2003 FLT MODELS
SERVICE MANUAL
Part Number 99483-03A
Section 1: Maintenance
Section 2: Chassis
Section 3: Engine
Section 4: Fuel System
Section 5: Starter
Section 6: Drive
Section 7: Transmission
Section 8: Electrical
Section 9: Fuel Injection
Appendix
ELECTRICAL DIAGNOSTICS
Part Number 99497-03
Section 1: Starting & Charging
Section 2: Instruments
Section 3: TSM & TSSM
Section 4: Engine Management
Section 5: Engine Management (EFI)
Section 6: Sound System
Section 7: Cruise Control
Section 8: Wiring
SUBJECT PAGE NO.
1.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Shop Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.3 Tool Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.4 Scheduled Maintenance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.5 Scheduled Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
MAINTENANCE 1
T ab le Of Contents
2003 Touring: Maintenance 1-1
HOME
TROUBLESHOOTING 1.1
GENERAL
The following check list of possible operating troubles and
their probable causes will be helpful in keeping your motorcy-
cle in good operating condition. More than one of these con-
ditions may be causing the trouble and all should be carefully
checked. 1WARNING
The troubleshooting section of this manual is intended
solely as a guide to diagnosing problems. Carefully read
the appropriate sections of this manual before perform-
ing any work. Improper repair and/or maintenance could
result in death or serious injury.
ENGINE
Starter Motor Does Not Operate or Does
Not Turn Engine Over
1. Ignition/Light Key Switch not in IGNITION position.
2. Engine Stop switch in the OFF position.
3. Discharged battery, loose or corroded connections
(solenoid chatters).
4. TSM/TSSM BAS tripped and Ignition/Light Key Switch
not cycled to OFF and then back to IGNITION.
5. Starter control circuit, relay or solenoid faulty.
6. Electric starter shaft pinion gear not engaging or over-
running clutch slipping.
Engine Turns Over But Does Not Start
1. Fuel tank empty.
2. Fuel supply valve turned to OFF.
3. Fouled spark plugs.
4. Engine flooded with gasoline as a result of over use of
enrichener.
5. Fuel valve or filter clogged.
6. Vacuum hose to automatic fuel supply valve discon-
nected, leaking or pinched.
7. Discharged battery, loose or broken battery terminal
connections.
8. Loose wire connection at coil, battery or plug between
ignition sensor and module.
9. Spark plug cables in bad condition and shorting, cable
connections loose, or cables connected to wrong cylin-
ders.
10. Ignition timing incorrect due to faulty ignition coil, ignition
module or sensors (MAP, CKP and/or TSM/TSSM).
11. Engine lubricant too heavy (winter operation).
NOTE
Always disengage clutch for cold weather starts.
12. Sticking or damaged valve or push rod wrong length.
13. Primary cam sprocket spline sheared or missing spacer.
Starts Hard
1. Spark plugs in bad condition, have improper gap or are
partially fouled.
2. Spark plug cables in bad condition.
3. Battery nearly discharged.
4. Loose wire connection at one of the battery terminals,
ignition coil or plug between ignition sensor and module.
5. Carburetor controls not adjusted correctly.
6. Water or dirt in fuel system and carburetor.
7. Intake air leak.
8. Fuel tank vent hose and vapor valve plugged, or carbu-
retor fuel line closed off and restricting fuel flow.
9. Enrichener valve inoperative.
10. Engine lubricant too heavy (winter operation).
NOTE
Always disengage clutch for cold weather starts.
11. Ignition not functioning properly (possible sensor failure).
12. Faulty ignition coil.
13. Valves sticking.
Starts But Runs Irregularly or Misses
1. Spark plugs in bad condition or partially fouled.
2. Spark plug cables in bad condition and leaking.
3. Spark plug gap too close or too wide.
4. Faulty ignition coil, module and/or sensor.
5. Battery nearly discharged.
6. Damaged wire or loose connection at battery terminals,
ignition coil, or plug between ignition sensor and module.
7. Intermittent short circuit due to damaged wire insulation.
8. Water or dirt in fuel system, carburetor or filter.
9. Fuel tank vent system plugged or carburetor vent line
closed off.
