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Harley Davidson FLHTCI Electra Glide Classic EFi Motorcycle 2005 Factory Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHTCI Electra Glide Classic EFI Year: 2005 Product Name: Harley Davidson FLHTCI Electra Glide Classic EFi Motorcycle 2005 Factory Service Repair Workshop Manual...
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🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FLHTCI Electra Glide Classic EFI
Year:
2005
Product Name:
Harley Davidson FLHTCI Electra Glide Classic EFi Motorcycle 2005 Factory Service Repair Workshop Manual Download
Codes
Model Code:
FLHTCI
Chassis Type:
Touring
👋 Introduction
Market Position
Segment:
Full-size, luxury touring motorcycle.
Target Audience:
Long-distance touring riders, riders prioritizing comfort and luggage capacity.
Competitive Analysis
Key Competitors:
Other Harley-Davidson touring models, Indian Chief, Honda Gold Wing, Yamaha Star Venture.
Key Features
Features:
Comfortable ride, ample storage (saddlebags, optional tour-pak), rider and passenger amenities, large displacement V-twin engine, iconic Harley-Davidson styling.
Manual Value Proposition
Value:
Essential resource for owners and technicians to maintain, diagnose, and repair the 2005 Electra Glide Classic EFI, saving on dealership service costs and enabling DIY maintenance.
📋 Manual Details
Coverage Areas
All Repairs:
True
Servicing:
True
Page Count
Estimated Pages:
Approximately 700-900 pages (typical for a full factory service manual of this era)
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Detailed coverage of the Twin Cam 88 engine, including disassembly, assembly, diagnostics, and tuning.
Fuel System:
Electronic Fuel Injection (EFI) system, including sensors, injectors, fuel pump, and diagnostics.
Ignition System:
Ignition module, spark plugs, coils, and timing.
Transmission:
5-speed constant mesh transmission, clutch, primary drive, and final drive servicing.
Electrical System:
Complete wiring diagrams, starter system, charging system (alternator, regulator), battery, lighting, instrumentation, and accessories.
Chassis:
Frame, front fork, steering head, rear suspension, wheel bearings, and alignment.
Brakes:
Hydraulic braking system (front and rear calipers, master cylinders, brake lines, pads, rotors), parking brake.
Bodywork And Fittings:
Fairing, saddlebags, tour-pak mounting, seat, controls, instruments, and fairing components.
Diagnostics:
Troubleshooting guides, diagnostic codes (DTCS), and procedures for identifying issues.
Procedures Included
Maintenance:
Routine maintenance tasks such as oil changes, filter replacements, chain/belt adjustments, and lubrication.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon problems across all systems.
Repair:
Detailed instructions for disassembly, component replacement, and reassembly of all major motorcycle systems.
Installation:
Instructions for installing accessories and replacement parts.
Engine Rebuild:
Complete engine overhaul procedures, including piston ring replacement, valve adjustments, and bearing checks.
Technical Depth
Depth:
Comprehensive, covering everything from basic rider maintenance to complete engine and transmission overhauls.
Detail Level:
Includes detailed exploded views, torque specifications, and clearance measurements.
Wiring Diagrams:
High-quality, detailed wiring diagrams for all electrical circuits.
Illustrations:
Step-by-step instructions accompanied by clear photographs and illustrations.
📊 Manual Specifications
File Format
Format:
PDF
Searchable Text:
Likely contains searchable text for quick information retrieval.
Print Quality
Resolution:
High-resolution scans suitable for printing.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, Twin Cam 88 V-twin
Displacement:
1449 cc (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), pushrod actuated, two valves per cylinder.
Performance
Horsepower:
Estimated 65-70 HP (at the crank, actual may vary based on tune and conditions)
Torque:
Estimated 80-85 ft-lbs (at the crank, at approx. 3000 RPM)
Fuel System
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI) with throttle body
Fuel Type:
Unleaded gasoline, minimum 87 octane
Oil System
Oil Capacity:
3.5 US quarts (3.3 liters) with filter change
Oil Type Specification:
Harley-Davidson SYN3 (Synthetic) SAE 20W50, or equivalent API CG-4 rated diesel engine oil.
