2007 Harley-Davidson FLT Touring Service & Electrical Diagnostics Manual Set (P/N 99483-07)

The service manual provides component repair procedures. The electrical diagnostics publication connects symptoms and trouble codes with circuit tests and directs you to the relevant component work.

Searchable PDF, Bookmarks and Wiring Detail

Text search and diagram navigation: Searchable text and detailed section bookmarks support navigation through both publications. The top-level Electrical Diagnostics bookmark opens the service contents; its individual section bookmarks provide the appropriate destinations. Small labels in dense wiring diagrams require zooming for comfortable reading.

Both publications are combined in one printable, 1,248-page PDF, including one shared contents page, 16 blank or separator pages and 22 notes pages.

Engine Overhaul, Chassis Service and Electrical Fault Tracing

These selected topics are supplemented by HDI active exhaust/intake service and California evaporative-emissions system coverage.

• Engine repair: Engine removal and installation, top- and bottom-end overhaul, cylinder-head service, piston inspection, cam-support-plate work and oil-pump service.

• Primary drive and transmission: Clutch disassembly, primary-chain tensioner service, mainshaft/countershaft inspection, shift-fork work and main-drive-gear bearing replacement.

• Chassis and brakes: Master-cylinder and caliper service, hydraulic brake bleeding, front-fork overhaul, steering-head bearing service and rear suspension repair.

• Fuel injection: Induction-module service, intake-leak testing, fuel-pressure diagnosis, idle-air-control checks and troubleshooting for cranking, stalling and misfire complaints.

• Electrical diagnosis: Starting and charging tests, instrument fault tracing, TSM/HFSM troubleshooting and separate Japan/Korea TSM/TSSM diagnostic coverage.

• Audio and cruise control: Advanced Audio System radio and speaker diagnostics, CB troubleshooting, cruise inoperative/dropout charts and cable-lash initialization.

• Circuit documentation: Model-specific wiring diagrams, connector pinout views, harness illustrations, diagnostic flowcharts, exploded assembly views and component cutaways.

This set suits experienced mechanics equipped for internal repair and electrical testing; the brake section recommends a Harley-Davidson dealer or another qualified technician.

Maintenance and Chassis Work

The maintenance schedule links service intervals with inspection criteria and step-by-step procedures for engine oil/filter replacement, air-cleaner service, clutch adjustment and transmission lubricant changes. Tire-pressure checks, wheel-spoke tightening and stabilizer-link inspection are also covered.

Chassis procedures extend to steering-head bearing repacking, front-fork oil changes and laced-wheel truing. Tool references include oil-filter wrenches, the HD-35381A belt tension gauge and the HD-47925 axle-nut torque adapter.

The drive-belt section explains how incorrect torque-adapter alignment can overtighten the cone nut and damage parts. The clutch-inspection-cover notes also explain how residual lubricant in the seal-ring groove can cause temporary weepage that resembles a seal leak.

Working on a heavy touring motorcycle requires strict adherence to factory safety protocols to prevent component failure or rider injury.

Internal Engine and Transmission Repair

The engine section distinguishes top-end work that can be performed with the engine in the chassis from bottom-end work requiring engine removal and a stand. Manufacturing tolerances, service wear limits and component-specific torque tables accompany the repair procedures, including HD-6R12 spark-plug data.

Flywheel/connecting-rod inspection leads to replacement of the complete assembly when the flywheel, connecting rods or right-side bearing inner race requires replacement.

Clutch instructions distinguish clutch-pack-only work from complete disassembly and bearing replacement. Transmission procedures cover shaft and shift-component service with the case remaining in the frame unless the case itself needs replacement.

EFI, Security and Touring Electronics

For a crank-but-no-start complaint, separate diagnostic sections address ECM power, fuel-system electrical faults and fuel pressure. The EFI breakout-box instructions specify HD-43876 with a DVOM for testing harness circuits and connections.

Security coverage distinguishes hands-free HFSM equipment from the Japan/Korea TSM/TSSM system. HFSM fob assignment requires Digital Technician at an authorized Harley-Davidson dealer.

Illustrations include Engine Oil Flow – Top End, the Transmission Power Flow Schematic, Charging System Circuit (Typical), model-specific Main Harness diagrams and the Fuel Pressure Test flowchart. Audio coverage extends to CB antenna SWR adjustment; cruise-control material includes initialization after relevant cable, module or throttle-body work.

A Preview of Engine Clearances and Pressure Tests

Oil-system specifications include 30–38 psi at 2,000 rpm and a normal operating temperature of 230°F. The piston table lists a manufacturing piston-to-cylinder fit of 0.0014–0.0025 in., distinct from service wear limits.

For EFI diagnosis, the fuel-pressure test specifies a steady 55–62 psi while engine speed is varied. Its diagnostic chart distinguishes low, high and steady pressure readings.