Harley-Davidson Touring 2003 Service Manual Set (P/N 99483-03A)

The service manual supplies the base repair procedures, while Electrical Diagnostics provides the system tests and fault charts referenced by those procedures. The Police and FLHRSEI2 supplements add model-specific differences and are used with the base manual.

Searchable Sections, Bookmarks and Wiring Detail

Text access and diagram detail: The technical-section PDFs and shared contents PDF have searchable text and embedded bookmarks. Separate section-contents PDFs have linked entries but no embedded bookmarks; blank pages have no searchable text. Dense wiring sheets require zooming to read small pin numbers, connector identifiers, and wire-color codes.

The ZIP download contains 77 printable PDFs totaling 1,273 pages. Included in that total are the appendices, 72 pages in separate section-contents/reference files (including 26 blank pages), and a one-page shared contents file.

Touring Overhaul, Electrical Diagnosis and Special-Model Service

The following highlights are a selection of the included procedures, rather than a complete contents list. Other topics include evaporative-emissions system checks and electrical-terminal crimping and repair.

• Engine repair: Step-by-step engine removal and installation, top-end and bottom-end overhaul, cylinder-head work, piston inspection, cam-drive service, and lubrication-system repair.

• Chassis and brakes: Wheel removal, lacing and truing, vehicle alignment, master-cylinder and caliper rebuilding, hydraulic brake bleeding, fork service, and steering-head bearing work.

• Primary drive and transmission: Primary-chain and sprocket service, clutch repair, secondary-belt replacement, shifter components, mainshaft/countershaft disassembly, and main-drive-gear service.

• Fuel-system service: Carburetor disassembly and adjustment, fuel-valve and tank service, EFI fuel-pump replacement, induction-module work, injector service, and fuel-pressure diagnosis.

• Electrical troubleshooting: Starting and charging tests, instrument checks, TSM/TSSM diagnosis, carbureted/EFI fault charts, connector pin tables, wiring diagrams, sound-system testing, and cruise-control troubleshooting.

• Special-model procedures: Police lighting, siren/PA and chassis service, plus FLHRSEI2 oil-cooler, thermostat, hydraulic clutch, starter, drive, and transmission differences.

This material suits technicians and experienced owners comfortable with internal engine work and circuit diagnosis; the procedures call for workshop measuring equipment and dedicated service tools.

Engine Overhaul and Drivetrain Repair

Engine configurations: The base manual covers the air-cooled, 45-degree Twin Cam 88 at 88 cu. in. / 1450 cc, with 9.0:1 compression and a 5,500 rpm maximum sustained engine speed. The FLHRSEI2 supplement documents its separate 103 cu. in. / 1690 cc engine and 5,800 rpm maximum sustained speed.

Internal engine work: Cylinder-head procedures extend to valve-guide replacement and valve/seat refacing. Piston, cam-drive and bearing work is supported by manufacturing tolerances, service wear limits, and lubrication-system information.

Flywheel/connecting-rod coverage includes removal, inspection, and assembly replacement. Where the flywheels, connecting rods, or right-side bearing inner race need replacement, the manual specifies replacing the complete flywheel assembly.

Drive and gearbox: The transmission chapter combines power-flow explanations and wear-limit tables with internal shaft and gear work. Primary-chaincase, transmission-case and oil-pan procedures include removal and installation, with related bearing and seal service. The repair sections let you plan major work around the required inspections, wear limits, and service tools.

The camshaft-removal cautions address support-plate and bearing-retainer damage from separating shafts from their bearings, while the primary-chaincase instructions flag lip-seal damage from mainshaft splines when the specified protector is omitted.

Brake, Suspension and Bodywork Service

Chassis procedures include scheduled maintenance, 16-inch wheel lacing and truing, vehicle alignment, brake master-cylinder and caliper disassembly, and hydraulic brake bleeding. Front-fork, steering-head bearing, rear air-suspension and swingarm sections cover inspection, adjustment, and component service.

Control cables, handlebars, fairings, windshields, headlamp nacelles, saddlebags, Tour-Pak assemblies, and exhaust components have removal and installation information. Starter coverage includes the motor, solenoid, and jackshaft.

