and photographs to illustrate procedures.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Manual

Language:

English

Format:

Printed Book

Page Count:

Approx. 600-700 pages (estimated for comprehensive coverage of FLT model)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, inspection, and repair for Twin Cam 88 / 88B engines.

Fuel System:

Carburetor (CV 40mm) and fuel injection (EFI) systems, fuel pump, fuel lines, fuel filter, and tank servicing.

Ignition System:

Ignition module, spark plugs, ignition coils, wiring, and troubleshooting.

Transmission Drivetrain:

5-speed constant mesh transmission (e.g., Cruise Drive), clutch operation and adjustment, primary drive system, final drive belt.

Suspension:

Front fork (e.g., 41mm Telescopic), rear shock absorbers, swingarm, and related components. Service and adjustments.

Brakes:

Front and rear brake systems, calipers, master cylinders, brake lines, rotors, pads, and bleeding procedures.

Electrical System:

Battery, charging system (alternator, regulator), starting system (starter motor), lighting, instruments, horn, and accessory wiring.

Chassis Frame:

Frame inspection, steering head bearing service, and general chassis component maintenance.

Bodywork Fairings:

Fairing removal and installation, saddlebag servicing, body panel maintenance, and related trim.

Diagnostics Troubleshooting:

Diagnostic charts and procedures for common faults and electrical system issues.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, lubrication points, tire pressure checks, brake adjustments, chain/belt adjustment (if applicable).

Engine Overhaul:

Detailed step-by-step instructions for engine disassembly, component inspection, machining, and reassembly.

Transmission Repair:

Clutch service, transmission gear inspection, bearing replacement, and shifting mechanism adjustments.

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, multimeter usage, and component testing.

Suspension Service:

Fork seal replacement, fork oil changes, shock absorber servicing, and swingarm bearing checks.

Brake System Maintenance:

Brake pad replacement, caliper servicing, master cylinder rebuild, and brake fluid flush.

Carburetor Rebuild Tuning:

Complete procedures for disassembling, cleaning, and tuning the CV 40mm carburetor.

Fuel Injection Troubleshooting:

Basic troubleshooting for EFI systems, including sensor checks and diagnostic code reading (if applicable).

Wheel Tire Service:

Wheel bearing replacement, tire mounting and balancing, and spoke tension adjustment (if applicable).

Steering Head Maintenance:

Steering head bearing inspection, adjustment, and replacement.

Technical Depth

Depth Level:

Comprehensive; covers from routine maintenance to complete engine and transmission rebuilds.

Diagnostic Capability:

Advanced; includes detailed diagnostic charts, troubleshooting flows, and component specifications.

Special Tools:

Lists required Harley-Davidson special tools and their applications.

Torque Specifications:

Provides exact torque values for all critical fasteners and assemblies.

Wiring Diagrams:

Includes detailed color-coded wiring diagrams for the entire electrical system.

Schematics:

Features detailed schematics for all major systems, aiding in understanding component relationships.

📊 Manual Specifications

File Format

Print Quality:

High-quality printing on durable paper for workshop use.

Binding Type:

Professional binding (e.g., stitched or perfect bound) to withstand frequent use.

Paper Type:

Heavy-duty, gloss or semi-gloss paper to resist oil and shop grime.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Harley-Davidson Twin Cam 88 / 88B V-Twin

Displacement:

1450cc (88 cubic inches)

Bore X Stroke:

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

Compression Ratio:

Approx. 8.8:1 to 9.2:1 (depending on specific configuration)

Valvetrain:

Overhead valve (OHV), 2 valves per cylinder, pushrod actuated.

Performance

Horsepower Est:

Approx. 70-75 HP (at crank, varies with tuning)

Torque Est:

Approx. 86-90 ft-lbs (at crank, varies with tuning)

Fuel System

Fuel Delivery:

Keihin CV 40mm Carburetor or Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline, minimum 87 octane

Cooling

Cooling Method:

Air-cooled

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh, manual foot shift

Primary Drive:

Duplex chain, 34/46T (1.353:1) with compensating sprocket

Final Drive:

Belt drive, 32/66T (2.06:1)

Features

Clutch Type:

Wet, multi-plate, diaphragm spring

Clutch Actuation:

Hydraulic

Transmission Oil Capacity:

Approx. 2.75 US quarts (2.6 Liters) for transmission and primary chaincase.

