2004 Harley-Davidson FLT Motorcycle Touring Line Factory Service Manual
Harley-Davidson Models Covered & Key Technical Specifications
Models: 2004 Harley-Davidson FLT models (Touring line)
Sub-models / Variants: FLHT, FLHTC, FLHRI, FLHTCUI, FLHR, FLHTCI, FLHTCUI W/SC, FLHPI, FLHTCI Shrine, FLHTCUI Shrine, FLHTPI, FLHRCI, FLTRI, FLHPEI, FLHTI, FLHRI Shrine, FLHRS, FLHRSI
Trade Names: Electra Glide, Road King, Road Glide, Ultra Classic
Model Years: 2004
Serial Numbers: 1HD1DJV134Y500001 (Example format)
Technical Data:
- Engine Bore: 95.25 mm
- Engine Stroke: 4.00 inches
- Compression Ratio: 9.0:1
- Wheelbase: 63.5 inches
- Idle Speed: 950–1050 rpm
- Primary Chain Deflection (Cold): 5/8–7/8 inch (15.9–22.2 mm)
- Primary Chain Deflection (Hot): 3/8–5/8 inch (9.5–15.9 mm)
- Transmission Lubricant Capacity: 20–24 oz (590–710 ml)
- Engine Oil Capacity: 4 quarts (3.8 L)
- Spark Plug Gap: 0.038–0.043 inch (0.97–1.09 mm)
- Spark Plug Torque: 12–18 ft-lbs (16–24 Nm)
Harley-Davidson Manual Features & Content Preview
- Official 1271-page OEM publication covering 2004 FLT Touring models, including the Electra Glide, Road King, Road Glide, and Ultra Classic.
- Combines Service Manual (P/N 99483-04) and Electrical Diagnostics (P/N 99497-04) released for the 2004 production year.
- Features 68 high-resolution exploded-view diagrams detailing complex assemblies.
- Includes 16 critical fastener torque tables for precise hardware seating.
- Serves as the primary reference utilized during the initial 2004 FLT-series launch, delivering exact factory powertrain and chassis specifications.
Component and Systems Documentation
This comprehensive technical reference delivers the exact factory specifications required to maintain the engine, chassis, transmission, and fuel-injection systems. Whether you are dealing with routine upkeep or a complete teardown, the material outlines strict maintenance intervals. It thoroughly details component removal alongside required fluid services. You will find granular guidance navigating complex mechanical systems. Additionally, a dedicated electrical diagnostics section covers starting systems, charging circuits, and intricate engine management wiring diagrams.
Technical Data and Specifications
Extensive specification tables provide the mandatory torque values, fluid capacities, and operational clearances for major assemblies. As an example of the depth provided, the reference material documents 95–105 ft-lbs for the rear axle cone nut. Primary chaincase lubricant capacity is listed precisely at 32 oz. Furthermore, the designated engine idle speed is rated for 950–1050 rpm. Intake valve clearance and ignition timing thresholds are thoroughly mapped out within the engine assembly section. Safety remains paramount in any professional or home garage environment. Always cross-reference the complete original OEM documentation before undertaking hands-on work, as relying on complete factory data ensures both vehicle integrity and operator safety.
Document Reference: Part Number 99483-04, 2004 Touring Edition
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