MOTORCYCLE SERVICE MANUAL

Models covered:

FLHT/FLHTI Electra Glide Standard (1999-2005)
FLHTC/FLHTCI Electra Glide Classic (1999-2005)
FLHTCUI Electra Glide Ultra Classic (1999-2005)
FLHTCSE2 Screamin’ Eagle Electra Glide 2 (2005)
FLHR/FLHRI Road King (1999-2005)
FLHRCI Road King Classic (1999-2005)
FLHRS/FLHRSI Road King Custom (2004-2005)
FLTR/FLTRI Road Glide (1999-2005)

This Harley-Davidson FLH FLT Motorcycle Manual is 720 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Basic tools / Special tools / Precision measuring tools / Electrical system fundamentals / Basic service methods / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Engine starting / Engine performance / Starting system / Charging system / Ignition system / Engine management system diagnostic codes / Cruise control system diagnostic codes / Fuel system (carbureted models) / Fuel system (fuel injected models) / Engine noises / Engine lubrication / Clutch / Transmission / Lighting system / Excessive vibration / Front suspension and steering / Brake system / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Maintenance schedule intervals / Periodic lubrication / Engine oil change / Transmission oil change / Periodic maintenance / Control cables / Tune-up / Idle speed adjustment / Specifications

CHAPTER FOUR / ENGINE
Removal installation / Rocker arms and pushrods / Cylinder head / Valves and components / Cylinder / Piston and rings / Pushrods / Valve lifters / Oil pump / Camshaft support plate / Crankcase and crankshaft / Break-in / Specifications

CHAPTER FIVE / CLUTCH AND PRIMARY DRIVE
Primary chaincase cover / Clutch shell, compensating sprocket and primary drive chain / Clutch shell, clutch hub and sprocket / Primary chain and guide / Compensating sprocket / Primary chaincase housing / Starter jackshaft / Clutch cable / Specifications

CHAPTER SIX / TRANSMISSION
Shifter assembly / External shift mechanism / Transmission top cover / Shift cam / Shift arm assembly / Shift forks / Transmission side door and transmission shaft / Transmission shafts / Main drive gear / Transmission clutch release cover assembly / Transmission drive sprocket / Transmission case / Oil pan / Specifications

CHAPTER SEVEN / FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS
Air filter backplate / Carburetor operation / Carburetor / Intake manifold (carbureted models) / Electronic fuel injection (EFI) / Depressurizing the fuel system / (fuel injected models) / Induction module (fuel injected models) / Throttle and idle cables (carbureted models) / Starting enrichment valve (choke) / cable replacement (carbureted models) / Throttle and idle cables (fuel injected models) / Fuel tank console / Fuel tank (carbureted models) / Fuel tank (fuel injected models) / Fuel pump and fuel filter (fuel injected models) / Fuel shutoff valve (carbureted models) / Fuel tank gauge (FLHR) / Exhaust system / Evaporative emission control system (California models) / Specifications

CHAPTER EIGHT / ELECTRICAL SYSTEM
Basic information / Battery / Charging system / Alternator / Voltage regulator / Ignition system / Starting system / Lighting system / Switches / Horn / Turn signal module (1999-2000 models) / Turn signal module and turn signal/security / module (2001-on models) / Speedometer speed sensor / Starter relay switch replacement / Instruments / Premium sound, CB and intercom systems / Fuses / Circuit breaker / Electrical connector service / Wiring diagrams / Specifications

CHAPTER NINE / WHEELS, HUBS AND TIRES
Motorcycle stands / Front wheel / Rear wheel / Front and rear hubs (1999) / Front and rear wheel bearing end play check (1999 models) / Front and rear hubs (2000-on) / Driven sprocket assembly / Drive sprocket / Drive belt / Wheel runout / Rim and laced wheel service / Cast wheels / Wheel balance / Tires / Tubeless tire changing / Tire repairs / Motorcycle alignment / Specifications

CHAPTER TEN / FRONT SUSPENSION AND STEERING
Handlebar / Front fork—non-cartridge type (all 1999-2001 models and 2002 FLHR, / FLHRI and FLHRCI (right side only) / Front fork air pressure adjustment (1999-2001 models) / Front fork—cartridge type (2002 models except 2002 FLHR, FLHRI and FLHRCI right side) / Steering head and stem / Steering head bearing race replacement / Steering play adjustment / Specifications

CHAPTER ELEVEN / REAR SUSPENSION
Shock absorbers / Shock air pressure adjustment / Rear swing arm / Specifications

CHAPTER TWELVE / BRAKES
Brake service / Front brake pad replacement / Front brake caliper / Front master cylinder / Rear brake pad replacement / Rear brake caliper / Rear master cylinder and rear brake pedal / Brake hose and line replacement / Brake disc / Bleeding the system / Rear brake pedal / Specifications

CHAPTER THIRTEEN / CRUISE CONTROL
System components and operation / Control cables / Cruise control module / Switches / Specifications

CHAPTER FOURTEEN / BODY
Seat / Front and rear fender / Windshield and headlight nacelle / Front fairing / Saddlebags and guards / Tour-pak / Footboards / Specifications

SUPPLEMENT / 2003-2005 MODEL SERVICE INFORMATION
Routine safety checks / Periodic lubrication / Periodic maintenance / Engine / Rocker arm and pushrods / Cylinder head / Valve and valve components (2005 models– / except FLHTCSE2 models) / Pistons and piston rings / Oil cooler, oil filter mount and thermostat / (FLHTCSE2 models) / Crankcase and crankshaft / Clutch assembly (all 2005 models) / Clutch assembly (FLHTCSE2 models) / Clutch release bearing and pushrod / (FLHTCSE2 models) / Clutch service (FLHTCSE2 models) / Clutch master cylinder (FLHTCSE2 models) / Clutch release mechanism (FLHTCSE2 models) / Clutch hydraulic hose replacement / (FLHTCSE2 models) / Clutch system flushing (FLHTCSE2 models) / Clutch system bleeding (FLHTCSE2 models) / Shifter assembly (FLHTCSE2 models) / External shift mechanism (FLHTCSE2 models) / Shift arm assembly (all models) / Shift linkage adjustment (all models) / Transmission side door and transmission / shaft assemblies / Fuel tank console / Fuel tank (carbureted models) / Fuel tank (fuel injected models) / Charging system (FLHTCSE2 models) / Alternator (FLHTCSE2 models) / Ignition system (2004-2005 carbureted models) / Lighting system / Switches / Instruments (FLHTSCE2 and all FLHT models) / Maxi-fuse replacement (2004-2005 models) / Front wheel / Front and rear hubs / (FLHTCSE2 and 2004-2005 models) / Front fork–cartridge type / Steering head and stem / Shock absorbers / Front brake pad replacement / Rear brake pad replacement / Rear master cylinder and rear brake pedal / Brake disc (FLHTCSE2 models) / Rear brake pedal (2004-2005 models) / Passenger backrest (FLHTCSE2 models) / Headlight and nacelle / (2004-2005 FLHR models) / Lower fairing / (FLHTCSE2 and 2005 FLHTCUI models / Saddlebags and guards / Footboards / Specifications

INDEX

COLOR WIRING DIAGRAMS