Positioning:
Comprehensive technical resource for owners and technicians of 2004 Harley-Davidson Touring motorcycles, aiming to facilitate DIY maintenance and professional repair.
Analogy:
This manual is akin to a doctor's medical textbook for your Harley-Davidson Touring model, providing all the necessary diagnostic and treatment information.
Features:
Detailed step-by-step instructions, clear diagrams and illustrations, comprehensive system coverage, includes specific supplements for police and performance models.
Primary Coverage:
Service, Repair, Maintenance
Specific Models Covered:
FLHT Electra Glide Standard, FLHTC Electra Glide Classic, FLHTCI Electra Glide Classic Fuel Injection, FLHTI Electra Glide Standard Fuel Injection, FLHR Road King, FLHRI Road King Fuel Injection, FLHRCI Road King Classic Fuel Injection, FLHTPI Road King Police, FLTR Road Glide, FLTRI Road Glide Fuel Injection
Supplementary Coverage:
Police Service Supplement, Electrical Diagnostics, FLHTCSE Service Supplement
Estimated Page Count:
Estimated ~1000+ pages (across all included manuals)
Type:
Official Workshop Service Repair Manual
Police Supplement Pn:
99483-04SP
Electrical Diagnostics Pn:
99497-04
Flhtcse Supplement Pn:
99500-04
Operating Systems:
Compatible with all versions of Windows & Mac
Delivery Method:
Download link provided on checkout page after payment.
Software Requirements:
Adobe PDF Reader
Engine Systems:
Engine teardown/rebuild, lubrication, cooling, ignition, fuel system (carburetor & EFI), exhaust system, emissions control
Drivetrain Systems:
Clutch, transmission (5-speed constant mesh), primary drive, final drive (belt drive), starter system
Chassis Systems:
Frame, front suspension (forks), rear suspension (shock absorbers), wheels, tires, brakes (front and rear), steering, bodywork (fairings, saddlebags, fenders)
Electrical Systems:
Battery, charging system (alternator, regulator), starting system (starter motor, solenoid), ignition system, lighting, instruments, TSM/TSSM (Turn Signal Model/Security), engine management systems (EFI), sound system, cruise control, wiring diagrams
Police Specific Systems:
Specialized equipment and configurations for police duty models (covered in Police Service Supplement).
Performance Specific Systems:
Details for the Screamin' Eagle CVO model (FLHTCSE) including any unique components or tuning (covered in FLHTCSE Service Supplement).
Maintenance Procedures:
Scheduled maintenance, fluid changes (oil, brake fluid, primary fluid, transmission fluid), filter replacement, spark plug service, chain/belt inspection and adjustment
Diagnostic Procedures:
Troubleshooting guides, fault code interpretation (for EFI models), symptom-based diagnostics
Repair Procedures:
Step-by-step instructions for disassembly, assembly, adjustment, and replacement of all major components and systems
Specialty Procedures:
Exploded views, diagrams, illustrations, torque specifications, electrical schematics, fuel injection tuning (EFI)
Technical Specifications Included:
Torque values, clearances, tolerances, electrical resistance values, fluid capacities.
Depth:
Comprehensive (from routine maintenance to full engine and transmission rebuilds)
Engine Type:
Air-cooled, Twin Cam 88 (96 cu. in. / 1550 cc) V-Twin engine
Bore X Stroke:
3.75 in. x 4.25 in. (95.25 mm x 108 mm)
Compression Ratio:
8.8:1 (Typical)
Horsepower:
Approx. 65-70 HP (Varies slightly by model and tuning)
Torque:
Approx. 78-85 ft-lbs @ 3200 RPM (Varies slightly)
Fuel Delivery:
Carburetor (Keihin CV 40mm) or Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, minimum 87 octane (91 Research Octane Number)
Ignition Type:
Electronic ignition with single fire spark
Transmission Type:
5-speed, constant mesh, helical gears
Optional Transmissions:
N/A (Standard 5-speed for 2004 Touring models)
Clutch Type:
Wet, multi-plate, diaphragm spring
Primary Drive:
Duplex chain, 34/46 ratio
Final Drive:
Belt drive, 32/66 ratio
Crash Test Ratings:
N/A (Motorcycle safety ratings are not comparable to automotive)
Active Safety:
Disc brakes front and rear, integrated braking system (on some models), stable chassis design.
Passive Safety:
TSSM (Turn Signal Security Module) with immobilizer and alarm, rider protection through motorcycle design.
Initial Service:
1,000 miles (1600 km) or 6 months, whichever comes first
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first (includes engine oil change, primary chaincase lubrication, and inspection)
Other Intervals:
Brake fluid flush every 2 years, spark plug replacement typically every 10,000-20,000 miles, drive belt inspection at every service.
Engine Oil:
Harley-Davidson SYN3 (20W50) or equivalent API SG, Jaso MA certified synthetic motorcycle oil
Primary Chaincase Fluid:
Harley-Davidson Primary Chaincase Lubricant or SAE 50 motorcycle oil
Transmission Fluid:
Harley-Davidson Transmission Fluid or SAE 75W90 GL-5 synthetic gear lubricant
Brake Fluid:
DOT 4 hydraulic brake fluid
Engine Oil Capacity:
Approx. 4 quarts (3.8 L) - Check manual for exact capacity
Primary Chaincase Capacity:
Approx. 1 quart (0.95 L) - Check manual for exact capacity
Transmission Capacity:
Approx. 20 oz (0.59 L) - Check manual for exact capacity
Common Issues 2004 Touring:
Potential for oil leaks (especially around crankcase seals), starter clutch wear, charging system issues (stator/regulator), fuel injection sensor inaccuracies (on EFI models), clutch cable adjustment sensitivity.
Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its cruiser and touring motorcycles.
Evolution:
The Touring line has evolved significantly, with the 2004 models featuring the Twin Cam 88 engine and advancements in chassis and electrical systems over previous generations.
Production Years:
Harley-Davidson Touring models have been in continuous production for decades, with the Twin Cam 88 platform debuting in 1999.
