2002 Harley-Davidson Touring FLHR, FLHRI, FLHRCI, FLTR, FLTRI, FLHT, FLHTC, FLHTCI, FLHTCUI Service Manual (P/N 99483-02)

This factory manual set covers 2002 Harley-Davidson FLT Touring motorcycles, pairing the main mechanical service information with the separate electrical-diagnostics volume and the Police and FLHRSEI supplements. It is suited to experienced mechanics and technicians equipped for engine, drivetrain, brake, and electrical testing; it is not written as a basic owner's handbook.

• Manual set: a 1,207-page PDF collection - 2002 Touring Models Service Manual P/N 99483-02 (638 pages), Electrical Diagnostic Manual P/N 99497-02 (426 pages), Police Service Supplement P/N 99483-02SP (78 pages), FLHRSEI Service Manual Supplement P/N 99500-02 (64 pages), and a one-page set index.
• Model coverage: FLHR, FLHRI, FLHRCI, FLTR, FLTRI, FLHT, FLHTC, FLHTCI, and FLHTCUI, including identified Shrine and sidecar configurations. Dedicated supplement material covers FLHP-I and FLHTP-I Police models and the FLHRSEI.
• Engine and drivetrain repair: Twin Cam 88 engine removal and installation, top- and bottom-end overhaul, cylinder-head and piston service, cam support plate and oil-pump work, starter repair, primary drive and clutch service, final-drive belt setup, and transmission disassembly and reassembly.
• Chassis procedures: wheel lacing and truing, cast-rim runout checks, vehicle alignment, master-cylinder and caliper repair, hydraulic brake bleeding, fork and steering-head service, rear air suspension, swingarm work, fairings, saddlebags, Tour-Pak, and exhaust removal and installation.
• Electrical fault isolation: starter and charging tests, instruments and speedometer checks, TSM/TSSM security diagnosis, carbureted and EFI engine-management DTC paths, premium sound-system diagnostics, cruise-control dropout charts, and repair validation.
• Schematics and connector service: model-specific main, interconnect, ignition, engine-sensor, starting/charging, lighting, instrument, and audio wiring diagrams; connector-location views; and terminal repair for Deutsch DT, Amp Multilock, Packard, sealed butt-splice, and Amp connectors.

Mechanical Service and Overhaul Depth

Beyond scheduled maintenance, the Service Manual carries Twin Cam 88 repair through motorcycle strip-down, engine removal, top- and bottom-end overhaul, and reassembly. Manufacturing tolerances, wear limits, and special-tool references support work on the rocker gear, lifters, cylinders, pistons, cam support plate, oil pump, crankcase, and flywheel/connecting-rod assembly. Carbureted fuel-system service and EFI tank, sensor, electrical-bracket, and induction-module procedures are kept in distinct sections.

The manual warns that the high-output rotor requires Rotor Remover/Installer and Shaft Protector Sleeve HD-41771 because its stronger magnets can damage parts. Primary-chaincase bearing work calls for correct casting support and the seal protector supplied with HD-41405; poor support can crack the case, while exposed mainshaft splines can cut the lip seal.

Electrical Diagnosis, Module Setup, and Wiring

The Electrical Diagnostic Manual supplies the fault-isolation paths referenced by the mechanical chapters. Starting and charging coverage includes voltage-drop, relay, solenoid, assembled-starter, battery-load, regulator-output, and stator checks. Its test tables distinguish standard- and high-output charging applications by model.

Instrument diagnosis covers gauges, speedometer trouble codes, and speedometer performance testing. Fuel-level sender testing separates the 7-95 ohm range used on FLHT/C/U and FLTR models from the 27-260 ohm FLHR/C range. The tester procedure checks speedometer operation, but the manual expressly states that it does not verify or certify calibration.

TSM/TSSM material covers key-fob assignment, personal codes, alarm sensitivity, transport and storage modes, solo/sidecar configuration, DTC diagnosis, module setup, and TSM/TSSM-to-ECM password learning with or without the Scanalyzer. Referenced equipment includes Scanalyzer HD-41325 with cartridge HD-41325-95C, Harness Connector Test Kit HD-41404, and breakout boxes HD-42682 and HD-43876.

Named visual references include the ECM Power Circuit diagrams for FLHR/C-I and FLTR-I/FLHTC/U-I, Turn Signal Circuit: FLHR/I/CI, Cruise Engaged Lamp Dropout Code Timing Diagram, radio Diagnostic Mode Group matrices, and Headlamp Nacelle and Inner Fairing connector views. Separate sheets cover TLE and TLE Ultra sidecar chassis and audio harnesses.

Special-Model Supplements and Scope

The Police supplement adds the FLHP-I/FLHTP-I maintenance, chassis, strobe lighting, pole lamp, siren/public-address system, air horn, Police Tour-Pak, connector locations, and wiring diagrams; its wiring sheets also identify FLHPE-I. The FLHRSEI supplement separates the 95 cu. in. engine specifications, tolerances, and wear limits from the Twin Cam 88 data and adds model-specific chassis, trim, instrument-console, turn-signal, and tachometer procedures. Both supplements rely on the main Service Manual for systems not unique to those models.

This set does not include a parts catalog. Harness part numbers printed on some schematics are identified as reference-only, and the manuals direct parts ordering to the appropriate catalog.

High-current electrical tests, fuel-system work, and major disassembly require the exact isolation and test setup stated in the manuals. Disconnect the negative battery cable before disassembly; when a powered test is specified, use properly rated equipment and the prescribed connections to avoid shorts, component damage, fuel ignition, or accidental cranking.