Harley Davidson FLHTCSE Electra Glide 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHTCSE Electra Glide Year: 2004 Type: Motorcycle Codes Model Code: FLHTCSE 👋 Introduction Market Position Positioning: The FLHTCSE Electra Glide was Harley-Davidson's premium...

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标签: 2004 FLHTCSE Electra Glide Harley Davidson Misc Motorcycle Motorcycles

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

FLHTCSE Electra Glide

Year:

Type:

Motorcycle

Codes

Model Code:

FLHTCSE

👋 Introduction

Market Position

Positioning:

The FLHTCSE Electra Glide was Harley-Davidson's premium touring model for 2004, representing the pinnacle of comfort and performance for long-distance riders.

Competitive Analysis

Competitors:

Competed with other large-displacement touring motorcycles from manufacturers like Honda (Gold Wing series) and BMW (K-series touring).

Key Features

Features:

Exclusive CVO (Custom Vehicle Operations) model with a larger displacement engine (Twin Cam 103), custom paint, premium audio, and enhanced comfort features.

Target Audience

Audience:

Discerning Harley-Davidson enthusiasts seeking a high-performance, feature-rich touring motorcycle with exclusive styling.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Repair, Overhaul

Page Count

Estimated Page Count:

Refer to actual manual content

Manual Type

Type:

Service Manual / Workshop Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine System:

Detailed diagnosis, repair, and overhaul of the Twin Cam 103 V-Twin engine.

Fuel System:

Carburetor (Keihin CV40, specific to CSE models) and fuel injection system diagnosis and repair.

Transmission System:

Diagnosis, disassembly, inspection, and reassembly of the 5-speed Cruise Drive transmission.

Electrical System:

Comprehensive wiring diagrams, component testing, ignition system, lighting, instrumentation, and accessory circuits.

Chassis System:

Frame, suspension (front forks and rear shock absorbers), steering, and wheel/tire service.

Braking System:

Front and rear brake caliper overhaul, hydraulic system bleeding, and component replacement.

Bodywork And Trim:

Fairing removal/installation, body panel repair, saddlebag service, and cosmetic components.

Cooling System:

Air-cooled engine specifics, thermal management.

Exhaust System:

Exhaust component inspection and replacement.

Clutch System:

Clutch operation, adjustment, and component servicing.

Procedures Included

Basic Maintenance:

Oil changes, filter replacements, chain adjustment (if applicable), spark plug replacement, battery maintenance.

Troubleshooting:

Diagnostic flowcharts and common problem identification for various systems.

Engine Rebuild:

Detailed steps for engine disassembly, component inspection (pistons, rings, cylinders, valves, camshafts), and reassembly.

Transmission Overhaul:

Complete disassembly, inspection of gears, bearings, and shift components, and reassembly.

Electrical Diagnostics:

Using multimeter and specialized tools to diagnose electrical faults, including ignition timing and fuel injection system checks.

Suspension Service:

Fork seal replacement, fluid changes, rear shock absorber adjustment and replacement.

Brake Service:

Brake pad replacement, rotor inspection, caliper service, and brake fluid flush.

Body Panel Repair:

Procedures for removing and reinstalling fairings, fenders, and saddlebags, including fastener torque specifications.

Carburetor Tuning:

Adjustment and troubleshooting for the Keihin CV carburetor.

Fuel Injection Servicing:

Diagnosis and potential adjustments or component replacement for the fuel injection system (if applicable to CSE specifics).

Technical Depth

Depth:

Comprehensive; covers routine maintenance, detailed diagnostics, component-level repair, and complete engine/transmission rebuilds.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable, enabling quick information retrieval.

Print Quality

Printability:

Designed for digital viewing and printing of specific sections or full manual.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, Twin Cam 103, V-Twin

Displacement:

103 cubic inches (1690 cc)

Bore X Stroke:

Refer to specific manual data, but typically around 3.927 in. x 4.25 in.

Compression Ratio:

Refer to specific manual data, likely around 9.0:1 or higher for the 103.

Performance

Horsepower:

Estimated around 70-75 HP (specific figures vary based on tuning and emissions).

Torque:

Estimated around 90-95 lb-ft (specific figures vary).

Fuel System

Carburetor Model:

Keihin CV40 (Constant Velocity) specifically for CSE model tuning.

Fuel Delivery:

Carbureted or Fuel Injection depending on specific sub-model/market, however FLHTCSE is generally carbureted with performance tuning.

