Harley Davidson Touring 2004 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Touring Year: 2004 Codes Platform Code: TBA (Commonly referred to as the FLHT chassis family for this era) 👋 Introduction Market Position Market...

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类型: Motorcycle

斯库: 390091

标签: 2004 Harley Davidson Misc Motorcycle Motorcycles Touring

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Touring

Year:

Codes

Platform Code:

TBA (Commonly referred to as the FLHT chassis family for this era)

👋 Introduction

Market Position

Market Segment:

Premium Long-Distance Touring Motorcycle

Competitive Analysis

Key Competitors:

Indian Chief, Honda Gold Wing, Yamaha Royal Star Venture

Key Features

Touring Features:

Large fairings, saddlebags, comfortable seating for rider and passenger, often equipped with audio systems and cruise control.

Engine Philosophy:

Harley-Davidson's iconic V-twin engine, known for its distinctive sound, torque delivery, and rider experience.

Manual Value Proposition

Value:

Essential resource for owners and technicians to maintain, diagnose, and repair 2004 Harley-Davidson Touring models, ensuring longevity and optimal performance.

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop Service and Repair

Page Count

Total Pages:

Manual Type

Type:

Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

V-Twin (Twin Cam 88, Twin Cam 96 variants likely included for 2004 models, with focus on 88)

Fuel System:

Carbureted (CV Carburetor) and Electronic Fuel Injection (EFI) systems

Ignition System:

Electronic Ignition, Coil, Spark Plugs

Transmission:

5-speed Cruise Drive Transmission

Clutch:

Primary Drive, Clutch Assembly, Actuation

Brakes:

Hydraulic Disc Brakes (Front and Rear), Calipers, Master Cylinders, Hoses

Suspension:

Front Forks (Telescopic), Rear Shock Absorbers, Swingarm

Electrical System:

Battery, Charging System (Stator, Regulator/Rectifier), Lighting, Horn, Starter Motor, Wiring Diagrams

Cooling System:

Air-Cooled Engine Design, Oil Cooler (if equipped)

Exhaust System:

Exhaust Pipes, Mufflers, Heat Shields

Frame And Bodywork:

Frame, Fairings, Saddlebags, Tour-Pak, Fenders, Seat

Wheels And Tires:

Wheel Bearings, Tire Sizes, Inflation Pressures

Control Systems:

Handlebars, Levers, Cables, Foot Controls

Diagnostics:

Troubleshooting guides, diagnostic fault codes (if applicable to EFI models)

Procedures Included

Scheduled Maintenance:

Oil Changes, Filter Replacements, Spark Plug Service, Belt Inspection/Tensioning, Brake Fluid Flush

Engine Overhaul:

Top End Rebuild (Cylinder Head, Piston), Bottom End Rebuild (Crankshaft, Connecting Rods), Camshaft Installation

Transmission Repair:

Gear Set Service, Clutch Pack Replacement, Shifter Mechanism Repair

Brake System Service:

Brake Pad Replacement, Rotor Service, Bleeding Procedure, Master Cylinder Rebuild

Suspension Service:

Fork Seal Replacement, Fork Oil Change, Rear Shock Replacement

Electrical Troubleshooting:

Wiring Harness Repair, Component Testing, Charging System Diagnosis

Fuel System Maintenance:

Carburetor Cleaning and Adjustment, Fuel Injector Service, Fuel Pump Testing

Bodywork Repair:

Fairing Repair, Saddlebag Mounting, Tour-Pak Installation

Wheel And Tire Service:

Tire Mounting and Balancing, Wheel Bearing Replacement

Specifications Data:

Torque values, clearances, timing specifications

Technical Depth

Depth:

Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and electrical system schematics.

📊 Manual Specifications

File Format

File Type:

Searchable:

Likely searchable text within the PDF for efficient information retrieval.

Print Quality

Quality:

High-resolution PDF, suitable for printing individual pages or sections.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 45-degree V-twin, Pushrod OHV, 4 valves per cylinder (2 per head)

Engine Displacement:

1450cc (88 cubic inches)

Bore X Stroke:

3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)

Compression Ratio:

8.9:1 (typical for Twin Cam 88)

Performance

Horsepower:

Approx. 65-70 HP (at crankshaft, varies slightly by model and tuning)

Torque:

Approx. 86 ft-lbs (at crankshaft, ~2800 RPM, varies slightly)

Fuel System

Fuel Delivery:

Keihin CV 40mm Carburetor (for carbureted models) or Delphi Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline, 91 Octane Minimum Recommended

Lubrication

Oil Capacity:

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

Oil Type:

Harley-Davidson Genuine V-Twin 20W-50 or equivalent API SG rated oil

🔧 Transmission

Standard

Type:

5-speed Constant Mesh, Sequential Synchromesh

Gear Ratios:

1st: 9.312, 2nd: 6.471, 3rd: 4.786, 4th: 3.804, 5th: 3.115 (Typical for Twin Cam 88 5-speed)

