Harley Davidson FLTC-UI Tour Glide-Ultra Classic Motorcycle 1996 Factory Service Repair Workshop Manual
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๐ท๏ธ Basic Information Identification Make: Harley-Davidson Model: FLTC-UI Tour Glide-Ultra Classic Year: 1996 Product Type: Factory Service Repair Workshop Manual Product Format: Digital Download (PDF) ๐ Introduction Market Position Positioning: The definitive guide for owners and technicians working on the 1996 Harley-Davidson FLTC-UI Tour Glide-Ultra Classic, offering professional-level repair and maintenance information. Competitive Analysis Advantages: Provides factory-specific procedures, unlike generic repair guides, ensuring accuracy and completeness for all tasks. Key Features Accessibility: Instant digital delivery allows immediate access to repair information, enabling same-day servicing. User Friendliness: Designed for ease of use with step-by-step instructions and visual aids, making it suitable for a wide range of skill levels. ๐ Manual Details Coverage Areas Overall Coverage: Comprehensive A-Z coverage for all servicing, repair, and maintenance procedures. Model Coverage: All FLTC-UI Tour Glide-Ultra Classic models for the 1996 model year, encompassing all engine types. Page Count Estimated Pages: Likely 500+ pages based on typical factory service manuals for this era and complexity. Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format File Format: PDF ๐ Manual Coverage Systems Covered Engine: Detailed overhaul, disassembly, assembly, tuning, diagnostics, and repair for all engine components. Fuel System: Carburetor adjustment, cleaning, rebuilds, fuel pump service, fuel lines, and fuel tank. Ignition System: Ignition timing, spark plugs, coils, ignition module, troubleshooting. Transmission: Gearbox disassembly, assembly, clutch service, lubrication, and repair procedures. Drivetrain: Belt drive inspection, adjustment, replacement, rear wheel alignment. Electrical System: Complete wiring diagrams, starter system, charging system (alternator, regulator), lighting, battery, fuses, relays, and accessory circuits. Brakes: Hydraulic brake system, caliper service, master cylinder, brake lines, brake pads, fluid replacement, and bleeding procedures. Suspension: Front fork service (oil changes, seal replacement), rear shock absorber inspection and replacement, wheel bearings. Chassis And Frame: Frame inspection, steering head bearing service, swingarm maintenance. Bodywork And Fairings: Fairing removal and installation, body panel repair and replacement, seat maintenance. Controls: Handlebar controls, throttle cables, brake levers, clutch operation. Procedures Included Maintenance: Routine maintenance checks, oil changes, filter replacements, spark plug service, lubrication points, tire pressure checks. Troubleshooting: Diagnostic procedures for common and uncommon issues, fault finding charts. Repair: Step-by-step instructions for component removal, repair, and reinstallation. Rebuilds: Complete engine and transmission rebuild procedures with torque specifications. Wiring Diagrams: Detailed and clear wiring schematics for all electrical systems. Specifications: Torque values, clearances, fluid types, and other critical technical data. Technical Depth Depth: Factory-level detail suitable for both novice mechanics and experienced technicians. Illustrations: Includes pictures and diagrams to aid in understanding complex procedures. Diagnostic Tools: Information on standard tools required and potential diagnostic techniques. ๐ Manual Specifications File Format Format: PDF Compatibility: Windows, macOS, Linux Searchability: Likely searchable text within the PDF for quick information retrieval. Print Quality Quality: Digital reproduction of original factory document, clarity may vary based on original source. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) โ๏ธ Engine Specifications Primary Engine Engine Type: Air-cooled, Evolution V-Twin (commonly known as the 'Evo' engine) Displacement: Typically 1340cc (82 cubic inches) Bore X Stroke: Typically 3.500 in. x 4.250 in. (88.9 mm x 108.0 mm) - requires manual verification for exact spec Compression Ratio: Typically 8.0:1 or 8.5:1 - requires manual verification Performance Horsepower: Approximately 65-70 HP (at crankshaft) - requires manual verification Torque: Approximately 80-85 ft-lbs (at crankshaft) - requires manual verification Fuel System Carburetor: Keihin CV (Constant Velocity) 40mm carburetor Fuel Type: Unleaded gasoline, 87 octane or higher recommended Oil System Oil Type: Harley-Davidson 20W-50 or equivalent motorcycle-specific oil (e.g., Yamalube, Mobil 1 V-Twin) Oil Capacity: Approximately 4 quarts (3.8 liters) with filter change - requires manual verification ๐ง Transmission Standard Type: 5-speed manual constant mesh Clutch: Wet, multi-plate Features Primary Drive: Duplex chain Final Drive: Belt drive Fluid Type Transmission Oil: Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant or equivalent (e.g., Spectro Heavy Duty Primary Oil) ๐ Dimensions Exterior Length: Approx. 96.5 inches (2450 mm) - requires manual verification Width: Approx. 37.0 inches (940 mm) - requires manual verification Height: Approx. 54.0 inches (1370 mm) - requires manual verification Weights Dry Weight: Approx. 745 lbs (338 kg) - requires manual verification Gross Vehicle Weight Rating: Requires manual verification, typically around 1200 lbs (544 kg) for this model Cargo Tour Pak Capacity: Integral to the Ultra Classic, offering significant luggage storage. ๐ก๏ธ Safety Features Ratings Crash Safety: Motorcycle safety is primarily rider-dependent; formal crash ratings are not applicable in the same way as automobiles. Active Features Braking: Front and rear disc brakes with hydraulic actuation. Lighting: Headlight, taillight, brake light, turn signals, and fairing lower spotlights (typical for Ultra Classic). Passive Features Chassis Design: Robust steel frame designed for stability at speed and touring comfort. Wind Protection: Full fairing and windshield provide substantial wind and weather protection for the rider. ๐ก Technology Features Infotainment Audio System: Typically equipped with a factory-installed...
