This highly detailed repair manual covers all repairs, servicing and troubleshooting procedures. All technical details taken directly from the manufacturer can be found in this manual, It is the factory manual from the manufacturer. 1999-2005 Harley-Davidson FLH/FLT TWIN CAM 88 & 103 service repair manual is the same manual used by professional technicians, mechanics and workshops around the world.
1999-2005 Harley-Davidson FLH/FLT TWIN CAM 88 & 103 service repair manual has easy-to-read text sections with top quality diagrams and instructions, will guide you through fundamentals of maintaining and repairing, step-by-step, to teach you what the factory trained technicians already know by heart. For that reason, you will not find it difficult to repair or to maintain some of the innovative features loaded on the vehicle when you have the manual. Using this repair manual is the true way to keep your vehicle working properly.
FLHT/FLHTI Electra Glide Standard (1999-2005)
FLHTC/FLHTCI Electra Glide Classic (1999-2005)
FLHTCUI Electra Glide Ultra Classic (1999-2005)
FLHTCSE2 Screamin’ Eagle Electra Glide 2 (2005)
FLHR/FLHRI Road King (1999-2005)
FLHRCI Road King Classic (1999-2005)
FLHRS/FLHRSI Road King Custom (2004-2005)
FLTR/FLTRI Road Glide (1999-2005)
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Basic tools / Special tools / Precision measuring tools / Electrical system fundamentals / Basic service methods / Storage / Specifications
CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Engine starting / Engine performance / Starting system / Charging system / Ignition system / Engine management system diagnostic codes / Cruise control system diagnostic codes / Fuel system (carbureted models) / Fuel system (fuel injected models) / Engine noises / Engine lubrication / Clutch / Transmission / Lighting system / Excessive vibration / Front suspension and steering / Brake system / Specifications
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Maintenance schedule intervals / Periodic lubrication / Engine oil change / Transmission oil change / Periodic maintenance / Control cables / Tune-up / Idle speed adjustment / Specifications
CHAPTER FOUR / ENGINE
Removal installation / Rocker arms and pushrods / Cylinder head / Valves and components / Cylinder / Piston and rings / Pushrods / Valve lifters / Oil pump / Camshaft support plate / Crankcase and crankshaft / Break-in / Specifications
CHAPTER FIVE / CLUTCH AND PRIMARY DRIVE
Primary chaincase cover / Clutch shell, compensating sprocket and primary drive chain / Clutch shell, clutch hub and sprocket / Primary chain and guide / Compensating sprocket / Primary chaincase housing / Starter jackshaft / Clutch cable / Specifications
CHAPTER SIX / TRANSMISSION
Shifter assembly / External shift mechanism / Transmission top cover / Shift cam / Shift arm assembly / Shift forks / Transmission side door and transmission shaft / Transmission shafts / Main drive gear / Transmission clutch release cover assembly / Transmission drive sprocket / Transmission case / Oil pan / Specifications
CHAPTER SEVEN / FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS
Air filter backplate / Carburetor operation / Carburetor / Intake manifold (carbureted models) / Electronic fuel injection (EFI) / Depressurizing the fuel system / (fuel injected models) / Induction module (fuel injected models) / Throttle and idle cables (carbureted models) / Starting enrichment valve (choke) / cable replacement (carbureted models) / Throttle and idle cables (fuel injected models) / Fuel tank console / Fuel tank (carbureted models) / Fuel tank (fuel injected models) / Fuel pump and fuel filter (fuel injected models) / Fuel shutoff valve (carbureted models) / Fuel tank gauge (FLHR) / Exhaust system / Evaporative emission control system (California models) / Specifications
CHAPTER EIGHT / ELECTRICAL SYSTEM
