Harley-Davidson FLT Touring 2001 Service Manual Set (P/N 99483-01)

The service manual supplies the mechanical repair procedures, while Electrical Diagnostics provides circuit testing and fault isolation. The FLTRSEI2 supplement directs readers to the base manual for information outside its model-specific sections.

FLTRSEI2 coverage: The supplement’s maintenance, engine, fuel-system, starter, drive and transmission sections contain divider pages rather than additional procedures. Its detailed coverage concentrates on chassis equipment, electrical components and wiring.

Searchable Text, Bookmarks and Wiring Detail

Search and diagram detail: Searchable PDF text and embedded bookmarks cover all three publications. Small connector numbers and wire-color labels on the wiring sheets require zooming for comfortable reading.

All three publications are combined in one printable, English-language, 1,106-page PDF. This total includes one shared contents page, 39 blank or notes pages, six section dividers without procedures and 11 diagram-title sheets.

Twin Cam Repair and Touring-System Diagnostics

The following selected coverage highlights are not a complete contents list; additional topics include exhaust-system removal and connector-terminal repair.

• Engine repair: Step-by-step top-end and bottom-end overhaul procedures, engine removal and installation, cam-support-plate service, oil-pump inspection and cylinder-head repair.

• Primary drive and transmission: Clutch inspection and adjustment, primary-chain service, drive-belt replacement, shifter-fork inspection and mainshaft/countershaft disassembly.

• Brakes and chassis: Master-cylinder and caliper overhaul, hydraulic brake bleeding, laced-wheel truing, vehicle alignment, steering-head bearing service and air-suspension checks.

• Carburetion and EFI: Carburetor disassembly, vacuum-operated fuel-valve testing, California EVAP service, induction-module work, fuel-pressure testing and idle-speed-control diagnosis.

• Electrical fault finding: Starter and charging tests, sensor and ignition diagnosis, TSM/TSSM troubleshooting, key-fob assignment and solo/sidecar configuration.

• Touring equipment: Premium sound-system diagnostics, cruise-control fault charts and cable-lash initialization, plus FLTRSEI2 CD-changer, lighting and security-component service.

This set suits technicians and experienced owners who can follow electrical diagnostic charts and have access to the specified meters, test adapters and mechanical service tools.

Engine Overhaul and Drivetrain Inspection

The engine section distinguishes work that can be done with the engine in the chassis from repairs requiring removal and an engine stand. Manufacturing tolerances, service wear limits, valve-to-guide fits and multi-stage cylinder-head tightening sequences accompany the relevant procedures.

Flywheel assembly: Inspection and replacement are covered, but flywheels and connecting rods requiring replacement are treated as one assembly and referred for factory service or replacement.

Transmission coverage extends to the main drive gear, bearings, shift mechanism and case. Illustrated special-tool references include the cam-chain tensioner unloader HD-42313 and crankshaft/camshaft sprocket locking tool HD-42314.

The cylinder-head instructions warn that incorrect valve-guide removal can drag carbon through the head bore and damage the interference fit.

Fuel-System and Electrical Fault Isolation

The diagnostic charts support fault isolation across the powertrain and electrical systems. For an EFI engine that cranks but will not start, separate electrical and fuel-pressure tests help distinguish fuel-delivery problems from ignition or control faults.

Check-engine-lamp diagnosis: EFI procedures allow current trouble codes to be read without the Scanalyzer. Historic codes are not displayed by this method; the manual separately explains code clearing and post-repair validation.

Circuit diagrams, connector-location views and terminal information support the diagnostic flowcharts. Examples include the Main Harness, Starting and Charging Circuit, Complete Audio Circuit, Cruise System Diagram and Cruise Chart A: Initial Diagnostics.

Dedicated FLHTP-I wiring sheets identify police-specific siren, strobe, instrument and starting circuits.

Chassis Service and Touring Accessories

Periodic-service tables connect maintenance intervals with the related procedures, including steering-head bearing lubrication, primary-chain adjustment and clutch checks. Air-shock coverage provides inspection and replacement information; the shocks are not internally repairable.

The handlebar-switch instructions identify a risk of damage to the front stoplight-switch boot and plunger during incorrect removal or installation.

The FLTRSEI2 material adds Tour-Pak and backrest work, clutch-cable routing, CD-changer service, TSSM replacement and siren-battery procedures.

Brake service, pressurized fuel and heavy assemblies require the precautions and workshop equipment specified for the relevant task.

Selected Oil, Chain and Spoke Specifications

For the base FLT engine, the specifications distinguish a 4-quart dry oil capacity from an approximate 3½-quart wet capacity, rather than treating the larger figure as a routine refill amount.

Primary-chain free play is specified at 5/8–7/8 inch with the engine cold and 3/8–5/8 inch hot. Laced-wheel instructions include spoke-nipple torque of 40–50 in-lbs (4.5–5.6 Nm).