2002 Harley-Davidson FLT Touring & FLHRSEI Service and Electrical Diagnostics Manual Set (P/N 99483-02)

The service manual provides mechanical repair procedures, while the electrical manual supplies circuit tests and diagnostic charts. The FLHRSEI supplement adds model-specific differences and refers back to the included Touring manuals for shared procedures.

Twin Cam Repair, Electrical Diagnosis and FLHRSEI Differences

• Engine and driveline: Engine removal, top- and bottom-end overhaul, cam support plate service, clutch repair, primary drive alignment and transmission disassembly.

• Chassis and brakes: Vehicle alignment, engine mounts, wheel truing, steering-head bearing checks, front-fork service, master-cylinder overhaul and brake-caliper repair.

• Fuel systems: Carburetor disassembly and float inspection, vacuum-operated fuel valve testing, EFI fuel-tank service, induction-module work and fuel-pressure testing.

• Electrical troubleshooting: Starter and charging tests, carbureted and EFI diagnostic charts, TSM/TSSM fault tracing, connector pinouts and model-specific wiring diagrams.

• Touring equipment: Premium Sound System troubleshooting, cruise-control fault diagnosis, cable-lash initialization and instrument testing.

• FLHRSEI supplement: Separate engine specifications and wear limits, rear brake-pad procedures, handlebar and control service, instrument-console work and tachometer installation details.

This set is suited to technicians and experienced mechanics with measuring equipment and the specialist tools required for internal engine work and electrical diagnosis.

Engine, Clutch and Transmission Repair

The engine section separates top-end overhaul, bottom-end overhaul and individual component service. Cylinder-head inspection, piston and cylinder measurements, oil-pump work and cam support plate repair are backed by manufacturing tolerances and service wear limits.

The Engine Oil Flow diagrams and Cylinder Head Torque Sequence illustrations explain lubrication routing and assembly relationships. Clutch assembly views, primary-drive alignment checks and transmission shaft inspection data support work beyond routine maintenance.

The cam-chain tensioner instructions identify a specific damage risk: uncontrolled release with the chains and sprockets removed can stretch the spring or crack the tensioner shoe. The illustrated tool list identifies the Cam Chain Tensioner Unloader, HD-42313.

Chassis Service and Scheduled Maintenance

Steering-head service includes the swing-by test and specifies Special Purpose Grease, P/N 99857-97. Front-fork procedures distinguish the Road King’s conventional forks from the cartridge-type left fork used on the other standard Touring models.

Exploded views of the front brake master cylinder and calipers accompany disassembly, inspection and assembly procedures. Harley-Davidson recommends brake service by a dealer or another qualified technician.

The maintenance section covers oil and filter replacement at the initial 1,000-mile service and subsequent 5,000-mile intervals, with more frequent changes under demanding conditions. Primary-chain specifications distinguish hot and cold engines; clutch adjustment has its own checks and tolerances.

Carburetor, EFI and Electrical Fault Tracing

Carburetor service covers the enrichener, accelerator pump, float and fuel valve. Its float-pin warning explains how removal from the wrong pedestal side can damage the casting badly enough to require carburetor replacement.

Separate carbureted and EFI diagnostic sections prevent mixing ignition-module and ECM test paths. Check-engine-lamp code retrieval is documented, but some procedures require additional equipment: EFI idle-speed setting calls for a Scanalyzer, HD-41325, or Digital Technician, HD-44750.

TSM/TSSM connector views and breakout-box instructions connect pin assignments with the diagnostic charts. The documented breakout box, HD-42682, allows harness testing with a DVOM without piercing connections with sharp probes.

Model-specific Main Harness diagrams distinguish wiring configurations. Premium Sound System charts address radio, speaker, headset, intercom and CB faults; cruise-control charts separate inoperative, dropout and switch-input problems.

Using the FLHRSEI Supplement

The supplement supplies its own engine tolerances and wear limits, plus procedures for distinctive chassis fittings and electrical equipment. Its maintenance, fuel-system, starter, drive and transmission sections direct the reader to the Touring service manual, while fuel-injection diagnosis uses the electrical manual.

Keeping these references together lets the reader apply FLHRSEI-specific data while following the shared repair procedures.

Examples of Brake Inspection and Ignition Test Data

Front brake inspection specifies a pad-replacement threshold of 0.04 in. (1.02 mm) of friction material above the backing plate. Minimum brake-disc thickness is stamped on the disc; it is not the pad-wear value.

The EFI ignition specifications list coil primary resistance at 0.3–0.5 ohms and secondary resistance at 2,750–3,250 ohms, both at room temperature.

Searchable PDF with Bookmarks and Wiring Detail

Text search and diagram navigation: Searchable text and extensive bookmarks cover the manuals. The FLHRSEI supplement’s parent bookmark returns to the opening contents page; its chapter bookmarks provide direct access. Small wire-color codes and connector numbers in the detailed wiring diagrams require zooming.

Delivered as one printable, English-language PDF with 1,107 pages, including the three publications listed above and one shared opening contents page. Chapter contents, blank pages and notes pages are already included in the publication counts.