This Clymer 1999-2005 Harley-Davidson FLH FLT Twin Cam 88 Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1999-2005 Harley Davidson FLH and 1999-2005 Harley Davidson FLT Twin Cam 88 motorcycles.
1999 2000 2001 2002 2003 2004 2005
Everything you need to know to perform tune-up and routine maintenance on the engine, clutch and transmission, fuel and exhaust, ignition system, steering and suspension, wheels, brakes and tires, electrical system, cruise control, frame and body. Features complete wiring diagrams and 701 illustrated pages.
TABLE OF CONTENTS
Harley-Davidson FLH FLT Twin Cam 88 QUICK REFERENCE DATA
Harley-Davidson FLH FLT Twin Cam 88 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.
Harley-Davidson FLH FLT Twin Cam 88 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.
Harley-Davidson FLH FLT Twin Cam 88 LUBRICATION, MAINTENANCE AND TUNE-UP
Routine safety checks, Tires and wheels, Periodic lubrication, Periodic maintenance, Tune-up, Idle speed adjustment.
Harley-Davidson FLH FLT Twin Cam 88 ENGINE
Service precautions, Special tools, Servicing engine in frame, Engine, Rocker arms and pushrods, Cylinder head, Valves and valve components, Cylinder, Pistons and piston rings, Pushrods, Valve lifters, Oil pump, Oil filter mount, Camshaft support plate, Crankcase and crankshaft, Engine break-in.
Harley-Davidson FLH FLT Twin Cam 88 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.
Harley-Davidson FLH FLT Twin Cam 88 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.
Harley-Davidson FLH FLT Twin Cam 88 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).
Harley-Davidson FLH FLT Twin Cam 88 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.
Harley-Davidson FLH FLT Twin Cam 88 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.
Harley-Davidson FLH FLT Twin Cam 88 FRONT SUSPENSION AND STEERING
Handlebar, Front fork—non-cartridge type (all 1999-2001 and 2002 FLHR, FLHRI and FLHRCI right side only), Front fork air pressure adjustment (1999-2001 models), Front fork—cartridge type (2002 except 2002 FLHR, FLHRI and FLHRCI right side), Steering head and stem, Steering head bearing race replacement, Steering play adjustment.
Harley-Davidson FLH FLT Twin Cam 88 REAR SUSPENSION
Shock absorbers, Shock air pressure adjustment, Rear swing arm.
Harley-Davidson FLH FLT Twin Cam 88 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.
Harley-Davidson FLH FLT Twin Cam 88 CRUISE CONTROL
System components and operation, Control cables, Cruise control module, Cruise control switches.
Harley-Davidson FLH FLT Twin Cam 88 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
This service manual features a complete index by topic.
Harley-Davidson FLH FLT Twin Cam 88 WIRING DIAGRAMS
This repair manual features complete wiring diagrams.