10. Carburetor controls misadjusted.
11. Damaged carburetor.
1-2 2003 Touring: Maintenance
HOME
12. Loose or dirty ignition module connector at crankcase.
13. Faulty MAP and/or CKP Sensor.
14. Incorrect valve timing.
15. Weak or broken valve springs.
16. Damaged intake or exhaust valve.
A Spark Plug Fouls Repeatedly
1. Fuel mixture too rich or enrichener left out too long.
2. Incorrect spark plug for the kind of service.
3. Piston rings badly worn or broken.
4. Valve guides or seals badly worn.
Pre-Ignition or Detonation (Knocks or
Pings)
1. Fuel octane rating too low.
2. Faulty spark plugs.
3. Incorrect spark plug for the kind of service.
4. Excessive carbon deposit on piston head or in combus-
tion chamber.
5. Ignition timing advanced due to faulty sensor inputs
(MAP, CKP).
Overheating
1. Insufficient oil supply or oil not circulating.
2. Insufficient air flow over engine.
3. Heavy carbon deposit.
4. Ignition timing retarded due to faulty MAP and/or CKP
Sensor.
5. Leaking valve.
Valve Train Noise
1. Low oil pressure caused by oil feed pump not functioning
properly or oil passages obstructed.
2. Faulty hydraulic lifters.
3. Bent push rod.
4. Incorrect push rod length.
5. Rocker arm binding on shaft.
6. Valve sticking in guide.
7. Chain tensioner spring or shoe worn.
Excessive Vibration
1. Wheels and/or tires worn or damaged.
2. Engine/transmission/vehicle not aligned properly.
3. Primary chain badly worn or links tight as a result of
insufficient lubrication or misalignment.
4. Engine to transmission mounting bolts loose.
5. Upper engine mounting bracket loose.
6. Ignition timing incorrect/poorly tuned engine.
7. Internal engine problem.
8. Broken frame.
9. Stabilizer links worn or loose.
10. Rubber mounts loose or worn.
11. Rear fork pivot shaft nuts loose.
12. Front engine mounting bolts loose.
Check Engine Lamp Illuminates During
Operation
1. Fault detected. Check for trouble codes.
LUBRICATION SYSTEM
Oil Does Not Return To Oil Pan
1. Oil pan empty.
2. Oil pump not functioning.
3. Restricted oil lines or fittings.
4. Restricted oil filter.
5. Oil pump misaligned or in poor condition.
6. O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).
Engine Uses Too Much Oil Or Smokes
Excessively
1. Oil pan overfilled.
2. Restricted oil return line to pan.
3. Restricted breather operation.
4. Restricted oil filter.
5. Oil pump misaligned or in poor condition.
6. Piston rings badly worn or broken.
7. Valve guides or seals worn.
8. O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).
Engine Leaks Oil From Case, Push Rods,
Hoses, Etc.
1. Loose parts.
2. Imperfect seal at gaskets, push rod cover, washers, etc.
3. Restricted oil return line to pan.
4. Restricted breather hose to air cleaner.
5. Restricted oil filter.
2003 Touring: Maintenance 1-3
HOME
6. Oil pan overfilled.
7. Rocker housing gasket (bottom) installed upside down.
Low Oil Pressure
1. Oil pan underfilled.
2. Faulty low oil pressure switch.
3. Oil pump O-ring(s) damaged or missing.
4. Oil pressure relief valve stuck in open position.
5. Ball or clean out plug missing from cam support plate.
High Oil Pressure
1. Oil pan overfilled.
2. Oil pressure relief valve stuck in closed position.
ELECTRICAL SYSTEM
Alternator Does Not Charge
1. Module not grounded.
2. Engine ground wire loose or broken.
3. Faulty regulator-rectifier module.
4. Loose or broken wires in charging circuit.
5. Faulty stator and/or rotor.
Alternator Charge Rate Is Below Normal
1. Weak or damaged battery.
2. Loose connections.
3. Faulty regulator-rectifier module.
4. Faulty stator and/or rotor.
Speedometer Operates Erratically
1. Contaminated speedometer sensor (remove sensor and
clean off metal particles).
