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

The Service Manual provides the mechanical repair procedures, while the Electrical Diagnostic Manual supplies the corresponding fault-isolation paths. Both supplements rely on the main manual for systems not unique to their models.

Parts ordering: A parts catalog is not included. Harness part numbers on the schematics are reference-only; the manuals direct parts ordering to the appropriate catalog.

Searchable Chapter PDFs and Wiring Detail

Text search and chapter navigation: All 74 PDFs contain searchable text. Embedded bookmarks are present in the service and diagnostic chapter/appendix files, Police content files, and collection index; the FLHRSEI files and separate chapter contents files have none. Dense wiring sheets need zooming for small connector numbers and wire-color codes.

The index’s Service Manual appendix link opens the electrical connector contents sheet. The service appendices for tools, connectors/wiring, and conversions are supplied separately.

The ZIP contains 74 printable PDFs totaling 1,207 pages, divided into chapter, appendix, and contents files. That total includes 70 separate contents/reference pages, including 34 blank reverse pages, plus 28 notes pages and the one-page collection index.

Engine Overhaul, Chassis Service, and Electrical Fault Isolation

These coverage highlights are a selection, not a complete table of contents. Other topics include engine-oil/filter service and road-test checks.

• Engine repair: Step-by-step Twin Cam 88 top- and bottom-end overhaul, engine removal and installation, cylinder-head and piston service, cam support plate work, and oil-pump service.

• Starter and drivetrain: Starter repair, primary-chain and clutch service, final-drive belt setup, and transmission disassembly, inspection, and reassembly.

• Chassis and brakes: Wheel lacing and truing, cast-rim runout checks, vehicle alignment, master-cylinder and caliper repair, hydraulic bleeding, forks, steering-head bearings, rear air suspension, and swingarm service.

• Bodywork and exhaust: Removal and installation procedures for fairings, saddlebags, Tour-Pak components, and the exhaust system.

• Electrical diagnosis: Starting and charging tests, gauges and speedometer checks, TSM/TSSM security diagnosis, carbureted and EFI DTC paths, premium sound-system diagnostics, cruise-control dropout charts, and repair validation.

• Schematics and connector repair: Main, interconnect, ignition, engine-sensor, starting/charging, lighting, instrument, and audio diagrams; connector-location views; Deutsch DT, Amp Multilock, Packard, sealed butt-splice, and Amp terminal service.

This material is suited to experienced mechanics and technicians equipped for engine, drivetrain, brake, and electrical testing; it is not a basic owner’s handbook.

Mechanical Service and Overhaul Depth

Manufacturing tolerances, wear limits, and special-tool references extend the overhaul coverage to the rocker gear, lifters, crankcase, and flywheel/connecting-rod assembly.

Fuel systems: Carburetor disassembly, enrichener adjustment, and vacuum-operated fuel-valve checks are separate from EFI tank, sensor, electrical-bracket, fuel-pump, and induction-module procedures. EFI diagnosis includes fuel-pressure testing and idle-air-control fault isolation.

The high-output rotor’s stronger magnets can cause parts damage; its removal and installation procedures specify Rotor Remover/Installer and Shaft Protector Sleeve HD-41771. Primary-chaincase bearing work warns that inadequate casting support can crack the case, while exposed mainshaft splines can damage the lip seal without the protector supplied with HD-41405.

Electrical Diagnosis, Module Setup, and Wiring

Choosing the test path: Voltage-drop, relay, solenoid, and assembled-starter checks help distinguish circuit faults from starter or drivetrain problems. Charging tables distinguish standard- and high-output applications by model.

Instrument testing: Fuel-level sender diagnosis uses separate model-specific resistance ranges. Speedometer coverage includes trouble codes and performance checks, but the tester procedure does not verify or certify calibration.

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

Named references include 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.

Police Equipment and FLHRSEI Differences

The Police supplement adds maintenance and chassis information, strobe lighting, pole lamps, siren/public-address diagnosis, air horns, Police Tour-Pak installation, connector locations, and wiring. Its wiring sheets also identify FLHPE-I.

The FLHRSEI supplement supplies engine-specific specifications, tolerances, and wear limits, along with chassis, trim, instrument-console, turn-signal, and tachometer procedures.

High-current electrical tests, fuel-system work, and major disassembly require the isolation and test setup stated in the manuals. Their precautions address negative-battery-cable isolation, powered-test connections, shorts, fuel ignition, and accidental cranking.

A Preview of Charging-System Test Values

The diagnostic charging table lists alternator stator-coil resistance at 0.1–0.3 ohms and regulator voltage output at 14.4–14.6 volts at 3,000 rpm. Separate model rows distinguish standard- and high-output charging applications.