Harley Davidson FLHTCUI Electra Glide EFI 04 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHTCUI Electra Glide Ultra Classic Year: 2004 Engine Type: V-Twin, Air-Cooled, Fuel-Injected Codes Model Code: FLHTCUI 👋 Introduction Market Position Vehicle Segment: Full-dress...

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标签: 2004 FLHTCUI Electra Glide EFI Harley Davidson Misc Motorcycle Motorcycles

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

FLHTCUI Electra Glide Ultra Classic

Year:

Engine Type:

V-Twin, Air-Cooled, Fuel-Injected

Codes

Model Code:

FLHTCUI

👋 Introduction

Market Position

Vehicle Segment:

Full-dress touring motorcycle, flagship model for Harley-Davidson.

Competitive Analysis

Key Competitors 2004:

Honda Gold Wing, Kawasaki Vulcan Voyager, Indian Chief, BMW R1200LT.

Key Features

Touring Capability:

Designed for long-distance comfort and luggage carrying capacity, featuring large fairings, saddlebags, and a tour-pak.

Engine Performance:

Torquey V-twin engine providing strong acceleration and comfortable cruising.

Comfort And Ergonomics:

Spacious rider and passenger seating, floorboards, ample wind protection, and rider amenities.

Technology Integration:

Early integration of electronic fuel injection, cruise control, and often an audio system.

📋 Manual Details

Coverage Areas

Manual Coverage Scope:

Comprehensive service and repair for the 2004 Harley-Davidson FLHTCUI Electra Glide Ultra Classic.

Page Count

Estimated Page Count:

Approximately 700-900 pages (typical for this model's service manual).

Manual Type

Manual Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine System:

Complete disassembly, inspection, overhaul, and reassembly of the Twin Cam 88 engine, including cylinder heads, pistons, crankshaft, camshafts, and timing.

Fuel System:

Fuel injection system (EFI) diagnostics, component testing (injectors, fuel pump, regulator), throttle body, sensors (MAP, IAT, O2).

Ignition System:

Ignition module, spark plugs, ignition coils, timing adjustments, troubleshooting ignition faults.

Transmission System:

5-speed Cruise Drive transmission disassembly, repair, clutch operation, lubrication, and troubleshooting.

Electrical System:

Wiring diagrams, charging system (alternator, regulator), starting system (starter, solenoid), battery service, lighting, horn, instruments, fuses, relays, and accessory circuits.

Suspension System:

Front fork (telescopic) overhaul, fluid replacement, seal replacement, rear shock absorber service and adjustment.

Brake System:

Front and rear hydraulic brake systems, caliper overhaul, master cylinder service, brake fluid replacement, bleeding procedures, rotor and pad inspection.

Chassis And Frame:

Frame inspection, swingarm service, wheel bearings, steering head bearings, and alignment.

Bodywork And Fairings:

Fairing removal and installation, saddlebag service, tour-pak mounting, body panel repairs, and cosmetic component service.

Cruise Control:

Service and troubleshooting of the electronic cruise control system.

Audio System:

Troubleshooting and basic service for the integrated audio system (if applicable).

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, air filter service, spark plug replacement, lubrication points, brake fluid checks.

Troubleshooting Guides:

Systematic diagnostic procedures for common issues, fault code interpretation (if applicable), and symptom-based troubleshooting.

Rebuilding And Overhaul:

Detailed procedures for engine, transmission, forks, and brake system rebuilds.

Component Replacement:

Step-by-step instructions for replacing wear items and major components.

Special Tools:

Identification and usage of specialized tools required for specific repairs and adjustments.

Technical Depth

Diagnostic Capabilities:

Advanced diagnostics for EFI systems, sensor readings, and electrical component testing.

Repair Scope:

Full range of repairs from minor adjustments to complete engine and transmission rebuilds.

Precision Measurements:

Clear specifications for clearances, tolerances, torque values, and other critical measurements.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution, searchable PDF with clear diagrams and text.

Print Quality

Scalability:

Designed for clear viewing and printing of all diagrams and text.

Binding Type

Digital Format:

N/A (Digital PDF)

Paper Type

Digital Format:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Harley-Davidson Twin Cam 88

Displacement:

1450 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

Valvetrain:

Overhead valves (OHV), 2 valves per cylinder

Cooling System:

Air-cooled

Performance

Horsepower Estimated:

Approximately 65-70 HP (at crank)

Torque Estimated:

Approximately 85-90 lb-ft (at crank)

Fuel System

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, 91 octane (R+M)/2 recommended

Fuel Tank Capacity:

5.0 US gallons (18.9 L)

🔧 Transmission

Standard

Transmission Type:

5-speed Constant Mesh, Cruise Drive

Optional

Transmission Options:

N/A (Standard 5-speed)

Features

Clutch Type:

Wet, multi-plate, diaphragm spring

Primary Drive:

46/25, 1.84:1

Final Drive:

32/46, 1.4375:1

Transmission Fluid Type:

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

📐 Dimensions

Exterior

Overall Length:

Approx. 98.7 inches (2507 mm)

Overall Width:

Approx. 37.0 inches (940 mm)

Overall Height:

Approx. 56.5 inches (1435 mm)

Wheelbase:

Approx. 63.5 inches (1613 mm)

Ground Clearance:

Approx. 5.1 inches (130 mm)

Weights

Dry Weight:

Approx. 800 lbs (363 kg)

Gvwr:

Approx. 1360 lbs (617 kg)

Payload Capacity:

Approx. 560 lbs (254 kg)

Cargo

Saddlebag Capacity:

Integrated, approximately 2.2 cu ft total

Tour Pak Capacity:

Integrated, approximately 2.5 cu ft

🛡️ Safety Features

Ratings

Crash Test Ratings:

Motorcycles are typically not subject to the same formal crash test ratings as automobiles.

Active Features

Braking System:

Dual-disc front brakes, single disc rear brake with hydraulic actuation.

Lighting:

Halogen headlight, auxiliary passing lamps, LED tail/stop light, amber turn signals.

Passive Features

Frame Construction:

Steel, cradle frame providing structural integrity.

Fairing Wind Protection:

Large Batwing fairing offers significant rider and passenger protection from wind and elements.

💡 Technology Features

Infotainment

Audio System:

AM/FM Stereo radio with cassette player and CB/Intercom system (depending on specific trim and options).

Display Technology:

Analog gauges for speed, tachometer, oil pressure, voltage, and fuel. Small LCD for odometer and trip meters.

Driver Assistance

Cruise Control:

Electronic cruise control system for highway comfort.

Connectivity

Cb Radio Intercom:

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

Diagnostic Tools

OBD Ii Equivalent:

Harley-Davidson uses its own diagnostic interface (e.g., for the Delphi-based EFI system) which requires specific tools for full diagnostic access.

🔧 Maintenance

Service Intervals

Engine Oil Change:

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

Transmission Fluid Change:

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

Primary Chaincase Fluid Change:

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

Air Filter Cleaning:

Inspect every 5,000 miles (8,000 km), clean or replace as needed.

Spark Plug Replacement:

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

Brake Fluid Flush And Replace:

Every 2 years.

Fluid Specifications

Engine Oil Type:

Harley-Davidson SYN3 Synthetic Motorcycle Oil (or equivalent SAE 20W-50 API SG or higher)

Engine Oil Capacity:

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

Transmission Fluid Type:

Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant

Transmission Fluid Capacity:

Approx. 24 US fluid ounces (0.71 L)

Primary Chaincase Fluid Type:

Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant

Primary Chaincase Fluid Capacity:

Approx. 26 US fluid ounces (0.77 L)

Front Fork Oil Type:

Harley-Davidson Type E or 10W Fork Oil

Front Fork Oil Capacity:

Approx. 11.3 US fl oz (335 ml) per fork leg.

Brake Fluid Type:

DOT 4

Known Issues

Engine Oil Leaks:

Potential for leaks at primary cover, derby cover, and rocker boxes due to aging gaskets.

Cam Chain Tensioner Wear:

Early Twin Cam 88 models are known for hydraulic cam chain tensioner wear, leading to noise and potential damage. Upgrade kits are available.

Rear Cylinder Overheating:

Can occur in hot weather or heavy traffic due to air cooling. Proper maintenance and synthetic oil can mitigate this.

Cruise Control Actuator Failure:

The electronic cruise control actuator can sometimes fail, requiring replacement.

📚 Vehicle History

Brand Heritage

Manufacturer:

Harley-Davidson Motor Company, founded in 1903.

Core Philosophy:

American V-twin motorcycles, emphasis on rider experience, customization, and community.

Model Evolution

Electra Glide Lineage:

The Electra Glide series dates back to 1965, evolving from the Panhead and Shovelhead eras to the current Twin Cam platform.

Twin Cam Introduction:

The Twin Cam 88 engine was introduced in 1999, offering improved performance and reliability over its predecessors.

Production

Manufacturing Location:

United States (York, Pennsylvania and Milwaukee, Wisconsin)

Key Production Years For This Variant:

2000-2006 (Twin Cam 88 EFI models)

🏆 Awards & Recognition

Recognitions

Harley Davidson Reputation:

Harley-Davidson motorcycles, particularly the Electra Glide series, are renowned for their iconic status, rider community, and enduring appeal.

Ratings

Consumer Satisfaction:

Historically high customer satisfaction for the Electra Glide touring platform, emphasizing comfort and build quality.

Certifications

Epa Compliance:

Meets Environmental Protection Agency (EPA) standards for emissions.