2. Loose connections.
CARBURETOR
Carburetor Floods
1. Dirt or other foreign matter between valve and its seat.
2. Inlet valve sticking.
3. Inlet valve and/or valve seat worn or damaged.
4. Float misadjusted.
5. Leaky or damaged float.
6. Excessive “pumping” of hand throttle grip.
7. See TROUBLESHOOTING CHART in Section 4.
TRANSMISSION
Transmission Shifts Hard
1. Clutch dragging slightly.
2. Primary chaincase overfilled with lubricant.
3. Corners worn off shifter clutch dogs.
4. Shifter return spring bent or broken.
5. Bent shifter rod.
6. Shifter forks sprung.
7. Transmission lubrication too heavy (winter operation).
Jumps Out Of Gear
1. Shifter rod improperly adjusted.
2. Shifter drum damaged.
3. Shifter engaging parts (inside transmission) badly worn
and rounded.
4. Shifter forks bent.
5. Damaged gears.
Clutch Slips
1. Clutch controls improperly adjusted.
2. Insufficient clutch spring tension.
3. Worn friction discs.
Clutch Drags Or Does Not Release
1. Clutch controls improperly adjusted.
2. Lubricant level too high in primary chaincase.
3. Primary chain badly misaligned.
4. Clutch discs warped.
5. Insufficient clutch spring tension.
Clutch Chatters
1. Friction discs or steel discs worn or warped.
1-4 2003 Touring: Maintenance
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BRAKES
Brake Does Not Hold Normally
1. Master cylinder reservoir low on fluid.
2. Brake system contains air bubbles.
3. Master or wheel cylinder piston worn or parts damaged.
4. Brake pads contaminated with grease or oil.
5. Brake pads badly worn- friction material 0.04 inch (1.02
mm) thick or less.
6. Brake disc badly worn or warped.
7. Brake fades due to heat build up – brake pads dragging
or excessive braking.
8. Brake drags – insufficient brake pedal free play.
HANDLING
Irregularities
1. Improperly loaded motorcycle. Non-standard equipment
on the front end such as heavy radio receivers, extra
lighting equipment or luggage tends to cause unstable
handling.
2. Incorrect air suspension pressure.
3. Damaged tire(s) or improper front-rear tire combination.
4. Irregular or peaked front tire tread wear.
5. Incorrect tire pressure.
6. Shock absorber not functioning normally.
7. Loose wheel axle nuts. Tighten to recommended tight-
ness.
8. Excessive wheel hub bearing play.
9. Improper vehicle alignment.
10. Steering head bearings improperly adjusted. Correct
adjustment and replace pitted or worn bearings and
races.
11. Tire and wheel unbalanced.
12. Rims and tires out-of-round or eccentric with hub.
13. Rims and tires out-of-true sideways.
14. Shock absorber improperly adjusted.
15. Worn engine stabilizer links.
16. Damaged rear engine isolation mounts.
17. Swingarm pivot shaft nut improperly tightened or assem-
bled.
2003 Touring: Maintenance 1-5
HOME
SHOP PRACTICES 1.2
REPAIR NOTES
General maintenance practices are given in this section. All
special tools and torque values are noted at the point of use
and all required parts or materials can be found in the appro-
priate PARTS CATALOG.
Safety
Safety is always the most important consideration when per-
forming any job. Be sure you have a complete understanding
of the task to be performed. Use common sense. Use the
proper tools. Don’t just do the job – do the job safely.
Removing Parts
Always consider the weight of a part when lifting. Use a hoist
whenever necessary. Do not lift heavy parts by hand. A hoist
and adjustable lifting beam or sling are needed to remove
some parts. The lengths of chains or cables from the hoist to
the part should be equal and parallel, and should be posi-
tioned directly over the center of the part. Be sure that no
obstructions will interfere with the lifting operation. Never
leave a part suspended in mid-air.