Primary Drive:

Duplex chain, 34/46 teeth (2.086:1 ratio)

Final Drive:

Belt Drive, 32/66 teeth (2.0625:1 ratio)

Features

Clutch Type:

Multi-plate, wet clutch, cable-actuated

Transmission Fluid Type:

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

Transmission Fluid Capacity:

Approx. 20-24 US fl oz (0.6 - 0.7 L)

📐 Dimensions

Exterior

Length:

Refer to specific model (e.g., FLHTC, FLHTCU) - typically around 98-101 inches (2489-2565 mm)

Width:

Refer to specific model - typically around 38-40 inches (965-1016 mm)

Height:

Refer to specific model - typically around 55-60 inches (1397-1524 mm)

Weights

Dry Weight:

Refer to specific model - typically around 750-850 lbs (340-385 kg)

Gvwr:

Refer to specific model - typically around 1360 lbs (617 kg)

Payload Capacity:

Refer to specific model - typically around 400-450 lbs (181-204 kg)

Cargo

Saddlebag Capacity:

Integrated hard saddlebags, capacity varies by model but significant for touring.

Tour Pak Capacity:

Optional or standard depending on model (e.g., FLHTCU), adds significant lockable storage.

🛡️ Safety Features

Ratings

Safety Certification:

N/A (Motorcycles are not rated by organizations like NHTSA in the same way as cars).

Active Features

Braking System:

Linked or unlinked (depending on model) hydraulic disc brakes front and rear for reliable stopping power.

Lighting:

Halogen headlight, dual rear taillights, front and rear turn signals, brake light integrated into taillight/tour-pak.

Passive Features

Chassis Stability:

Heavyweight chassis and long wheelbase contribute to stable handling at speed.

Ergonomics:

Designed for rider comfort over long distances, reducing fatigue.

💡 Technology Features

Infotainment

Audio System:

Many 2004 Touring models featured integrated AM/FM/WB radios with CD players and CB/Intercom systems, often with handlebar-mounted controls.

Display:

Analog gauges for speedometer, tachometer, fuel, oil pressure, and voltage, with LCD information screens.

Driver Assistance

Cruise Control:

Electronic cruise control was a common feature on higher-trim Touring models for effortless highway cruising.

Connectivity

Diagnostic Ports:

EFI models will have diagnostic ports for connecting specialized Harley-Davidson diagnostic tools for fault code retrieval and data analysis.

🔧 Maintenance

Service Intervals

Initial Service:

1000 mile (1600 km) break-in service recommended.

Regular Oil Change:

Every 5000 miles (8000 km) or 6 months, whichever comes first.

Transmission Fluid Change:

Every 10,000 miles (16,000 km) or 12 months.

Primary Chaincase Fluid Change:

Every 10,000 miles (16,000 km) or 12 months.

Spark Plug Replacement:

Every 10,000 miles (16,000 km) or as needed based on inspection.

Drive Belt Inspection:

Inspect tension and condition every 5000 miles (8000 km); replacement interval varies greatly with riding conditions but typically 30,000-50,000 miles.

Fluid Specifications

Engine Oil Viscosity:

20W-50

Brake Fluid:

DOT 4 Hydraulic Fluid

Known Issues

Twin Cam Oil Consumption:

Some Twin Cam 88 engines, particularly early ones, could experience higher-than-average oil consumption due to valve guide wear. The manual will detail checks and potential remedies.

Cam Chain Tensioner Wear:

Hydraulic cam chain tensioners can wear over time, potentially leading to noise or premature wear. The manual will cover inspection and replacement procedures for these units.

Fuel Line Connectors:

Some early EFI models had issues with quick-disconnect fuel line fittings. The manual will provide guidance on proper installation and maintenance.

📚 Vehicle History

Brand Heritage

Heritage:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer with a rich history in building V-twin motorcycles.

Model Evolution

Touring Lineage:

The Touring line evolved from earlier large Harley-Davidson cruisers, with the 'Touring' designation becoming prominent as these models were specifically engineered for long-distance travel.

Twin Cam Introduction:

The Twin Cam 88 engine, introduced in 1999, was a significant update for Harley-Davidson's V-twin lineup, offering improved performance and reliability over the Evolution engine.

Production

Manufacturing Location:

Milwaukee, Wisconsin, USA (primary assembly)

2004 Significance:

2004 marked a continuation of the Twin Cam 88 platform in the Touring line, with various sub-models offering different levels of comfort and features.

🏆 Awards & Recognition

Recognitions

Brand Recognition:

Harley-Davidson motorcycles consistently receive high ratings for rider satisfaction and brand loyalty in industry surveys.

Ratings

Touring Segment Performance:

Harley-Davidson Touring models are consistently recognized as top-tier choices for long-distance touring due to their comfort, style, and V-twin performance.