🔧 Transmission
Standard
Type:
5-speed, constant mesh
Optional
Optional Features:
N/A (5-speed was standard)
Features
Primary Drive:
Duplex chain, oil bath, automatic chain tensioner
Final Drive:
Belt drive, 32/66 ratio
Clutch:
Cable-actuated, 9-plate, wet clutch
Fluid Capacity
Transmission Oil Capacity:
2.6 US quarts (2.5 liters)
Fluid Specification
Transmission Oil Type:
Harley-Davidson Synthetic Transmission Lubricant (or equivalent API GL-4 rated gear oil, e.g., SAE 75W-90)
📐 Dimensions
Exterior
Length:
98.2 inches (2494 mm)
Width:
36.3 inches (922 mm)
Height:
53.5 inches (1359 mm)
Wheelbase:
63.5 inches (1613 mm)
Weights
Dry Weight:
726 lbs (329 kg)
Gross Vehicle Weight Rating Gvwr:
1200 lbs (544 kg)
Cargo
Saddlebag Capacity:
Approx. 2.2 cubic feet per bag (total)
Fuel Capacity
Fuel Tank Capacity:
5.0 US gallons (18.9 liters)
Seat Height
Seat Height Laden:
29.5 inches (750 mm)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Motorcycles are not typically rated by organizations like NHTSA or IIHS.
Active Features
Braking System:
Dual 320 mm front discs with 4-piston calipers, Single 292 mm rear disc with 2-piston caliper.
Front Suspension:
41mm telescopic fork with dual rate springs, air-adjustable
Rear Suspension:
Air-adjustable, coil-over shock absorbers
Passive Features
Lighting:
Halogen headlight, front and rear turn signals, brake lights.
Chassis Design:
Steel, rigid backbone frame with forged steel downtubes.
💡 Technology Features
Infotainment
Audio System:
Integrated fairing-mounted audio system with AM/FM radio and CD player.
Controls:
Handlebar-mounted audio controls.
Driver Assistance
Cruise Control:
Electronic cruise control (standard on FLHTCI).
Connectivity
Connectivity Features:
N/A for this model year in the modern sense (no Bluetooth, USB, or smartphone integration).
Instrumentation
Dashboard:
Analog speedometer, tachometer, fuel gauge, oil pressure gauge, voltmeter, and indicator lights.
🔧 Maintenance
Service Intervals
First Service:
1000 miles (1600 km) or 6 months
Subsequent Service:
Every 5000 miles (8000 km) or 12 months
Engine Oil Change:
Every 5000 miles (8000 km) or annually, whichever comes first.
Transmission Oil Change:
Every 10000 miles (16000 km) or 24 months.
Primary Chain Case Oil Change:
Every 10000 miles (16000 km) or 24 months.
Spark Plug Replacement:
Typically at 20,000-30,000 miles, depending on plug type and wear.
Fluid Specifications
Brake Fluid:
DOT 4 hydraulic brake fluid
Front Fork Oil:
Harley-Davidson 10W fork oil (or equivalent)
Rear Shock Air Pressure:
User adjustable, refer to manual for recommended pressures based on load and rider preference.
Known Issues
Common Wear Items:
Wheel bearings, fork seals, clutch plates, exhaust gaskets.
Electrical Gremlins:
Wiring harness wear, especially at steering head and under seat; regulator/rectifier failures can occur.
Engine Performance:
Cam chain tensioner wear (hydraulic tensioners in later Twin Cams were better, but earlier ones could be an issue); potential for oil leaks from primary cover or rocker boxes.
Fuel System:
Injector O-ring wear, throttle position sensor (TPS) issues.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Harley-Davidson has a long and storied history in motorcycle manufacturing, known for its V-twin engines and cruiser/touring motorcycles.
Model Evolution
Electra Glide Lineage:
The Electra Glide has been a flagship touring model for Harley-Davidson since the late 1960s, evolving significantly in comfort, technology, and performance over the decades.
Twin Cam Era:
The Twin Cam 88 engine, introduced in 1999, represented a significant upgrade in power and refinement for Harley-Davidson's big twins, including the Electra Glide series.
Production
Production Years For Model:
FLHTCI Electra Glide Classic EFI models were produced in the early to mid-2000s, with the 2005 model being part of this generation.
Manufacturing Location:
York, Pennsylvania, USA (primary assembly location for Harley-Davidson touring models)
🏆 Awards & Recognition
Recognitions
Awards:
Specific awards for the 2005 FLHTCI are not widely documented; however, the Electra Glide model line has consistently been recognized for its touring capabilities and comfort in motorcycle industry reviews.
Ratings
Industry Perception:
Considered a benchmark in the V-twin touring segment for its era.
Certifications
Certifications:
Meets all applicable federal emissions and safety standards for motorcycles.