Transmission Oil Specification:

Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant (or equivalent SAE 85W-140 gear oil)

📐 Dimensions

Exterior

Wheelbase:

Approx. 63.2 in. (1605 mm)

Length:

Approx. 93.4 in. (2372 mm)

Height:

Approx. 54.0 in. (1372 mm)

Width:

Approx. 39.5 in. (1003 mm)

Weights

Dry Weight:

Approx. 720 lbs (327 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 1260 lbs (572 kg)

Fuel Capacity:

5.0 US gallons (18.9 L)

🛡️ Safety Features

Ratings

Safety Features Standard:

N/A (Motorcycle safety ratings differ from automobiles; focuses on rider protection and vehicle stability)

Active Features

Braking System:

Linked or non-linked dual-disc front and single-disc rear braking system.

Suspension Stability:

Designed for stable handling under various road conditions.

Passive Features

Lighting:

Halogen headlight, taillight, brake light, and turn signals for visibility.

Chassis Construction:

Robust steel frame designed for stability and rider support.

💡 Technology Features

Infotainment

Audio System:

Optional factory-installed AM/FM radio with CD player and CB/intercom capabilities on select Touring models.

Driver Assistance

Cruise Control:

Electronic cruise control typically standard on FLT models for comfortable highway riding.

Connectivity

Diagnostics:

On-board diagnostics for engine management and fault detection (often accessed via handlebar controls or external diagnostic tool).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles (8,000 km) or 12 months, whichever comes first.

Primary Chaincase Oil Change:

Every 10,000 miles (16,000 km) or 24 months.

Spark Plug Replacement:

Every 10,000 miles (16,000 km).

Drive Belt Inspection:

Inspect at every 5,000 miles (8,000 km) for wear and tension.

Brake Fluid Flush:

Every 24 months, regardless of mileage.

Fluid Specifications

Engine Oil Type:

Harley-Davidson SYN3 Full Synthetic Motorcycle Oil (or equivalent SAE 20W-50 motorcycle-specific oil)

Engine Oil Capacity:

Approx. 4.0 US quarts (3.8 Liters) with filter change.

Fork Oil Type:

Harley-Davidson Suspension Fork Oil (e.g., Type 10W or equivalent)

Fork Oil Quantity:

Refer to manual for specific fork model and quantity (typically around 10-12 fl oz per leg).

Brake Fluid Type:

DOT 4

Known Issues

Twin Cam Cam Chain Tensioner:

Early Twin Cam models (pre-2007) had plastic cam chain tensioner shoes that could wear prematurely, leading to noise or potential failure. Later models used improved tensioners.

Carburetor Lean Condition:

Stock CV carburetors could be prone to lean running conditions, especially at higher altitudes, potentially requiring re-jetting or tuning.

Rear Main Seal Leaks:

Some Twin Cam engines could develop leaks from the rear main seal over time.

Clutch Actuation Issues:

Potential for clutch master cylinder or slave cylinder seal leaks or performance degradation.

📚 Vehicle History

Brand Heritage

Brand Legacy:

Harley-Davidson boasts a rich history dating back to 1903, known for its iconic V-twin engines and cruiser motorcycle design.

Model Evolution

Touring Lineage:

The FLT is part of Harley-Davidson's long-standing Touring family, evolving from earlier FL models, offering comfort and carrying capacity for long-distance travel.

Twin Cam Introduction:

The 2004 model year features the Twin Cam 88 engine, a significant update from the Evolution engine, offering improved performance and reliability.

Production

Manufacturing Location:

York, Pennsylvania, USA and Milwaukee, Wisconsin, USA

🏆 Awards & Recognition

Recognitions

Model Awards:

Harley-Davidson Touring models consistently receive high marks for comfort, touring capability, and rider satisfaction in industry reviews and rider polls.

Ratings

Reliability Perception:

While vintage Harley-Davidsons have a reputation for requiring more frequent attention, the Twin Cam era represented a significant improvement in reliability and serviceability.