Carburetor and EFI Fuel Systems

The carburetor material includes enrichener and vacuum-operated fuel-valve service. EFI procedures distinguish fuel-rail and injector work from removal of the complete induction module, with separate electrical-bracket and sensor service information.

The fuel-pump instructions warn that hinge removal damages the hinge and requires replacement of the fuel-pump/bracket assembly, making fault confirmation important before that assembly is disturbed.

Starting, Instruments and Engine-Management Diagnostics

Power and instruments: Starting and charging diagnosis distinguishes low-output and high-output charging systems, with starter-current, stator-grounding, stator-resistance, and AC-output tests. Instrument sections cover speedometer performance, warning and indicator circuits, fuel gauge, oil-pressure indication, tachometer, and related harness checks.

Carbureted and EFI systems: Separate diagnostic paths address crank-no-start, starts-then-stalls, ignition-module or ECM power, and misfire conditions. EFI fault charts cover the system relay, injectors, IAC, MAP, IAT, engine-temperature, throttle-position, crank-position and vehicle-speed sensors, ignition coil, low-fuel indication, battery voltage, ECM, security-password, and serial-data faults.

Security, Sound System and Cruise Control

TSM/TSSM coverage includes key-fob assignment, five-digit personal security-code entry, arming/disarming, sidecar configuration, bank-angle operation and calibration, password learning with the engine-management system, breakout-box testing, and separate carbureted/EFI trouble-code mappings.

Premium Sound System diagnostics combine onboard diagnostic displays with symptom-based software and hardware flowcharts. Audio, CB/intercom, headset and microphone faults are covered, along with separate cruise-control charts for inoperative or dropout conditions.

Wiring Sheets and Factory Test Equipment

The base Touring wiring section contains 12 schematic pages, repeated in Electrical Diagnostics; the Police supplement adds 12 police-specific wiring pages. Connector-location views and pin-function tables accompany the circuit information.

Engine and power circuits: Sheets include “Ignition Harness, Engine Sensor Harness and Engine Management Circuitry” and “Starting and Charging.”

Controls and audio: Examples include “Handlebar Controls, Speedometer, Tachometer, Indicator Lamps and Dash Panel Switches” and “Radio, CB/Intercom and Rear Speakers.”

Road King and sidecar wiring: FLHR/FLHRC “Main Harness” sheets are included, along with a TLE/TLE-U sidecar “Chassis and Audio Harness” schematic. The sidecar sheet provides electrical coverage; it is not a mechanical sidecar repair section.

Diagnostic equipment: Tool references include the HD-41325D Scanalyzer with HD-41325-95C diagnostic cartridge, HD-42682 carbureted/TSM breakout box, HD-43876 EFI breakout box, and HD-42376 battery/charging-system load tester.

Mechanical and fuel-system tools: The procedures identify the HD-41182 fuel-pressure gauge with HD-44061 adapters and the HD-43644 camshaft/camshaft-bearing remover/installer. These references identify the dedicated equipment used by the corresponding factory procedures.

Electrical and fuel-system work requires the isolation, live-test, and fuel-pressure precautions specified for the individual procedure.

Police Equipment and FLHRSEI2 Differences

Police equipment: The supplement covers strobe headlamp and PAR-36 equipment, pole lamp, siren/PA, speaker, handlebar controls, air horn, and Tour-Pak electrical work. Its chassis material addresses police-specific seat, footboard, luggage-rack and instrument-bracket service.

FLHRSEI2: The supplement adds engine specifications and wear limits, factory thermostat-controlled oil-cooler service, hydraulic clutch master cylinder and fluid line, secondary clutch actuator, and model-specific chassis work. Starter, drive and transmission differences, instruments, and turn signals are also documented.

Examples of Charging, Fuel-Pressure and Sender Test Data

Charging checks: Low-output systems specify 34-40 amps and high-output systems 41-48 amps at 3,000 rpm with the test load adjusted to 13.0 volts. The stator-socket resistance check specifies less than 0.5 ohm.

EFI fuel pressure: The fuel-pressure test specifies 55-62 psi (380-425 kPa), remaining steady as engine speed changes.

Fuel-gauge diagnosis: Sender checks distinguish approximately 7-95 ohms for FLHT/C/U and FLTR from 27-260 ohms for FLHR/C, with separate full- and empty-tank readings.