Fuel Type:

Unleaded gasoline, minimum 91 octane recommended.

Ignition System

Ignition Type:

Electronic Ignition with knock sensor.

🔧 Transmission

Standard

Type:

5-speed Cruise Drive manual transmission

Clutch Type:

Wet, multi-plate, diaphragm spring

Primary Drive:

Helical, offset crankshaft, chain drive

Final Drive:

Belt drive

Features

Gear Ratios:

Refer to manual for specific ratios (1st: 9.573, 2nd: 6.650, 3rd: 4.948, 4th: 3.801, 5th: 3.158 - approximate for 5-speed Cruise Drive).

Transmission Fluid Spec:

Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant (or equivalent).

📐 Dimensions

Exterior

Length:

Approximately 94.5 inches (2400 mm)

Width:

Approximately 37.0 inches (940 mm)

Height:

Approximately 54.0 inches (1372 mm)

Weights

Dry Weight:

Approximately 765 lbs (347 kg)

Wet Weight:

Approximately 820 lbs (372 kg) (fully fueled)

Gross Vehicle Weight Rating:

Refer to manual, typically around 1300 lbs (590 kg).

Wheels And Tires

Front Tire Size:

130/70R18

Rear Tire Size:

140/75R17

Wheel Bolt Pattern:

N/A (Hub-mounted wheels)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Motorcycle safety is not typically rated by government agencies in the same manner as passenger cars. Focus is on design and rider aids.

Active Features

Braking System:

Dual 32mm, 4-piston front caliper; dual 32mm, 4-piston rear caliper with linked braking (partially).

Suspension Handling:

Large diameter front forks and adjustable rear suspension contribute to stable handling.

Passive Features

Lighting:

Halogen headlight, full complement of taillight, brake light, and turn signals.

Frame Construction:

Steel frame and swingarm for rigidity and durability.

💡 Technology Features

Infotainment

Audio System:

Premium 6-speaker audio system with CB radio and passenger intercom (standard on CSE).

Display:

Analog gauges for speedometer, tachometer, fuel level, oil pressure, and voltage; LCD information display.

Driver Assistance

Cruise Control:

Electronic cruise control (standard).

Connectivity

Connectivity Features:

CB radio and intercom functionality for rider-to-passenger and external communication.

🔧 Maintenance

Service Intervals

Initial Service:

Typically at 1,000 miles (1600 km) for initial break-in service (oil change, filter, inspection).

Routine Maintenance:

10,000 miles (16,000 km) or annual service intervals for major checks, fluid changes, and inspections.

Engine Oil Change:

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

Transmission Primary Fluid Change:

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

Rear Drive Belt Inspection:

Check tension and condition at every service interval; replace as needed.

Fluid Specifications

Engine Oil Type:

Harley-Davidson 20W50 SYN3 (Synthetic) or equivalent V-Twin motorcycle oil meeting Harley-Davidson specifications.

Engine Oil Capacity:

Approximately 4.0 US quarts (3.8 liters) with filter change.

Transmission Fluid:

Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant.

Primary Chaincase Fluid:

Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant.

Brake Fluid:

DOT 4 heavy-duty hydraulic fluid.

Known Issues

Common Wear Items:

Clutch wear, brake pad and rotor wear, fork seals, drive belt wear, and potential carburetor tuning needs.

Electrical Gremlins:

Older Harley-Davidsons can sometimes experience issues with aging wiring harness insulation, connectors, or charging system components if not properly maintained.

Engine Performance:

Tuning of the Twin Cam 103 may require specific attention due to its higher performance nature.

📚 Vehicle History

Brand Heritage

Heritage:

Harley-Davidson, founded in 1903, has a long-standing reputation for building iconic American motorcycles, particularly in the touring segment.

Model Evolution

Electra Glide Evolution:

The Electra Glide line, introduced in 1965, has evolved from basic touring bikes to sophisticated, feature-rich machines, with the CSE representing a significant performance and customization step.

Production

Production Years:

The FLHTCSE was a limited production model, part of Harley-Davidson's Custom Vehicle Operations (CVO) line, produced for the 2004 model year.

Production Location:

York, Pennsylvania, USA

🏆 Awards & Recognition

Recognitions

Cv Program Recognition:

CVO models are recognized for their exclusive styling, custom finishes, and enhanced performance, positioning them as premium offerings within the motorcycle market.