Basic information / Battery / Charging system / Alternator / Voltage regulator / Ignition system / Starting system / Lighting system / Switches / Horn / Turn signal module (1999-2000 models) / Turn signal module and turn signal/security / module (2001-on models) / Speedometer speed sensor / Starter relay switch replacement / Instruments / Premium sound, CB and intercom systems / Fuses / Circuit breaker / Electrical connector service / Wiring diagrams / Specifications
CHAPTER NINE / WHEELS, HUBS AND TIRES
Motorcycle stands / Front wheel / Rear wheel / Front and rear hubs (1999) / Front and rear wheel bearing end play check (1999 models) / Front and rear hubs (2000-on) / Driven sprocket assembly / Drive sprocket / Drive belt / Wheel runout / Rim and laced wheel service / Cast wheels / Wheel balance / Tires / Tubeless tire changing / Tire repairs / Motorcycle alignment / Specifications
CHAPTER TEN / FRONT SUSPENSION AND STEERING
Handlebar / Front fork—non-cartridge type (all 1999-2001 models and 2002 FLHR, / FLHRI and FLHRCI (right side only) / Front fork air pressure adjustment (1999-2001 models) / Front fork—cartridge type (2002 models except 2002 FLHR, FLHRI and FLHRCI right side) / Steering head and stem / Steering head bearing race replacement / Steering play adjustment / Specifications
CHAPTER ELEVEN / REAR SUSPENSION
Shock absorbers / Shock air pressure adjustment / Rear swing arm / Specifications
CHAPTER TWELVE / BRAKES
Brake service / Front brake pad replacement / Front brake caliper / Front master cylinder / Rear brake pad replacement / Rear brake caliper / Rear master cylinder and rear brake pedal / Brake hose and line replacement / Brake disc / Bleeding the system / Rear brake pedal / Specifications
CHAPTER THIRTEEN / CRUISE CONTROL
System components and operation / Control cables / Cruise control module / Switches / Specifications
CHAPTER FOURTEEN / BODY
Seat / Front and rear fender / Windshield and headlight nacelle / Front fairing / Saddlebags and guards / Tour-pak / Footboards / Specifications
SUPPLEMENT / 2003-2005 MODEL SERVICE INFORMATION
Routine safety checks / Periodic lubrication / Periodic maintenance / Engine / Rocker arm and pushrods / Cylinder head / Valve and valve components (2005 models– / except FLHTCSE2 models) / Pistons and piston rings / Oil cooler, oil filter mount and thermostat / (FLHTCSE2 models) / Crankcase and crankshaft / Clutch assembly (all 2005 models) / Clutch assembly (FLHTCSE2 models) / Clutch release bearing and pushrod / (FLHTCSE2 models) / Clutch service (FLHTCSE2 models) / Clutch master cylinder (FLHTCSE2 models) / Clutch release mechanism (FLHTCSE2 models) / Clutch hydraulic hose replacement / (FLHTCSE2 models) / Clutch system flushing (FLHTCSE2 models) / Clutch system bleeding (FLHTCSE2 models) / Shifter assembly (FLHTCSE2 models) / External shift mechanism (FLHTCSE2 models) / Shift arm assembly (all models) / Shift linkage adjustment (all models) / Transmission side door and transmission / shaft assemblies / Fuel tank console / Fuel tank (carbureted models) / Fuel tank (fuel injected models) / Charging system (FLHTCSE2 models) / Alternator (FLHTCSE2 models) / Ignition system (2004-2005 carbureted models) / Lighting system / Switches / Instruments (FLHTSCE2 and all FLHT models) / Maxi-fuse replacement (2004-2005 models) / Front wheel / Front and rear hubs / (FLHTCSE2 and 2004-2005 models) / Front fork–cartridge type / Steering head and stem / Shock absorbers / Front brake pad replacement / Rear brake pad replacement / Rear master cylinder and rear brake pedal / Brake disc (FLHTCSE2 models) / Rear brake pedal (2004-2005 models) / Passenger backrest (FLHTCSE2 models) / Headlight and nacelle / (2004-2005 FLHR models) / Lower fairing / (FLHTCSE2 and 2005 FLHTCUI models / Saddlebags and guards / Footboards / Specifications
COLOR WIRING DIAGRAMS
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