Segment:
Full-size, touring motorcycle.
Target Audience:
Harley-Davidson owners seeking to perform their own maintenance and repairs, independent repair shops.
Competitors 2004:
Honda Gold Wing, Indian Chief, Kawasaki Vulcan series.
Model Features:
Comfortable ride, large fairing for weather protection, ample storage (saddlebags), electronic fuel injection (EFI) for improved performance and emissions.
Engine:
Detailed procedures for the Harley-Davidson Twin Cam 88 EFI engine, including disassembly, assembly, inspection, and troubleshooting.
Fuel System:
EFI system diagnostics, component testing, fuel pump, injectors, throttle body service.
Transmission:
5-speed Cruise Drive transmission service, clutch operation, gear shift linkage adjustment.
Electrical System:
Wiring diagrams, ignition system, lighting, charging system, starter, battery, diagnostics.
Suspension:
Front fork service, rear shock absorber replacement, suspension adjustments.
Brakes:
Brake system service, hydraulic lines, caliper maintenance, rotor inspection, bleeding procedures.
Bodywork And Frame:
Fairing removal and installation, saddlebag service, frame inspection, mounting hardware.
Chassis:
Wheel bearing service, steering head bearing adjustment, swingarm maintenance.
Maintenance:
Scheduled maintenance, fluid changes (engine oil, primary fluid, transmission fluid), filter replacements, tune-up procedures.
Troubleshooting:
Systematic troubleshooting guides for common and uncommon issues, diagnostic flowcharts.
Repair:
Detailed step-by-step repair instructions for all major components and systems.
Disassembly Assembly:
Comprehensive guides for removing and installing parts, including exploded views.
Adjustments:
Clutch adjustment, throttle cable adjustment, primary chain tensioner adjustment.
Diagnostics:
Diagnostic procedures for EFI system, sensor testing, and electrical fault finding.
Depth Of Coverage:
From basic maintenance and fluid checks to complete engine rebuilds, transmission overhauls, and advanced electrical diagnostics.
Pictorial Representation:
Includes detailed illustrations, exploded diagrams, drawings, and photos for clarity.
Special Tools:
References and illustrations for required special service tools.
Specifications:
Includes service data, factory specifications, allowable limits, and tightening torques.
Engine Type:
Air-cooled, Twin Cam 88, pushrod V-twin
Displacement:
1450 cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Horsepower:
Approx. 67 hp @ 5200 rpm (varies slightly by source/tune)
Torque:
Approx. 86 ft-lbs @ 3200 rpm (varies slightly by source/tune)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Oil Type:
Harley-Davidson Genuine V-Twin Motor Oil or equivalent SAE 20W-50
Oil Capacity:
3.0 US qt. (2.8 L) with filter change
Transmission Type:
5-speed Constant Mesh, Cruise Drive
Primary Drive:
Duplex chain, assisted by a centrifugal clutch
Clutch Type:
Wet, multi-plate, assisted
Transmission Fluid:
Harley-Davidson Genuine Primary Chaincase Lubricant or equivalent
Transmission Fluid Capacity:
2.5 US qt. (2.4 L)
Safety Compliance:
Adheres to all relevant safety standards for motorcycle operation.
Braking System:
Hydraulic disc brakes front and rear.
Lighting:
Halogen headlight, full complement of running and signaling lights.
Chassis Design:
Robust frame designed for stability and rider confidence.
Operator Manual:
Emphasizes safety precautions, rider training recommendations, and proper operation.
Initial Service:
First service typically at 1,000 miles (1600 km).
Routine Maintenance:
Engine oil and filter change every 5,000 miles (8,000 km) or annually. Primary chaincase fluid and transmission fluid checks at regular intervals.
Engine Oil Spec:
SAE 20W-50 motorcycle specific (e.g., Harley-Davidson Genuine V-Twin Motor Oil).
Primary Fluid Spec:
Harley-Davidson Genuine Primary Chaincase Lubricant or equivalent.
Transmission Fluid Spec:
Harley-Davidson Genuine Transmission Fluid or equivalent SAE 80W-90.
Brake Fluid Spec:
DOT 4 hydraulic brake fluid.
Common Wear Items:
Clutch plates, brake pads, wheel bearings, fork seals, spark plugs.
Potential Issues 2004:
Harley-Davidson faced some known issues with early Twin Cam 88 engines, including cam chain tensioner wear and oil leaks.EFI system tuning and sensor reliability can also be areas of attention.
