2004 Harley-Davidson Touring Service Manual
Harley-Davidson Models Covered & Key Technical Specifications
Models: Road Glide, Electra Glide, Road King, Screamin Eagle, Ultra Classic, FLHR, FLHRI, FLHRCI, FLHRS, FLHRSI, FLHT, FLHTI, FLHTC, FLHTCI, FLHTCUI, FLTR, FLTRI
Sub-models / Variants: EFI models, Carbureted models, FLHR/C/S, FLTR, FLHT/C/U
Model Years: 2004
Technical Data:
- Battery CCA rating: 300 CCA
- Typical charging system output: 34–40 amperes (Low Output), 41–48 amperes (High Output)
- Starter current draw range: 160–200 amperes
- Battery voltage (fully charged): 12.8V
- Fuel sender resistance (FLHT/C/U, FLTR): 7–14 ohms (full), 30–38 ohms (half), 74–95 ohms (empty)
- Fuel sender resistance (FLHR/C/S): 27–40 ohms (full), 97–118 ohms (half), 240–264 ohms (empty)
- AC charging output (Low Output): 16–20 VAC per 1000 RPM
- AC charging output (High Output): 19–26 VAC per 1000 RPM
Harley-Davidson Manual Features & Content Preview
- Covers 2004 Harley-Davidson Touring models, including Road King, Electra Glide, and Road Glide variants with EFI or carbureted fueling systems.
- Official 78-page OEM workshop publication (part number 99483-04) documenting engine, chassis, and electrical specifications for the complete build.
- Documents electrical circuits with 22 comprehensive wiring diagrams, diagnostic flow charts, and component connector tables essential for accurate repair planning.
Diagnostic Coverage and Electrical Systems
Working on the electrical backbone of a Touring platform requires precise data. This manual delivers deep-dive documentation on the starting, charging, and instrument systems unique to this model year. Before initiating any comprehensive repair process or electrical testing, always ensure the main fuse is pulled and the battery is disconnected to prevent system damage or personal injury.
The contents detail standardized diagnostic sequences for electrical faults, including battery load testing, starter solenoid operation, and charging system output verification. It spans technical procedures for the TSM and TSSM security modules, providing vital data on security lamp status, key fob assignment, and personal code entry for immobilizer disarming. Expect clear identification of diagnostic trouble codes, ranging from serial data errors like U1016 to specific fuel level sensor faults.
Electrical Specification Data
Having factory-correct numbers on hand prevents guesswork in the workshop. Specification highlights include detailed resistance ranges for the fuel sending unit and specific AC output values for the alternator. For the 2004 charging system, output is documented between 34–40 amperes for low-output variants and 41–48 amperes for high-output systems. The required battery load test demands 9.6V or more after 15 seconds of testing at a 50% CCA rating, with a full 100% state of charge defined strictly as 12.8V.
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