🏷️ Basic Information

Make:

Harley Davidson

Model:

Softail

Year:

2004

Product Type:

Workshop Repair Service Manual

Product Format:

PDF Download

👋 Introduction

Segment:

Cruiser Motorcycle Segment

Brand Loyalty:

Harley Davidson is renowned for its strong brand loyalty and dedicated owner base.

Competitors 2004:

V-twin cruisers from brands like Indian, Honda (Shadow series), Yamaha (V-Star series), Kawasaki (Vulcan series), and Suzuki (Boulevard series).

Design Philosophy:

Classic styling with modern V-twin performance, emphasizing rider comfort and highway cruising capability.

Manual Value:

An indispensable resource for owners and technicians to maintain, repair, and diagnose the Harley Davidson Softail, ensuring optimal performance and longevity.

📋 Manual Details

Covered Models:

All Softail models, engines, and trims for 2004

Estimated Page Count:

Approximately 800-1000 pages (typical for comprehensive workshop manuals)

Type:

Workshop Repair and Service Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine:

Detailed coverage of Twin Cam 88B, Twin Cam 95, and potential Screamin' Eagle engine variants; including disassembly, assembly, component testing, and specifications.

Fuel System:

Carbureted (Keihin CV) and fuel injected (EFI) systems, including fuel pump, injectors, throttle body, sensors, and ECU diagnostics.

Ignition System:

Ignition module, coils, spark plugs, wiring, and troubleshooting.

Transmission:

5-speed constant mesh transmission, clutch, primary drive, and final drive (belt drive) service and repair.

Brakes:

Hydraulic disc brake systems (front and rear), including caliper service, master cylinder repair, brake lines, fluid bleeding, and component specifications.

Suspension:

Front fork (telescopic) service, fork seal replacement, oil changes, and rear shock absorber inspection and replacement.

Electrical System:

Comprehensive wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), battery service, lighting, instrumentation, and accessory wiring.

Frame And Bodywork:

Frame inspection, body panel removal and installation, fender, seat, and tank service.

Wheels And Tires:

Wheel bearing inspection and replacement, tire mounting and balancing, and spoke wheel maintenance.

Exhaust System:

Exhaust pipe and muffler replacement, heat shield service.

Cooling System:

Air-cooled engine design, emphasis on airflow and heat dissipation; oil cooler service if equipped.

Diagnostics:

Troubleshooting guides for common symptoms, diagnostic codes (if applicable for EFI models), and testing procedures for electrical components.

Maintenance:

Regular scheduled maintenance tasks, including oil changes, filter replacements, spark plug checks, brake fluid flushes, and chain/belt adjustments.

Repair:

Step-by-step instructions for component overhaul, replacement, and repair across all major vehicle systems.

Troubleshooting:

Systematic approaches to identifying and resolving mechanical and electrical issues, often with diagnostic flowcharts.

Diagnostics:

Guidance on using diagnostic tools and interpreting system feedback for EFI models.

Special Tools:

Identification and usage of specialized tools required for specific Harley Davidson procedures.

Depth:

Comprehensive. Covers everything from basic fluid checks and adjustments to full engine and transmission rebuilds, and complex electrical diagnostics.

📊 Manual Specifications

File Type:

Portable Document Format (PDF)

Resolution:

High-resolution scans, typically suitable for clear printing of diagrams, schematics, and text.

Binding:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

Text Search:

Likely text-searchable PDF, allowing users to quickly find specific information.

Hyperlinks:

May contain internal hyperlinks for easier navigation between sections and diagrams.

⚙️ Engine Specifications

Engine Family:

Harley Davidson Evolution (Evo) and Twin Cam 88B

Engine Configuration:

45-degree V-twin, air-cooled

Displacement Options:

Commonly 88 cubic inches (approx. 1450cc) for Twin Cam 88B, with potential 95 cubic inch (approx. 1550cc) configurations and Screamin' Eagle variants.

Bore X Stroke:

Twin Cam 88B: 3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)

Compression Ratio:

Typically around 8.8:1 to 9.0:1 for stock Twin Cam 88B.

Horsepower:

Estimated 65-70 HP (peak, varies by model and tuning)

Torque:

Estimated 80-85 ft-lbs (peak, varies by model and tuning)

Carburetor:

Keihin CV (Constant Velocity) 40mm (standard on many models)

Fuel Injection:

Electronic Sequential Port Fuel Injection (ESPFI) on EFI models.

