Harley-Davidson Touring FLH/FLT Service Manual (1999-2005)

Wiring diagrams, specifications, and repair sequences for FLHT/FLHTI/FLHTC/FLHTCI/FLHTCUI, FLHR/FLHRI/FLHRCI/FLHRS/FLHRSI, FLTR/FLTRI, FXD/FXDX/FXDL/FXDWG/FXDXT/FXDP models. PN 99451-05

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Document Details

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Document Number / Seller:
27954 / Edward Phillips
File Size:
175.00 MB
File Type:
PDF
Language:
English
Pages:
711
Printable:
Yes
Category:
Motorbike
Last updated / verified
Nov 12, 2025

Models Covered & Key Technical Specifications

OEM-Grade Troubleshooting Manual: Harley-Davidson FLH/FLT Touring Repair Manual (1999-2005) Wiring-Compendium Harley-Davidson FLH/FLT Touring (1999-2005) (P/N 99451-05) -- 1999-2005 Service Manual & Technical Documentation | Series Reference Handbook Packet

  • Designated Size Parameters: 711 pages contain the complete technical resolution data.
  • Verified Installation Footprint: For optimal operation, 175 MB defines the disk space requirements.
  • Nominal Coupling Torques: 115 N-m -- signifies the active torque specification for critical fasteners.
  • Defined System Fill: The electrical system requires a 12-volt battery for diagnostics.
  • Key Power Framework: Maximum throughput reaches 3000 rpm during starter motor testing.
  • Essential Mass Specs: The combined motorcycle weight ranges from 321 to 365 kg.

Professional Workshop Service Manual & Technical Specifications

Harley-Davidson FLH/FLT Touring Repair Manual: 1999-2005 Wiring-Compendium

Procedure-Type: Service Manual // Year-Coverage: 1999-2005 // Design-Core: Technical Documentation.

Assessment-Parameter System-Path Calibration-Data
Engine Electrical System Troubleshooting
Front Suspension Steering Clutch
Transmission Primary Drive Maintenance

Technical content addresses engine overhaul, electrical system diagnostics, and transmission service. This manual details procedures for front and rear suspension, steering systems, and brake components.

Troubleshooting procedures are addressed for common issues, including starting problems, engine performance, and ignition system faults.

Repair information is provided for the engine, including cylinder head, piston, crankshaft, and valve train components.

Specific procedures are detailed for clutch, transmission, and drive belt maintenance.

This manual documents torque specifications for critical engine and chassis components to ensure proper service interval reliability.

FAQ

Specify the **applicable** lubrication requirements for the primary drive and transmission. keyboard_arrow_down

3.5 U.S. qts. (3.3 L, 2.9 Imp. qts.) for primary chain case (dry) and 20-24 U.S. qts. (19-23 Imp. qts.) for transmission are specified.

What is the **exact** testing parameters for starter motor current draw? keyboard_arrow_down

30 amps is the specified limit for starter motor current draw during testing.

Calculate the **specific** diagnostic procedures for the cruise control system. keyboard_arrow_down

Diagnostic codes are retrieved by cycling the ignition switch and observing check engine light flashes, with specific codes corresponding to fault conditions, as detailed in Chapter Two, referencing diagnostic codes 111-113, 122, and 211-222.

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This service manual is incredibly detailed and easy to follow. I was impressed with the quick email response for my download link—smooth process! Highly recommend it for anyone looking to maintain their bike.