Harley-Davidson Touring 2005 Service Manual Set (P/N 99483-05)

Use the Touring service chapters for mechanical repair and Electrical Diagnostics for circuit-level fault isolation. The supplements cover police equipment and FLHTCSE2-specific differences, referring shared service work back to the included base manual.

Police wiring coverage: ABS diagnostic circuits and connector-location information are included. The full police harness wiring sheets listed in the supplement’s diagram index are not included.

Searchable Chapter PDFs and Wiring Detail

Text search and diagram navigation: The chapter PDFs contain searchable text and embedded bookmarks. Most separate contents sheets have no bookmarks. Dense wiring diagrams require zooming to read small pin numbers and wire-color codes comfortably.

The ZIP download contains 80 printable English PDF files totaling 1,470 pages. This includes 74 section contents/divider pages, 34 notes pages and the two-page set index.

Engine Overhaul, Electrical Diagnosis and Model-Specific Service

These selected coverage highlights outline the main workshop areas rather than reproduce the complete contents. Other topics include evaporative-emissions service and garage-door-opener components.

• Engine overhaul: Engine removal and installation, top- and bottom-end overhaul, cylinder-head and valve service, cam support plate work, and oil-pump inspection.

• Drive and transmission: Primary chain and clutch service, final belt replacement, transmission disassembly, shifter inspection, and main-drive-gear and bearing replacement.

• Chassis repair: Wheel lacing and truing, vehicle alignment, brake master cylinder and caliper service, hydraulic bleeding, fork overhaul, and steering-head work.

• Fuel and ignition: Carburetor service, EFI induction-module work, fuel-pressure testing, and separate carbureted ICM and EFI ECM diagnostic procedures.

• Electrical troubleshooting: Starter and charging tests, instrument and serial-data diagnosis, TSM/TSSM security checks, cruise-control charts, and premium sound fault isolation.

• Police equipment: ABS self-diagnostics and component tests, strobe lighting, siren/PA equipment, handlebar controls, and police Tour-Pak electrical service.

• FLHTCSE2 procedures: Hydraulic clutch service, cylinder-head and piston work, cam timing references, oil-cooler and thermostat service, and wiring-harness overlays.

The overhaul procedures, DTC trees, breakout-box tests and special-tool references make this set suited to technicians and experienced owners equipped for internal mechanical work and electrical diagnosis.

Mechanical Repair and Overhaul Detail

Engine service: The manual distinguishes top-end work that can be performed with the engine in the chassis from flywheel-compartment work requiring engine removal and a stand. Its service flowcharts help identify the required level of disassembly before a repair begins.

Bench procedures address rocker gear, lifters, cylinders, pistons, upper connecting-rod bushings, the cam support plate, oil pump and crankcase. The flywheel/connecting-rod assembly receives inspection and replacement instructions; damaged flywheels or connecting rods call for replacement of the assembly.

The engine chapters warn that uncontrolled cam-chain-tensioner release can stretch the spring or crack the shoe, while lifting the crankcase by its cylinder studs risks dropping and damaging the assembly.

Driveline detail: Transmission coverage extends to the shifter cam and forks, mainshaft/countershaft, main drive gear, bearings, case and oil pan. A separate appendix provides Japan-market mainshaft/countershaft procedures.

Chassis, Bodywork and Fuel Systems

Beyond the brake and wheel procedures, chassis coverage includes rear air-suspension adjustment, shock absorbers, swingarm service and control cables. Separate FLHT/C/U, FLTR and FLHR/C/S bodywork procedures address fairings, windshields, saddlebags and Tour-Pak assemblies.

Carbureted fuel-system sections cover the enrichener, vacuum-operated fuel valve and fuel tank. EFI chapters provide sensor, fuel-pump, tank and induction-module removal and installation procedures.

Diagnostics, Wiring and Electronic Systems

Starting-system diagnosis separates relay activation, voltage-drop faults, assembled-starter tests, solenoid problems and current-draw checks. Low- and high-output charging configurations have distinct tests, helping the technician select the applicable specifications before assessing an alternator fault.

Instrument coverage includes speedometer self-diagnostics, gauges, indicator lamps, communication faults and breakout-box checks. TSM/TSSM sections address bank-angle input, security arming, key-fob assignment and faults, password learning and related DTCs.

Separate ICM and ECM diagnostic trees trace no-start, stall, misfire, sensor, relay, injector and ignition faults. Radio, CB/intercom, headset, speaker and cruise-control symptoms receive dedicated charts.

Illustrations include the Transmission Power Flow Schematic, Cam Support Plate/Oil Pump Assemblies (Exploded View), Cruise Engaged Lamp Dropout Code Timing Diagram, Serial Data Circuit layouts, police ABS Circuit diagrams and Touring Main Harness sheets. TLE/TLE-U sidecar chassis and audio wiring is also included.

Connector service covers Deutsch, Amp Multilock, Packard, Autofuse and sealed butt-splice connections.

Police ABS and FLHTCSE2 Differences

Police ABS material covers wheel-speed sensors, tone rings, solenoids, calipers, the motor/pump, relays and the control module, with initial/final diagnostic checks and component service procedures.

The FLHTCSE2 supplement adds hydraulic clutch master-cylinder, fluid-line and secondary-actuator work, plus oil-cooler and thermostat procedures. It warns that incompatible clutch fluid can damage the hydraulic system and that reservoir fluid volume rises as the clutch wears.

Workshop Tools and Reference Data

Component-specific torque tables, fluid capacities, service wear limits, manufacturing tolerances and adjustment data accompany the relevant work. Tool references include the HD-42310 engine/transmission bench stand, HD-42682 carbureted-system breakout box, HD-43876 EFI breakout box and HD-35316B main-drive-gear service tool.

Follow the manual’s battery-isolation, fuel-handling, brake-system, lifting and rotating-component warnings before beginning repair or diagnostic work.

Selected Charging Tests and Starter Wear Limits

Stator testing specifies less than 0.5 ohms across the stator socket. For FLHTCI, FLHTCUI and FLTRI, high-output charging current is 41–48 amperes at 3000 rpm with the test load maintaining 13.0 volts.

Starter service limits include a minimum brush length of 0.433 in. (11 mm) and a minimum commutator diameter of 1.141 in. (29 mm).