Harley-Davidson Touring FLHX, FLHTC, FLHTCU, FLTR, FLHR, FLHRC, FLHRS, and TLE 2000–2006 Service Manual (P/N 99483-06, 99497-06, and 99500-06)

• 2006 Touring coverage: FLHX, FLHT, FLHTC, FLHTCU, FLTR, FLHR, FLHRC, and FLHRS families, including the carbureted, fuel-injected, Shrine, and sidecar-equipped variants identified in the VIN tables. This is a 2006 factory manual set, not a complete service-manual set for model years 2000–2005.
• 1,419-page PDF: Harley-Davidson P/N 99483-06 Touring Service Manual, 713 PDF pages; P/N 99500-06 FLHTCUSE Service Supplement, 156 pages; P/N 99497-06 Electrical Diagnostics, 548 pages; plus two opening cover/index pages.
• Engine repair procedures: motorcycle stripping and reassembly, engine removal and installation, top-end and bottom-end overhaul, cylinder-head and piston service, cam support plate and oil-pump work, crankcase inspection, and flywheel/connecting-rod service.
• Chassis, wheel, and brake work: sealed wheel-bearing replacement, laced-wheel assembly and truing, rim and tire runout checks, vehicle alignment, front-fork service, steering-head bearings, rear air suspension and swingarm service, master-cylinder and caliper overhaul, pad replacement, and hydraulic brake bleeding.
• Primary drive and transmission service: primary chain and sprockets, clutch removal and repair, secondary drive-belt inspection and adjustment, transmission power-flow reference, shift linkage, shifter cam and forks, clutch-release cover, mainshaft and countershaft service, main-drive gear and bearing work, and transmission case and oil-pan procedures.
• Electrical and fault diagnosis: starter and charging tests, battery testing, speedometer self-diagnostics, TSM/TSSM and security diagnosis, carbureted ICM and EFI fault tracing, fuel-pressure and intake-leak tests, DTC test charts, advanced-audio self-diagnostics, serial-data BUS checks, and cruise-control diagnostic charts.
• FLHTCUSE and sidecar scope: the supplement adds model-specific engine, hydraulic clutch and secondary actuator, oil cooler and thermostat, chassis trim and controls, XM/audio equipment, garage-door opener, and dedicated wiring information. TLE/TLE-U coverage is limited to amplifier, sidecar speaker, headset, and switch wiring; it is not a mechanical sidecar repair manual.

Exact Model and Variant Scope

The main service manual separates carbureted and EFI systems and provides VIN decoding for domestic and international models, engine type, model designation, and assembly plant. The model-code table identifies the relevant FLHT, FLHR, FLHX, FLTR, FLHTCUI, FLHRCI, FLHRSI, Shrine, and sidecar-equipped configurations rather than treating every Touring motorcycle as mechanically identical.

The FLHTCUSE publication is model-specific rather than stand-alone. It covers only the components and specifications unique to that motorcycle and directs the technician back to the Touring Service Manual for standard procedures. Its unique sections include hydraulic-clutch maintenance and bleeding, clutch master-cylinder and fluid-line service, secondary clutch-actuator repair, the 103 cu. in. engine’s cylinder heads and pistons, cylinder boring and honing, cams and timing marks, and thermostat-controlled oil-cooler hardware.

Diagnostic Depth, Tools, and Reference Data

The electrical volume combines wiring diagrams with working diagnostic procedures. It includes initial checks, speedometer access to stored trouble codes, breakout-box testing, wiggle tests, no-start and stall fault trees, system-relay checks, EFI fuel-pressure diagnosis, TSSM password learn, radio switch and speaker DTCs, serial-data BUS diagnosis, and cruise-control charts for enable, resume, brake-light, throttle-switch, speedometer, and tachometer inputs. Connector service covers Deutsch, Multilock, Delphi, Packard, and sealed butt-splice systems, with connector locations and terminal repair information.

Appendix A identifies the factory tools used by the procedures, including the HD-44060 Wheel Bearing Remover/Installer, HD-46247 Vehicle Alignment Tool, HD-43293A Brake Caliper Piston Remover, HD-42682 carbureted and HD-43876 EFI Breakout Boxes, HD-43644 Camshaft/Camshaft Bearing Remover/Installer, and HD-44750 Digital Technician. The reference sections supply component-specific torque tables, fluid-capacity data, manufacturing tolerances, service wear limits, runout specifications, and electrical test values.

Diagrams and Manual-Specific Service Cautions

Representative visual references include the Front Wheel exploded view, Cam Support Plate/Oil Pump Assemblies exploded view, Side Door, Mainshaft and Countershaft Assembly exploded view, Rear Brake Master Cylinder cross-sectional view, Top/Bottom End Service flow chart, and model-specific Main Harness and Starting and Charging wiring diagrams. The FLHTCUSE appendix adds dedicated EFI, lamp, sound-system, and intercom wiring.

The rear-axle torque adapter must be held perpendicular to the torque wrench; using it inline multiplies torque and can damage parts. The laced-wheel section warns that a standard T30 bit damages the TORX Plus spoke nipples, and that steel-rim and chrome-profile spoke hardware must not be mixed. During front master-cylinder removal or installation, the specified lever insert protects the front stoplight-switch boot and plunger from damage.

Motorcycle repair can involve fuel, brake fluid, supported vehicle weight, rotating assemblies, and electrical isolation. Use the complete factory procedure, specifications, and final operational checks in the manual, especially for brake, wheel-alignment, fuel-system, and internal-engine work.