Harley Davidson Touring 1999-2005 Service Repair Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: Touring Applicable Model Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005 👋 Introduction Market Position Target Audience: Harley-Davidson Touring motorcycle owners and independent repair shops seeking to perform DIY maintenance and repairs. Competitive Analysis Value Proposition: Offers a cost-effective alternative to dealership service, empowering owners with the knowledge to maintain and repair their motorcycles, saving money and fostering self-sufficiency. Key Features Manual Benefits: • Empowers DIY repairs • Reduces repair costs • Provides detailed step-by-step instructions • Includes clear diagrams for visual guidance • Covers a wide range of model years and specific touring variants 📋 Manual Details Coverage Areas Covered Models: • Harley Davidson FLHT Electra Glide Standard • Harley Davidson FLHTC Electra Glide Classic • Harley Davidson FLHTCI Electra Glide Classic • Harley Davidson FLHTCU Ultra Classic Electra Glide • Harley Davidson FLHTCUI Ultra Classic Electra Glide • Harley Davidson FLHTCSE Screamin' Eagle Electra Glide • Harley Davidson FLHR Road King • Harley Davidson FLHRC Road King Classic • Harley Davidson FLHRCI Road King Classic • Harley Davidson FLHRS Road King Custom • Harley Davidson FLHRSI Road King Custom • Harley Davidson FLHT Trike (where applicable) Page Count Estimated Page Count: 500+ Manual Type Type: Service and Repair Manual Language Language: English Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Primary Systems: • Engine Mechanical • Fuel System • Ignition System • Exhaust System • Emission Control Systems • Clutch and Primary Drive • Transmission • Electrical System • Chassis • Suspension (Front & Rear) • Steering • Brakes • Wheels, Hubs, and Tires • Bodywork and Trim • Cruise Control • Troubleshooting • Lubrication and Maintenance Procedures Included Repair And Maintenance: • General Maintenance and Inspections • Engine Overhaul and Rebuilding • Transmission Service and Repair • Clutch Adjustment and Replacement • Fuel System Diagnostics and Servicing • Ignition System Troubleshooting • Brake System Maintenance and Bleeding • Suspension Component Replacement • Steering Head Bearing Service • Electrical System Diagnostics and Wiring Repair • Component Removal and Installation • Torque Specifications for all major fasteners • Troubleshooting guides for common problems • Tune-up procedures Technical Depth Depth Of Information: Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, with detailed diagrams and step-by-step instructions. 📊 Manual Specifications File Format Compatibility: All Versions of Windows & Mac Reader Requirement: Adobe PDF Reader Print Quality Digital Quality: High-resolution, clear text and diagrams suitable for viewing and printing. Binding Type Binding: Digital Download (PDF) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Family: Harley-Davidson Twin Cam 88 / 88B (for most models 1999-2006) Engine Variants Engine Displacement: 1450cc (88 cubic inches) Engine Configuration: V-twin, 45-degree cylinder angle, air-cooled Performance Bore X Stroke: 3.75 in. x 4.00 in. (95.25 mm x 101.6 mm) Compression Ratio: 8.5:1 (typical) Horsepower And Torque: Specifications vary by specific model and tuning, but typically in the range of 65-75 HP and 75-85 lb-ft of torque. Fuel System Fuel Delivery: Carburetor (Keihin CV) or Electronic Fuel Injection (EFI) depending on model and year. The manual will cover both. Fuel Type: Unleaded gasoline, minimum 87 octane Lubrication Oil Type: Harley-Davidson 20W50 motorcycle oil (or equivalent API SG or higher specification) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh, manual Optional Optional Gearbox: N/A for this period's touring models. Features Primary Drive: Duplex chain, wet clutch Final Drive: Belt drive Fluid Specifications Transmission Oil: Harley-Davidson Formula+ (or equivalent GL-4 75W90 synthetic gear oil) 📐 Dimensions Exterior Wheelbase: Approx. 63.5 inches (1613 mm) Length: Approx. 93.1 inches (2365 mm) Weights Dry Weight: Approx. 750-800 lbs (340-363 kg), depending on model Gross Vehicle Weight Rating Gvwr: Approx. 1200-1300 lbs (544-590 kg) 🛡️ Safety Features Ratings Crash Test Results: N/A (Motorcycle safety is assessed differently than automobiles, focusing on handling, braking, and rider protection equipment). Active Features Braking System: Dual disc front brakes, single disc rear brake. ABS was an optional feature on some models. Suspension: Air-adjustable rear suspension on many touring models for adjustable ride height and load capacity. Passive Features Lighting: Halogen headlamp, integrated turn signals, and brake lights. 💡 Technology Features Infotainment Audio System: Many Touring models from this era featured premium audio systems, often with cassette or CD players, and fairing-mounted speakers. Later models integrated MP3/auxiliary inputs. Display Technology: Analog gauges with digital odometer and trip meter. Some advanced models may have LCD displays for auxiliary information. Driver Assistance Cruise Control: Electronically controlled cruise control was a standard or optional feature on many Touring models, detailed within the manual. Connectivity Auxiliary Inputs: Some models may have auxiliary audio inputs for connecting external music players. 🔧 Maintenance Service Intervals First Service: Typically at 1,000 miles (1600 km) for oil change, filter, primary chain adjustment, and general inspection. Subsequent Oil Changes: Every 2,500 to 5,000...