Oil Type:

Harley Davidson recommend specific V-twin motorcycle oils (e.g., SAE 20W50 or similar weight for air-cooled engines).

Oil Capacity:

Approx. 4 quarts (3.8 liters) for crankcase and filter.

🔧 Transmission

Type:

5-speed Constant Mesh

Drive Type:

Belt Drive (primary and final)

Clutch Type:

Wet, multi-plate

Transmission Fluid Type:

Harley Davidson recommended transmission lubricant (e.g., Syn-3 or specific formulae).

📐 Dimensions

Wheelbase:

Varies by specific Softail model (e.g., approx. 64.2 inches for Fat Boy, 65.5 inches for Heritage Softail Classic)

Length:

Varies by specific Softail model (e.g., approx. 92.2 inches for Fat Boy)

Dry Weight:

Varies by specific Softail model (e.g., approx. 687 lbs for Fat Boy)

Wet Weight:

Varies by specific Softail model (approx. 720-750 lbs range typically)

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycles are not subject to the same standardized crash testing as passenger vehicles)

Braking System:

Dual-piston front caliper, single-piston rear caliper on disc brakes.

Frame Construction:

Steel cradle frame.

💡 Technology Features

Audio System:

Factory radio/audio systems were optional on many Softail models for 2004, often found on touring-oriented Softails like the Heritage Softail Classic.

ABS:

Anti-lock Braking System (ABS) was generally not a standard or widely available option on Softail models in 2004. Some specific touring variants might have offered it.

Connectivity Features:

Limited to basic handlebar-mounted controls for aftermarket or optional audio systems. No integrated smartphone connectivity or Bluetooth as standard.

🔧 Maintenance

Engine Oil Change:

Every 5,000 miles or 6 months, whichever comes first (check manual for specifics).

Primary Chain Tensioner Inspection:

Regular inspection recommended, often at 10,000-20,000 mile intervals, or if noise is present (especially for the '01-'06 Twin Cam 88B).

Spark Plugs:

Inspect/replace every 10,000 miles.

Brake Fluid:

Flush and replace every 2 years.

Belt Tension:

Check and adjust every 5,000 miles.

Engine Oil:

Harley Davidson Genuine V-Twin Motor Oil SAE 20W50 (or equivalent meeting HD-360 specification).

Transmission Oil:

Harley Davidson Genuine Formula + Transmission Lubricant (or equivalent meeting specific Harley-Davidson transmission fluid requirements).

Primary Chain Case Oil:

Harley Davidson Genuine Formula + Transmission Lubricant or specific primary lubricant.

Brake Fluid:

DOT 4 Hydraulic Brake Fluid.

Fork Oil:

Harley Davidson Genuine Fork Oil or equivalent (specific weight and type depends on fork model, typically around 15W).

Twin Cam Primary Chain Tensioner:

The original spring-loaded tensioner in early Twin Cam 88 engines (including some 2004 models) was prone to wear, leading to potential chain slap and damage. Later models and aftermarket upgrades feature hydraulic tensioners.

Cam Chain Tensioner Noise:

Another area of concern for some Twin Cam owners, especially with higher mileage, is the wear on the cam chain tensioner shoes, which can cause noise. The manual would detail inspection and replacement.

Efi Sensor Issues:

For EFI models, issues with sensors like the MAP, TPS, or O2 sensors can affect performance and require diagnostic attention.

📚 Vehicle History

Founding:

Founded in 1903, Harley Davidson is an iconic American motorcycle manufacturer.

Softail Introduction:

The Softail chassis, featuring a hidden rear suspension system to mimic a hardtail look, was introduced in 1983.

Twin Cam Introduction:

The Twin Cam 88 engine, a significant redesign of the Harley-Davidson V-twin, was introduced in 1999, with the 88B (balanced) version specifically for Softail models to reduce vibration.

Manufacturing Location:

Typically assembled in Milwaukee, Wisconsin, USA and Kansas City, Missouri, USA.

🏆 Awards & Recognition

Model Awards:

While specific awards for the 2004 Softail models are not widely documented, Harley Davidson motorcycles in this era consistently received recognition for their iconic styling and V-twin performance within the cruiser market.