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Harley Davidson FLHTC Electra Glide Classic Complete Workshop Service Repair Manual 2005
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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHTC Electra Glide Classic Year: 2005 Codes Engine Code Family: Twin Cam 88 Chassis Code: FLHTC 👋 Introduction Market Position Segment: Full-size touring...
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🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FLHTC Electra Glide Classic
Year:
2005
Codes
Engine Code Family:
Twin Cam 88
Chassis Code:
FLHTC
👋 Introduction
Market Position
Segment:
Full-size touring motorcycle
Target Audience:
Long-distance touring riders, experienced DIY mechanics
Competitive Analysis
Key Competitors Historical:
Honda Gold Wing, Indian Chief, BMW K series touring models
Key Features Vehicle
Touring Amenities:
Full fairing, saddlebags, tour-pak (trunk), comfortable seating for rider and passenger
Key Features Manual
Completeness:
Covers all aspects of service and repair, providing a single source of truth
User Friendliness:
Organized by system with clear diagrams and step-by-step instructions
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
Downloadable PDF
Page Count:
Estimated 500-700 pages (typical for this model/year)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, inspection, repair, torque specifications, timing, valve adjustments
Fuel System:
Carburetor (CV type), fuel tank, fuel lines, fuel pump (if applicable), fuel filter, fuel delivery diagnostics
Ignition System:
Ignition module, spark plugs, ignition coils, timing procedures, troubleshooting
Electrical System:
Wiring diagrams, lighting (headlight, taillight, turn signals), battery, charging system (alternator, regulator), starter motor, fuses, relays
Transmission:
Gearbox assembly, disassembly, inspection, shifting mechanisms, clutch service, lubrication
Drivetrain:
Primary drive, final drive (belt or chain), belt tension adjustment, pulley/sprocket inspection
Braking System:
Brake caliper service, master cylinder overhaul, brake fluid replacement, bleeding procedures, rotor and pad inspection
Suspension:
Front fork service (oil change, seal replacement), rear shock absorber inspection and replacement, air suspension (if applicable)
Steering System:
Handlebar replacement, steering head bearing service, steering damper (if equipped)
Chassis Frame:
Frame inspection, torque specifications for frame components
Bodywork And Trim:
Fairing removal and installation, body panel maintenance, seat service, luggage system details
Diagnostics And Troubleshooting:
Fault code identification, diagnostic procedures for various systems, common problem solutions
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, spark plug replacement, chain/belt adjustments, lubrication points
Engine Repair:
Top-end overhaul, bottom-end rebuild, piston and ring replacement, camshaft service
Transmission Repair:
Gearbox disassembly, bearing replacement, seal replacement, clutch plate replacement
Brake System Repair:
Brake caliper rebuilding, master cylinder seal replacement, brake line replacement
Electrical Diagnostics:
Tracing wiring faults, diagnosing charging system issues, starter circuit troubleshooting
Suspension Overhaul:
Fork seal replacement, fork oil changes, shock absorber mounting
Bodywork Refurbishment:
Panel alignment, fairing repair, mounting hardware replacement
Technical Depth
Diagnostic Tools:
Includes information on diagnostic procedures and potential use of specialized tools
Rebuild Procedures:
Covers complete disassembly and reassembly of major components
Troubleshooting Guides:
Detailed steps for diagnosing and resolving common and uncommon issues
Torque Specifications:
Comprehensive list of all critical torque values for fasteners
Wiring Diagrams:
Detailed, high-resolution wiring schematics for all electrical systems
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Searchable text content
Printability:
Printable pages
Quality:
High-resolution scans for clarity
Binding Type
Binding:
N/A (Downloadable PDF)
Paper Type
Paper Type:
