2000-2006 Harley-Davidson Touring Models Service Manual
Complete factory service documentation for Glide, Road King, and TLE models including FLHX, FLHTC, FLTR. Covers engine maintenance, chassis repair, and electrical systems.
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Sample pages from the 2000-2006 Harley-Davidson Touring Models Service Manual manual
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Models Covered & Key Technical Specifications
Harley-Davidson Touring Models (FLHX, FLHTC, FLHTCU, FLTR, FLHR, FLHRC, FLHRS) — 2000–2006 Professional-Grade Factory Service Archive | Touring Series Repository.
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Calibrated Engine Oil Capacity: The transmission oil capacity is calibrated to 20–24 ounces (590–710 mL) as specified for optimal lubrication Requirements.
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Measured Torque Specification: Engine oil drain plug fasteners are designed for 14–21 ft-lbs (19–28 Nm) tightening force establishing proper seal Configuration.
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Essential Wheel Spoke Tension: Spoke nipples provide 40–50 in-lbs (4.5–5.6 Nm) clamping force to maintain wheel integrity and balance Benchmarks.
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Primary Chain Deflection Data: Cold engine chain free play is set to 5/8–7/8 inch (15.9–22.2 mm) governing proper drive engagement Threshold.
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General Brake Pad Wear Limit: The friction material minimum thickness determines 0.04 inch (1.02 mm) replacement point to sustain braking performance Mapping.
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Approved Spark Plug Gap Setting: Ignition electrodes are calibrated to 0.038–0.043 inch (0.97–1.09 mm) spacing ensuring engine firing consistency Standards.
Professional Workshop Service Manual & Technical Specifications
Reference-Grade Assembly Manual: Harley-Davidson Glide, Road King, TLE Models Library-Master
Operational-Framework: FLHX, FLHTC, FLHTCU, FLTR, FLHR, FLHRC, FLHRS (2000-2006) // Operational-Scope: Powertrain and electrical Logic // Operational-Framework: 1447 pages, comprehensive technical resource.
| Component Category | Documentation Scope | Referenced Materials |
|---|---|---|
| Engine and Transmission Systems | Complete assembly sequences and component interactions | Torque specifications documented for all fasteners |
| Hydraulic and Brake Systems | Bleeding procedures, component architecture, fluid requirements | Maintenance intervals and seal specifications included |
| Suspension and Chassis Alignment | Frame geometry, bearing adjustment protocols, component clearance data | Vehicle alignment procedures with precision measurement guidance |
Reference chapters include Maintenance fundamentals addressing oil systems and filter protocols, Chassis architecture covering wheel assembly and brake hydraulic configurations, Engine disassembly and transmission lubricant management, Steering head bearing preload adjustment and fork suspension tuning, and Rear air suspension pressure tables for load-dependent operation and Vehicle alignment methodology using fixture-based frame geometry verification.
Precise Standard
The manual documents torque specifications for the engine mounting bracket to ensure proper bearing preload accuracy. Complete specifications are provided for critical fasteners including front axle assemblies, brake caliper mounting interface, and transmission housing retention. Assembly instructions are detailed for primary chaincase lubrication systems, belt tension gauge calibration, and wheel bearing installation procedures. The document includes reference data for spoke nipple tension, fork oil level measurement techniques, and steering geometry swing-by verification protocols.
Integrated Nexus
Hydraulic schematics are included for front and rear brake master cylinder operation, caliper piston removal using specialized tools, and brake line routing along the frame structure. The manual provides complete diagrams showing internal passage configurations, seal groove dimensions, and component interaction sequences. Bleeding system protocols document air evacuation procedures and fluid pressure establishment methods. Brake pad replacement guidance includes friction material thickness specifications and backing plate positioning requirements for both single and dual caliper configurations.
Core Logic-Path
Steering component information is provided for fork stem nut adjustment, bearing race removal using specialized equipment, and steering head assembly procedures. The document covers fork stop positioning, pinch bolt torque verification, and swing-by verification using rod-based bearing adjuster tools. Navigation through the steering system includes fork tube runout measurement protocols and upper fork bracket alignment specifications. Bearing inspection criteria and repack guidance reference Special Purpose Grease application and dust shield positioning.
Engineered Topology
Inspection guidelines are provided for wheel rim runout checking using truing stands, spoke offset dimension verification for laced wheel configurations, and tire lateral and radial runout assessment. The manual documents belt deflection measurement using tension gauges, adjuster cam positioning against rear swingarm geometry, and belt sprocket tooth condition evaluation. Rear suspension air pressure tables reference load-dependent inflation ranges from solo rider configurations through maximum GVWR operating limits. Vehicle alignment procedures document front rubber mount centering, stabilizer link adjustment using alignment fixtures, and clearance verification between powertrain and frame-mounted components.
Comprehensive Threshold
Alignment specifications are included for frame geometry verification, rear swingarm pivot shaft assembly and bearing installation using hydraulic press equipment, and swing-by pattern validation for steering head bearing preload. The document provides detailed clearance specifications between fuel tank and engine mounting brackets, rocker covers and fuel system components, and tire-to-fender spacing. Disassembly sequences address fork leg bushing installation using specialized seal installers, damper tube and rebound spring assembly, and fork oil level establishment using calibrated measurement tools. Complete parts listings reference bearing pilot dimensions, socket sizes for fastener removal, and tool requirements for component installation across all model variations.
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