2005 Harley-Davidson Touring Road King, Electra Glide Police, Screamin Eagle Electra Glide, and Custom Service Manual OEM (P/N PN 99492-05)

1,470 PDF pages total: 718-page Touring Models Service Manual; 494-page Electrical Diagnostics manual; 134-page Police Service Supplement; 122-page FLHTCSE2 Service Supplement; and a 2-page manual-set index.

This factory manual set covers mechanical repair and system diagnostics for the 2005 Harley-Davidson Touring line - not just starting and charging. Its overhaul procedures, DTC trees, breakout-box tests, and special-tool references make it best suited to professional technicians and experienced owners who have the required test equipment and are mechanically qualified for factory-level work.

• Model coverage: 2005 FLHT, FLHTC, FLHTI, FLHTCI, FLHTCUI, FLHR, FLHRI, FLHRCI, FLHRS, FLHRSI, and FLTRI, including Shrine and FLHTCUI sidecar listings. Dedicated supplements add FLHPI, FLHPEI, and FLHTPI police motorcycles plus the FLHTCSE2.
• Four factory publications: Touring Models Service Manual P/N 99483-05, Electrical Diagnostics P/N 99495-05, Police Service Supplement P/N 99483-05SP, and FLHTCSE2 Service Supplement P/N 99500-05.
• Engine and driveline repair: engine removal and installation, Twin Cam 88 top- and bottom-end overhaul, cylinder-head and valve service, cam support plate and oil pump work, primary drive and clutch service, and five-speed transmission disassembly.
• Chassis procedures: wheel lacing and truing, vehicle alignment, brake master cylinder and caliper service, hydraulic brake bleeding, fork and steering-head work, swingarm service, and rear air-suspension adjustment.
• Electrical and fuel diagnosis: starter, charging, instruments, TSM/TSSM security, carbureted ignition, EFI engine management, cruise control, and premium sound fault isolation, supported by connector views, DTC charts, and model-specific wiring diagrams.
• Configuration-specific material: police ABS, strobe, siren/PA, and Tour-Pak electrical service; FLHTCSE2 103 cu. in. EFI engine, hydraulic clutch, oil cooler, chassis, and harness-overlay procedures; and TLE/TLE-U sidecar wiring.

Mechanical Repair and Overhaul Coverage

The service manual moves from scheduled maintenance into workshop repair. Chassis chapters cover cast and laced wheels, wheel truing, alignment, brake hydraulics, forks, steering-head bearings, air shocks, swingarm, controls, fairings, saddlebags, and Tour-Pak assemblies. Separate FLHT/C/U, FLTR, and FLHR/C/S bodywork procedures show where the Touring variants differ.

Engine coverage is built around the 88 cu. in. Twin Cam used in the standard Touring range. It includes engine removal and installation, top- and bottom-end overhaul, and bench repair of the rocker gear, lifters, cylinders, pistons, connecting rods, cam support plate, oil pump, crankcase, and flywheel assembly. The driveline chapters continue through the primary chain, clutch, final belt, shifter cam and forks, mainshaft/countershaft, main drive gear, bearings, case, and oil pan. Carburetor and EFI service is separated by system type.

Diagnostics, Wiring, and Electronic Systems

Electrical Diagnostics supplies the fault-finding depth that the mechanical chapters reference. Starting-system trees cover relay activation, voltage-drop checks, assembled-starter testing, solenoid circuits, and current draw. Charging diagnosis covers the battery, stator, alternator output, voltage regulator, and ground paths, with distinct low- and high-output configurations identified for the applicable models.

Instrument and serial-data sections cover speedometer self-diagnostics, gauges, indicator lamps, communication faults, and breakout-box checks. TSM/TSSM material addresses turn-signal operation, bank-angle input, security arming, key-fob faults, password learning, and related DTCs. Separate carbureted ICM and EFI ECM chapters trace no-start, stall, misfire, sensor, relay, fuel-pressure, injector, ignition, and data-bus faults. Radio, CB/intercom, headset, speaker, and cruise-control symptoms receive dedicated diagnostic charts.

Named 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, the police ABS Circuit, and model-specific Main Harness and Interconnect Harness diagrams. Connector-location views and service procedures cover Deutsch, Amp Multilock, Packard, Autofuse, and sealed butt-splice connections.

Supplements, Specifications, and Workshop Use

The police supplement applies only to its listed FLT police models and adds police chassis and electrical equipment plus ABS self-diagnostics, wheel-speed sensor and tone-ring faults, solenoid, caliper, motor/pump, relay, and module checks. The FLHTCSE2 supplement documents the 103 cu. in. EFI build and its hydraulic clutch, oil cooler, chassis, transmission, and electrical differences; unchanged procedures remain in the base Touring manual.

Across the set, component-specific torque tables, fluid capacities, service wear limits, manufacturing tolerances, electrical test specifications, adjustment data, and special-tool references are placed with the relevant repair. Examples 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.

The engine chapters flag damage-prone work such as releasing the cam-chain tensioner retaining pin too early or handling the crankcase by the cylinder studs. The FLHTCSE2 material also warns that incompatible clutch fluid can damage the hydraulic system and that the reservoir level rises as the clutch wears. Follow the manual's battery-isolation, fuel-handling, brake-system, lifting, and rotating-component warnings before beginning repair or diagnostic work.