2004 Harley-Davidson Touring Service Manual

Detailed repair information for 2004 Harley-Davidson Touring models including Road Glide, Electra Glide Classic, Road King, and Screamin Eagle. Covers troubleshooting, specifications, and diagnostics.

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Document Details

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Document Number / Seller:
27986 / Kenneth Taylor
File Size:
56.34 MB
File Type:
ZIP
Language:
English
Pages:
78
Printable:
Yes
Category:
Motorcycle
Last updated / verified
Mar 23, 2025

Models Covered & Key Technical Specifications

2004 Harley-Davidson Touring Service Manual

This manual provides comprehensive repair and diagnostic information for 2004 Harley-Davidson Touring models, including Road Glide, Electra Glide Classic, Road King, Screamin Eagle, and Ultra Classic variants. Covers all systems and components for maintenance and repair.

  • System Coverage: Includes detailed procedures for starting and charging systems, including troubleshooting for starter issues and battery load tests.
  • Diagnostic Resolution: Offers extensive diagnostic flowcharts for engine management, TSM/TSSM, and ignition systems to pinpoint faults.
  • Component Specifications: Provides typical running values for sensors like MAP and RPM, alongside system fuse ratings and specifications for various electrical components.
  • Troubleshooting Guides: Features specific tests for common issues such as misfires, no-spark conditions, and serial data communication errors.
  • Electrical Schematics: Includes detailed wiring diagrams for ignition, starter, TSM/TSSM, and serial data circuits for accurate diagnosis.
  • Maintenance Procedures: Outlines key maintenance tasks including key fob battery replacement and TSSM setup for optimal system performance.

Professional Workshop Service Manual & Technical Specifications

2004 Harley-Davidson Touring Repair Manual: Harley-Davidson Touring Models Maintenance-Registry

Year-Coverage: 2004 // Validation-Data: All Models // Equipment-Series: Touring

Technically demanding systems are documented in this comprehensive manual, covering all aspects of your 2004 Harley-Davidson Touring motorcycle. From detailed diagnostic procedures for the engine management, ignition control module (ICM), and TSM/TSSM, to specific troubleshooting for starting and charging systems, this manual is your ultimate guide. It includes essential specifications, wiring harness connector details, and flowcharts for diagnosing issues like misfires, DTCs (U1300, U1301, P1009, P1010), and ignition coil circuit problems. Torque specifications for critical components ensure proper assembly and longevity.

The manual presents information on:

  • Ignition System Specifications & Troubleshooting
  • Starting and Charging System Diagnostics
  • TSM/TSSM Functions and Troubleshooting
  • Engine Management System (Carbureted) Diagnostics
  • Turn Signal and Security System Operation
  • MAP Sensor and Speedometer Diagnostics

Systems and procedures documented include detailed troubleshooting for starting system issues, ignition coil circuits, and MAP sensor diagnostics. The manual documents torque specifications for critical components to ensure proper axial load stability.

Component Technical-Path Context
Ignition Control Module Troubleshooting Diagnosis of ICM/ECM faults
TSM/TSSM Diagnostic Codes DTC U1016, U1255 analysis
Speedometer Circuit Diagnosis Troubleshooting serial data errors
Starter System Performance Tests Testing and diagnosis of starter operation
Engine Management Intake Leak Test Identifying intake manifold leaks
Turn Signals Error Codes Diagnosis of B1121, B1122, B1141 faults

FAQ

What **tools** are required for the diagnostic procedures? keyboard_arrow_down

2.5 Breakout Box (HD-42682) and instrument harness adapters (HD-46601) are commonly required for diagnostic procedures, along with a multimeter (DVOM, HD-39978) and specialized testers like the Spark Tester (HD-26792) and Speedometer Tester (HD-41354).

Identify the **critical** voltage specifications for the MAP sensor. keyboard_arrow_down

The MAP sensor signal voltage should typically be between 0.6-0.8 volts when active, with an acceptable range of 0-7.0 volts. For specific tests, voltage readings between 4.2-4.95 volts (engine off) and 1.5-3.0 volts (hot idle) are noted.

What **procedures** are involved in resetting the TSSM? keyboard_arrow_down

TSSM codes can be cleared using the speedometer's self-diagnostic function by pressing the reset switch for more than 5 seconds when a code is displayed. Specific procedures for password learning and TSM/TSSM replacement are detailed in Section 3.24 and 3.3.

Determine the **specified** service interval parameters for the key fob battery. keyboard_arrow_down

The key fob battery should be replaced every 2 years to ensure proper function of the TSSM security system.

What **specifications** are essential for the ignition system? keyboard_arrow_down

Essential ignition specifications include a spark timing advance of 0°-50° BTDC (range) or 30° BTDC @ 1000 RPM, an idle speed of 1000 ± 50 RPM, and spark plug gap of 0.038-0.043 in (0.97-1.09 mm).

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Reviews (3)

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Rated 4 out of 5 stars
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This repair manual is an absolute must-have for anyone with a 2004 Harley. The troubleshooting section is particularly helpful!
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The layout is user-friendly and the step-by-step guides make maintenance a breeze. Downloading was quick and support was very responsive!