Harley-Davidson FLT Touring 2004 Service & Diagnostics Manual Set (P/N 99483-04)

The service manual provides mechanical repair procedures, while Electrical Diagnostics follows faults through circuit tests and diagnostic charts. Use the FLHTCSE supplement alongside the base manual for model-specific procedures and specifications.

Searchable Text, Bookmarks and Wiring Detail

Finding procedures and circuits: Text search and embedded bookmarks cover all three publications. Small wire-color codes, connector numbers and pin labels in dense wiring diagrams require zooming for comfortable reading.

One printable 1,271-page PDF contains all three publications, including one shared contents page and the internal blank and notes pages.

Engine Overhaul, Chassis Service and Electrical Fault Tracing

The following topics are selected highlights from the publications. Wheel lacing and Tour-Pak component service are further examples of the material included.

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

• Primary drive and transmission: Primary chain and sprocket service, clutch disassembly and inspection, drive-belt adjustment, shifter service, and mainshaft/countershaft repair.

• Brakes and suspension: Master-cylinder and caliper repair, hydraulic brake bleeding, conventional and cartridge fork rebuilding, steering-head bearing service and rear suspension work.

• Fuel systems: Carburetor service, vacuum-operated fuel valve troubleshooting, EFI fuel-tank and induction-module procedures, and California evaporative emissions equipment.

• Starting and engine management: Starter and charging-system tests, diagnostic trouble codes, no-start and misfire diagnosis, fuel-pressure testing, and sensor-circuit checks.

• Security and touring equipment: TSM/TSSM diagnosis and password learning, instrument troubleshooting, Premium Sound System fault charts, and cruise-control testing.

• FLHTCSE-specific service: Hydraulic clutch components, revised engine specifications, piston measurement, cam timing marks, thermostatic oil-cooler service and model-specific electrical equipment.

Suited to technicians and experienced owners who can use precision measuring tools and electrical test equipment; internal engine and transmission work requires suitable workshop equipment.

Engine and Drivetrain Repair Depth

The Twin Cam 88 engine section separates top-end work that can be performed with the engine in the chassis from bottom-end overhaul and individual subassembly repair. Manufacturing tolerances, valve-to-guide fits, wear limits and ignition specifications accompany the procedures.

The Cam Chain Tensioner Shoe Wear illustrations show inspection criteria beyond a single wear measurement. The manual also warns that uncontrolled release of a spring-loaded cam-chain tensioner can stretch its spring or crack the shoe.

The Transmission Power Flow Schematic explains gear engagement, while Appendix D provides separate mainshaft/countershaft disassembly and assembly instructions for the Japan-market transmission. The clutch inspection-cover notes explain how lubricant trapped around the quad ring can cause temporary weepage.

Chassis and Fuel-System Differences

The base manual distinguishes Road King conventional forks from the left-side cartridge fork used on the other covered base models. Fork oil-level procedures, steering-head bearing packing and vehicle alignment receive separate treatment.

Carbureted and fuel-injected systems have their own service and diagnostic sections. Vacuum-valve troubleshooting and EVAP routing illustrations support the carbureted fuel-system material; EFI coverage extends to the fuel pump, pressure regulator, injectors and induction module.

EFI idle-speed setting requires Digital Technician, P/N HD-44750. The documentation identifies this equipment requirement rather than presenting the throttle-stop screw as an EFI idle adjustment.

Circuit Tests and Touring-System Diagnostics

The paired volumes connect component service with connector pinouts and electrical test specifications. For example, the Starter Testing 4: Nothing Clicks chart traces the relay-control circuit and its TSM/TSSM connections to help distinguish wiring faults from component faults.

The EFI Breakout Box, P/N HD-43876, is documented for use with a DVOM to test harness circuits without probing connectors with sharp objects. Carbureted ignition and EFI harness diagrams show the different control-module connections.

Premium Sound diagnosis separates software checks from hardware fault tracing for speakers, headsets, intercom and CB functions. Cruise Chart A: Initial Diagnostics leads into the system-specific cruise-control tests.

Using the FLHTCSE Supplement

The supplement supplies revised cylinder-head and piston information, including piston measurement with spherical ball-anvil adapters. It also documents the hydraulic clutch master cylinder, fluid line and secondary actuator rebuild.

Oil-cooler operation diagrams explain the thermostat’s different flow paths. Additional procedures cover passing-lamp hardware and the garage-door opener.

Always consult the complete procedures and safety notices before working on brakes, pressurized fuel or spring-loaded assemblies.

Axle, Primary and Fuel-System Data Preview

The chassis torque tables specify 95–105 ft-lbs for the rear axle cone nut. The drive section lists a primary chaincase lubricant quantity of 32 oz.

The EFI fuel-pressure test specifies a steady 55–62 psi while the engine is running and engine speed is varied. The accompanying diagnostic notes address low pressure and restricted fuel flow.