Harley Davidson FLH, FLT Twin Cam Repair Manual Chapters:
QUICK REFERENCE DATA
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
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 | Engine noises | Engine lubrication | Clutch | Transmission | Lighting system | Excessive vibration | Front suspension and steering | Brake system
LUBRICATION, MAINTENANCE AND TUNE-UP
Routine safety checks | Tires and wheels | Periodic lubrication | Periodic maintenance | Tune-up | Idle speed adjustment
ENGINE
Service precautions | Special tools | Servicing engine in frame | Engine | Rocker arms and pushrods | Cylinder head | Valves and valve components | Cylinder | Piston and piston rings | Pushrods | Valve lifters | Oil pump | Oil filter mount | Camshaft support plate | Crankcase and crankshaft | Engine break-in
CLUTCH AND PRIMARY DRIVE
Primary chaincase cover | Clutch assembly | Clutch shell, compensating sprocket and primary drive chain | Clutch shell, clutch hub and sprocket | Primary chain and guide inspection | Primary chain alignment | Compensating sprocket inspection | Primary chaincase housing | Starter jackshaft | Clutch cable replacement
TRANSMISSION
Shifter assembly | External shift mechanism | Transmission top cover | Shift cam | Shift arm assembly | Shift forks | Transmission side door and transmission shaft assemblies | Transmission shafts | Main drive gear | Transmission clutch release cover assembly | Transmission drive sprocket | Transmission case | Oil pan
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 tank gauge (FLHR) | Exhaust system | Evaporative emission control system (California models)
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 , CD and intercom systems | Fuses | Circuit breaker | Electrical connector service | Wiring diagrams
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
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
REAR SUSPENSION
Shock absorbers | Shock air pressure adjustment | Rear swing arm
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
CRUISE CONTROL
System components and operation | Control cables | Cruise control module | Cruise control switches
BODY
Seat | Front fender | Rear fender | Windshield and headlight nacelle (FLHR models) | Windshield and front fairing (FLTR models) | Front fairing (FLHT models) | Saddlebags and guards | Tour-pak (FLHT models) | Footboards
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
COLOR WIRING DIAGRAMS