The definitive guide for owners and technicians working on the 1996 Harley-Davidson FLTC-UI Tour Glide-Ultra Classic, offering professional-level repair and maintenance information.
Competitive Analysis
Advantages:
Provides factory-specific procedures, unlike generic repair guides, ensuring accuracy and completeness for all tasks.
Key Features
Accessibility:
Instant digital delivery allows immediate access to repair information, enabling same-day servicing.
User Friendliness:
Designed for ease of use with step-by-step instructions and visual aids, making it suitable for a wide range of skill levels.
๐ Manual Details
Coverage Areas
Overall Coverage:
Comprehensive A-Z coverage for all servicing, repair, and maintenance procedures.
Model Coverage:
All FLTC-UI Tour Glide-Ultra Classic models for the 1996 model year, encompassing all engine types.
Page Count
Estimated Pages:
Likely 500+ pages based on typical factory service manuals for this era and complexity.
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
File Format:
PDF
๐ Manual Coverage
Systems Covered
Engine:
Detailed overhaul, disassembly, assembly, tuning, diagnostics, and repair for all engine components.
Approx. 745 lbs (338 kg) - requires manual verification
Gross Vehicle Weight Rating:
Requires manual verification, typically around 1200 lbs (544 kg) for this model
Cargo
Tour Pak Capacity:
Integral to the Ultra Classic, offering significant luggage storage.
๐ก๏ธ Safety Features
Ratings
Crash Safety:
Motorcycle safety is primarily rider-dependent; formal crash ratings are not applicable in the same way as automobiles.
Active Features
Braking:
Front and rear disc brakes with hydraulic actuation.
Lighting:
Headlight, taillight, brake light, turn signals, and fairing lower spotlights (typical for Ultra Classic).
Passive Features
Chassis Design:
Robust steel frame designed for stability at speed and touring comfort.
Wind Protection:
Full fairing and windshield provide substantial wind and weather protection for the rider.
๐ก Technology Features
Infotainment
Audio System:
Typically equipped with a factory-installed AM/FM stereo radio, often with CB radio and intercom capabilities (depending on original options).
Driver Assistance
Cruise Control:
Cruise control was often an option or standard on Ultra Classic models during this era.
Connectivity
Intercom:
Standard on Ultra models for rider-to-passenger communication, and often connected to the CB radio.
๐ง Maintenance
Service Intervals
Engine Oil Change:
Every 2,500-3,000 miles or 6 months, whichever comes first - requires manual verification.
Primary Chaincase Oil Change:
Every 5,000-6,000 miles or annually - requires manual verification.
Transmission Oil Change:
Every 5,000-6,000 miles or annually - requires manual verification.
Spark Plug Replacement:
Every 10,000-12,000 miles - requires manual verification.
Drive Belt Inspection:
Inspect at every 5,000 miles for wear and tension, adjust as needed. Replacement interval varies significantly with usage.
Fluid Specifications
Engine Oil:
Harley-Davidson 20W-50 or equivalent (refer to manual for exact HD spec).
Primary Lubricant:
Harley-Davidson Formula+ or equivalent (refer to manual for exact HD spec).
Transmission Lubricant:
Harley-Davidson Formula+ or equivalent (refer to manual for exact HD spec).
Brake Fluid:
DOT 4 hydraulic brake fluid.
Fork Oil:
Harmonic Suspension Fluid or equivalent (e.g., Bel-Ray 10W) - requires manual verification for exact type and quantity.
Known Issues
Common Wear Items:
Clutch plates, drive belt, primary chain, brake pads, fork seals, and battery are common wear items.
Evolution Engine Specifics:
While generally robust, some models may experience oil leaks from gaskets or seals; proper torque specifications are critical during rebuilds.
Electrical System Notes:
Wiring harness integrity and connector corrosion can be potential issues on older bikes; the manual's diagrams are crucial for troubleshooting.
๐ Vehicle History
Brand Heritage
Heritage:
Harley-Davidson, an iconic American motorcycle manufacturer with a rich history dating back to 1903, known for its V-twin engines and touring motorcycles.
Model Evolution
Tour Glide Lineage:
The Tour Glide was Harley-Davidson's initial full-dresser touring platform, preceding the Electra Glide's dominance in the touring segment. The FLTC-UI represents a specific iteration with the Evolution engine.
Production
Era:
The 1996 model year falls within the early to mid-production run of the Evolution engine era for Harley-Davidson touring motorcycles.
๐ Awards & Recognition
Recognitions
Brand Awards:
Harley-Davidson motorcycles are consistently recognized for their iconic design, build quality, and rider community, though specific model awards are less common in motorcycle industry comparisons.