2004 Harley-Davidson Touring Service Manual (P/N 99483-04, 99497-04)

• Covers 2004 Harley-Davidson Touring models, including Road King and Electra Glide variants with EFI or carbureted fueling, plus the fuel-injected Road Glide (FLTRI).
• Engine repair extends to removal and installation, top- and bottom-end overhaul, cylinder-head service, cam support plate service, and oil-pump inspection.
• Drivetrain procedures cover clutch overhaul, primary-chain and sprocket service, final-drive belt replacement, and five-speed transmission disassembly, inspection, and reassembly.
• Chassis coverage includes brake master-cylinder and caliper rebuilding, hydraulic brake bleeding, fork service, steering-head bearing adjustment, and wheel lacing and truing.
• Fuel-system work ranges from carburetor overhaul and float-level adjustment to EFI fuel-pressure testing, injector-circuit diagnosis, and idle-air-control troubleshooting.
• Model-specific wiring diagrams, diagnostic flowcharts, and component connector tables support electrical repair, with terminal replacement and sealed-splice procedures.

Publications and Page Count

The set contains 1,351 pages across 78 PDF files: the Service Manual, P/N 99483-04, has 692 pages; the Electrical Diagnostic Manual, P/N 99497-04, has 482 pages.

The Police Service Supplement, P/N 99483-04SP, adds 78 pages, and the FLHTCSE Service Supplement, P/N 99500-04, adds 98 pages. A one-page master contents sheet completes the set. The publications are divided into section files rather than one continuous PDF. Page totals include contents, blank or notes pages, and repeated wiring material.

Touring Engine, Transmission, and Fork Differences

The standard engine material covers the Twin Cam 88, with separate inspection criteria for early- and late-style pistons. Flywheel or connecting-rod replacement is handled as a complete assembly, rather than an individual-component repair. Japan-market transmissions have a separate mainshaft/countershaft appendix.

Fork procedures distinguish the Road King's conventional forks from the cartridge-type left fork used on other Touring models. That distinction matters even for fork-oil service, because the cartridge unit requires partial disassembly.

The camshaft section warns that removing the shafts without their bearings can damage the cam support plate and bearing retainer. Its specified tool is the HD-43644 Camshaft/Camshaft Bearing Remover/Installer. Illustrated references include “Engine Oil Flow – Cam Support Plate/Right Crankcase Half” and “Transmission Power Flow Schematic.”

Diagnostic Coverage and Electrical Systems

The contents detail standardized diagnostic sequences for electrical faults, including battery load testing, starter solenoid operation, and charging system output verification. Instrument procedures include speedometer self-diagnostics and fuel-level sender fault isolation. Code-specific charts address serial-data faults such as U1016 and fuel-level sensor codes B1004/B1005.

The TSM/TSSM chapters cover turn-signal and bank-angle functions, security-lamp status, key-fob assignment, personal-code entry for disarming, and password learning after module replacement. Procedures distinguish speedometer-based checks from tests requiring Digital Technician, HD-44750, or the specified breakout boxes and harness adapters.

Cruise-control coverage includes inoperative and dropout diagnosis, with “Cruise Chart A: Initial Diagnostics” as the starting reference. Premium Sound System troubleshooting addresses CB/intercom, headset, speaker, and handlebar-control faults.

Electrical component repair and powered diagnostic testing require different precautions. Follow the manual's battery-isolation requirements for component work and its separate safety instructions for live-circuit tests.

Police and FLHTCSE Supplements

Police material covers FLHP/FLHTP service differences, including police-seat service and emergency equipment. The wiring section also covers FLHPE configurations. Siren/public-address and strobe troubleshooting is backed by the “Siren Amplifier and Strobe Harness” drawing; police Tour-Pak electrical equipment is covered separately.

The FLHTCSE supplement addresses its 103-cu.-in. EFI engine, including cylinder boring and honing, model-specific cam timing marks, and the thermostat-controlled oil cooler. Hydraulic-clutch coverage extends to the master cylinder, fluid line, release bearing, and secondary clutch actuator. Garage-door-opener programming is also included. These supplements cover differences from the standard models and are used with the base service and diagnostic manuals.

Electrical Specification Data and Wiring

Specification highlights include resistance ranges for the fuel sending unit and alternator output checks for low- and high-output charging systems. Battery state-of-charge and load-test criteria are included, along with component torque values. Mechanical chapters add fluid capacities, manufacturing tolerances, and service wear limits.

“Electronic Fuel Injection (EFI) Harness” schematics separate injected-model wiring from carbureted ignition circuits. Connector service covers Deutsch, AMP Multilock, and Packard designs, while TLE/TLE Ultra sidecar chassis and audio wiring is included alongside the motorcycle diagrams.