2003 Harley-Davidson Touring FLT/FLHRC/FLHTC/FLHTCU/FLHTP Factory Service Manual (P/N 99483-03A)

• 1,193-page PDF set: one combined title/contents sheet; 654 pages of Service Manual content (P/N 99483-03A); 406 pages of Electrical Diagnostics content (P/N 99497-03); and 132 pages of FLHRSEI2 Service Manual Supplement content (P/N 99500-03).
• 2003 Touring coverage spans FLHT/FLHTC, FLHR/FLHRI/FLHRCI, FLHTI/FLHTCI/FLHTCUI, FLTR/FLTRI, Shrine editions, FLHTCUI with sidecar, and supplemental FLHRSEI2 material. The VIN tables also identify FLHPI, FLHPEI, and FLHTPI police models, along with domestic/HDI and carbureted/EFI coding.
• Engine chapters cover removal and installation, top- and bottom-end overhaul, cylinder heads, cylinders and pistons, cam support plate and oil pump service, crankcase work, and flywheel/connecting-rod inspection and assembly.
• Chassis and driveline procedures include wheel-bearing service, laced-wheel truing, vehicle alignment, master-cylinder and caliper repair, brake bleeding, fork and steering-head work, rear air suspension, swingarm service, primary drive and clutch repair, belt service, and transmission teardown.
• Separate carburetor and EFI sections address the enrichener, carburetor, vacuum fuel valve, evaporative-emissions hardware, injected fuel tank, sensors, electrical bracket, and induction module. Diagnostic coverage adds trouble-code retrieval, no-start and misfire fault isolation, fuel-system electrical checks, and fuel-pressure testing.
• Electrical diagnosis covers starting/charging and battery-load testing, instruments and speedometer checks, TSM/TSSM setup and security faults, cruise-control charts, and Premium Sound, radio, CB, intercom, headset, and speaker troubleshooting. Connector-location tables and model-specific wiring sheets cover main, engine-management, starting/charging, lighting, sound, and sidecar circuits.
• The FLHRSEI2 supplement documents its unique engine, oil-cooler and thermostat, hydraulic-clutch, secondary clutch actuator, chassis, trim, instrument, and electrical service differences while referring shared procedures back to the base Touring manual.

Factory Repair Scope

This factory set is organized for service, diagnosis, and major repair rather than routine maintenance alone. The mechanical volume supplies component-specific torque tables, manufacturing tolerances, wear limits, fluid specifications, adjustment data, and final checks alongside the repair procedures. Its deeper overhaul and electrical sections assume press work, DVOM testing, dedicated fixtures, and Harley-Davidson diagnostic equipment, making the set best suited to professional technicians and experienced mechanics. The maintenance chapters are more approachable, but the major repair work is not beginner-level material.

The base Touring engine is identified as the 88 cu. in. (1450 cc) air-cooled Twin Cam, while the FLHRSEI2 supplement covers the 103 cu. in. (1690 cc) EFI engine under VIN model code PG and engine code E. That supplement provides the different specifications and service information for its cylinder heads, pistons, cams and timing marks, flywheel assembly, oil cooler, and thermostat. It also captures the FLHRSEI2 hydraulic clutch hardware that is not covered by the cable-clutch procedures in the base volume. The transmission material covers the constant-mesh five-speed, including shifter cam and forks, clutch release cover, mainshaft/countershaft assemblies, main drive gear, transmission case, and oil pan.

Diagnostics, Diagrams, and Specialty Tools

The diagnostic volume is organized around factory test charts rather than a short generic troubleshooting list. It covers carbureted ignition and EFI engine management separately, along with TSM/TSSM vehicle-delivery setup, password learning, current and historic trouble codes, breakout-box tests, circuit checks, and post-repair verification. Tool references include the HD-41325 Scanalyzer with HD-41325-95C cartridge, HD-42682 carbureted/TSM-TSSM breakout box, HD-43876 EFI breakout box, HD-44608 radio breakout box, HD-43644 camshaft/cam-bearing remover/installer, and HD-46247 vehicle alignment tool.

Representative engine and driveline drawings include the Engine Oil Flow - Cam Support Plate/Right Crankcase Half, Cylinder Head/Cylinder/Piston Assemblies exploded view, and Transmission Power Flow Schematic. Electrical visuals include the EFI System Circuit, Starter/TSSM Circuit, and TLE/TLE Ultra Sidecar Audio Harness. The wiring section separates these sheets by FLHT/FLHTC/FLHTCU, FLTR, FLHR/FLHRC, and sidecar configuration.

Scope and Repair Cautions

The FLHRSEI2 material is a supplement, not a standalone manual; systems it does not change are serviced through the base manual, while fuel-injection diagnosis remains in the electrical diagnostic volume. Police VIN codes and shared Touring information are present, but the separate police service supplement is not included in this PDF. Parts ordering is likewise referred to the appropriate parts catalog, which is not part of this set.

The engine chapter warns that movement or loss of the lifter anti-rotation pin can allow lifter rotation and catastrophic engine damage. The transmission section notes that unprotected mainshaft splines can cut the lip seal during assembly. Engine removal, raised-motorcycle work, brake and fuel-system service, and battery testing require secure support, proper isolation or pressure control, and normal workshop safety practices.