Harley-Davidson Touring motorcycle owners and independent repair shops seeking to perform DIY maintenance and repairs.
Competitive Analysis
Value Proposition:
Offers a cost-effective alternative to dealership service, empowering owners with the knowledge to maintain and repair their motorcycles, saving money and fostering self-sufficiency.
Key Features
Manual Benefits:
• Empowers DIY repairs
• Reduces repair costs
• Provides detailed step-by-step instructions
• Includes clear diagrams for visual guidance
• Covers a wide range of model years and specific touring variants
Approx. 750-800 lbs (340-363 kg), depending on model
Gross Vehicle Weight Rating Gvwr:
Approx. 1200-1300 lbs (544-590 kg)
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (Motorcycle safety is assessed differently than automobiles, focusing on handling, braking, and rider protection equipment).
Active Features
Braking System:
Dual disc front brakes, single disc rear brake. ABS was an optional feature on some models.
Suspension:
Air-adjustable rear suspension on many touring models for adjustable ride height and load capacity.
Passive Features
Lighting:
Halogen headlamp, integrated turn signals, and brake lights.
💡 Technology Features
Infotainment
Audio System:
Many Touring models from this era featured premium audio systems, often with cassette or CD players, and fairing-mounted speakers. Later models integrated MP3/auxiliary inputs.
Display Technology:
Analog gauges with digital odometer and trip meter. Some advanced models may have LCD displays for auxiliary information.
Driver Assistance
Cruise Control:
Electronically controlled cruise control was a standard or optional feature on many Touring models, detailed within the manual.
Connectivity
Auxiliary Inputs:
Some models may have auxiliary audio inputs for connecting external music players.
🔧 Maintenance
Service Intervals
First Service:
Typically at 1,000 miles (1600 km) for oil change, filter, primary chain adjustment, and general inspection.
Subsequent Oil Changes:
Every 2,500 to 5,000 miles (4000 to 8000 km), depending on riding conditions and oil used, as detailed in the manual.
Other Maintenance Items:
Includes spark plug replacement, transmission and primary fluid checks/changes, brake fluid checks/flushes, belt inspection/tensioning, and filter replacements at specific intervals outlined in the manual.
Fluid Specifications
Engine Oil Capacity:
3.5 quarts (3.3 liters) with filter change.
Transmission Oil Capacity:
Approximately 24 fluid ounces (0.7 liters).
Primary Chain Case Oil Capacity:
Approximately 28 fluid ounces (0.8 liters).
Known Issues
Common Wear Items:
• Primary chain tensioner wear (especially early models)
• Crankcase oil leaks
• Headpipe exhaust leaks
• Wheel bearings
• Brake pad wear
Diagnostic Support:
The manual's troubleshooting section is crucial for diagnosing and addressing these and other potential issues.
📚 Vehicle History
Brand Heritage
Brand Origin:
Harley-Davidson Motor Company, founded in Milwaukee, Wisconsin, USA in 1903. Known for its iconic V-twin engines and cruiser motorcycles.
Model Evolution
Touring Lineage:
The Touring line represents Harley-Davidson's commitment to long-distance comfort and touring capabilities, evolving from earlier Dressers and Electra Glides. The introduction of the Twin Cam 88 engine in 1999 marked a significant modernization.
Production
Manufacturing Locations:
Primarily Milwaukee, Wisconsin, USA, and York, Pennsylvania, USA.
🏆 Awards & Recognition
Recognitions
Industry Standing:
Harley-Davidson Touring motorcycles of this era are celebrated for their comfort, touring capability, and distinctive American style. They are consistently top sellers in the large-displacement touring segment.
Ratings
Rider Satisfaction:
High rider satisfaction for long-distance comfort and customization potential. While specific awards are rare for individual model years, the platform has a loyal following.