N/A (Downloadable PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 45-degree V-twin
Engine Family:
Twin Cam 88
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.75 in x 4.00 in (95.25 mm x 101.6 mm)
Compression Ratio:
8.8:1
Valve Train:
Overhead valves (OHV), 2 valves per cylinder, pushrod actuated
Performance
Horsepower Estimated:
Approx. 65-70 HP (at crank)
Torque Estimated:
Approx. 86-90 ft-lbs (at crank)
Fuel System
Fuel Delivery:
Carburetor (Keihin CV type, 40mm)
Fuel Type Recommendation:
Unleaded gasoline, minimum 91 octane (RON+MON)/2
Lubrication
Oil Type:
Harley-Davidson Genuine SYN3 Full Synthetic Motorcycle Lubricant or equivalent SAE 20W-50
Oil Capacity With Filter:
4.0 US quarts (3.8 L)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh, helical gear
Clutch Type:
Wet, multi-plate, diaphragm spring
Features
Primary Drive:
Multi-plate wet clutch, chain drive
Final Drive:
Belt drive
Fluid Specifications
Transmission Oil Type:
Harley-Davidson Formula+ or equivalent SAE 85W-140
Transmission Oil Capacity:
24 US fluid ounces (0.71 L)
📐 Dimensions
Exterior
Length Overall:
98.5 inches (2501.9 mm)
Width Handlebar:
37.3 inches (947.4 mm)
Height Overall:
56.0 inches (1422.4 mm)
Wheelbase:
63.5 inches (1612.9 mm)
Ground Clearance:
5.1 inches (129.5 mm)
Weights
Dry Weight:
812 lbs (368.3 kg)
Gross Vehicle Weight Rating:
1260 lbs (571.5 kg)
Fuel Capacity:
5.0 US gallons (18.9 L)
Wheels Tires
Front Tire Size:
BW 130/90-16
Rear Tire Size:
BW 150/80B16
Front Wheel:
16 x 3.00 inches
Rear Wheel:
16 x 3.50 inches
🛡️ Safety Features
Ratings
Safety Certification:
DOT (Department of Transportation) standards for motorcycles
Active Features
Braking System Type:
Dual-disc front, single-disc rear, hydraulic actuation
Lighting:
Halogen headlight, LED taillight and brake light, amber front and rear turn signals
Passive Features
Frame Construction:
Steel, single downtube, cradle frame
Rider Ergonomics:
Designed for comfort and control during long rides
💡 Technology Features
Infotainment
Audio System:
AM/FM radio, cassette player, CB radio, intercom system (integrated into fairing)
Speaker Configuration:
Fairing-mounted speakers
Driver Assistance
Cruise Control:
Standard feature on FLHTC models
Connectivity
Communications:
CB radio and intercom for rider-passenger communication
🔧 Maintenance
Service Intervals
First Service:
1000 miles (1600 km) or 3 months, whichever comes first
Subsequent Services:
Every 5000 miles (8000 km) or 6 months, whichever comes first
Engine Oil And Filter:
Every 5000 miles (8000 km) or 6 months
Transmission Oil Change:
Every 10,000 miles (16,000 km) or 12 months
Primary Chain Tensioner Inspection:
Every 10,000 miles (16,000 km)
Fluid Specifications
Front Fork Oil Type:
Harley-Davidson Factory Service Manual specifies Harley-Davidson Suspension Oil or equivalent SE Performance Fork Oil (e.g., SAE 15W)
Front Fork Oil Quantity:
Refer to manual for specific fork leg quantities (typically around 8-10 oz per leg)
Brake Fluid Type:
DOT 4
Known Issues
Primary Chain Tensioner:
Hydraulic tensioner can wear, leading to noise and potential damage; often upgraded to an automatic or manual tensioner conversion
Cam Chain Tensioners:
Early Twin Cam models can have cam chain tensioner wear; later models (post-2006) had improved tensioners
Fuel Line Connections:
Some early models experienced issues with fuel line fittings; proper maintenance is crucial
Exhaust Flange Gaskets:
Can sometimes require periodic replacement to prevent exhaust leaks
📚 Vehicle History
Brand Heritage
Brand Origin:
Founded in 1903, Milwaukee, Wisconsin, USA
Iconic Status:
Harley-Davidson is synonymous with American motorcycling culture
Model Evolution
Electra Glide Lineage:
The Electra Glide series dates back to the late 1960s, evolving into the premier touring platform
Twin Cam Introduction:
The Twin Cam 88 engine was introduced in 1999, offering improved performance and reliability over previous Big Twin engines
Production
Manufacturing Location:
USA
🏆 Awards & Recognition
Recognitions
Market Perception:
Consistently ranked as a top touring motorcycle, praised for comfort, style, and brand prestige