Always use blocking or proper stands to support the part that
has been hoisted. If a part cannot be removed, verify that all
bolts and attaching hardware have been removed. Check to
see if any parts are in the way of the part being removed.
When removing hoses, wiring or tubes, always tag each part
to ensure proper installation.
Cleaning
If you intend to reuse parts, follow good shop practice and
thoroughly clean the parts before assembly. Keep all dirt out
of parts; the unit will perform better and last longer. Seals, fil-
ters and covers are used in this vehicle to keep out environ-
mental dirt and dust. These items must be kept in good
condition to ensure satisfactory operation.
Clean and inspect all parts as they are removed. Be sure all
holes and passages are clean and open. After cleaning,
cover all parts with clean lint-free cloth, paper or other mate-
rial. Be sure the part is clean when it is installed.
Always clean around lines or covers before they are
removed. Plug, tape or cap holes and openings to keep out
dirt, dust and debris.
Always verify cleanliness of blind holes before assembly.
Tightening screws with dirt, water or oil in the holes can
cause castings to crack or break.
Disassembly and Assembly
Always assemble or disassemble one part at a time. Do not
work on two assemblies simultaneously. Be sure to make all
necessary adjustments. Recheck your work when finished.
Be sure that everything is done.
Operate the vehicle to perform any final check or adjust-
ments. If all is correct, the vehicle is ready to go back to the
customer.
Checking Torques on Fasteners with Lock
Patches
To check the torque on a fastener that has a lock patch:
1. Set the torque wrench for the lowest setting in the speci-
fied torque range.
2. Attempt to tighten fastener to set torque. If fastener does
not move and lowest setting is satisfied (torque wrench
clicks), then the proper torque has been maintained.
REPAIR AND REPLACEMENT
PROCEDURES
Hardware and Threaded Parts
Install helical thread inserts when inside threads in castings
are stripped, damaged or not capable of withstanding speci-
fied torque.
Replace bolts, nuts, studs, washers, spacers and small com-
mon hardware if missing or in any way damaged. Clean up or
repair minor thread damage with a suitable tap or die.
Replace all damaged or missing lubrication fittings.
Use Teflon tape on pipe fitting threads.
Wiring, Hoses and Lines
Replace hoses, clamps, electrical wiring, electrical switches
or fuel lines if they do not meet specifications.
Instruments and Gauges
Replace broken or defective instruments and gauges.
Replace dials and glass that are so scratched or discolored
that reading is difficult.
1-6 2003 Touring: Maintenance
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Bearings
Anti-friction bearings must be handled in a special way. To
keep out dirt and abrasives, cover the bearings as soon as
they are removed from the package.
Wash bearings in a non-flammable cleaning solution. Knock
out packed lubricant inside by tapping the bearing against a
wooden block. Wash bearings again. Cover bearings with
clean material after setting them down to dry. Never use com-
pressed air to dry bearings.
Coat bearings with clean oil. Wrap bearings in clean paper.
Be sure that the chamfered side of the bearing always faces
the shoulder (when bearings installed against shoulders).
Lubricate bearings and all metal contact surfaces before
pressing into place. Only apply pressure on the part of the
bearing that makes direct contact with the mating part.
Always use the proper tools and fixtures for removing and
installing bearings.
Bearings do not usually need to be removed. Only remove
bearings if necessary.
Bushings
Do not remove a bushing unless damaged, excessively worn
or loose in its bore. Press out bushings that must be
replaced.
When pressing or driving bushings, be sure to apply pres-
sure in line with the bushing bore. Use a bearing/bushing
driver or a bar with a smooth, flat end. Never use a hammer
to drive bushings.
Inspect the bushing and the mated part for oil holes. Be sure
all oil holes are properly aligned.
Gaskets
Always discard gaskets after removal. Replace with new gas-
kets. Never use the same gasket twice (unless instructed
otherwise). Be sure that gasket holes match up with holes in
the mating part.
If a gasket must be made, be sure to cut holes that match up
with the mating part. Serious vehicle damage can occur if
any flange holes are blocked by the gasket. Use material that
is the right type and thickness.
Lip Type Seals
Lip seals are used to seal oil or grease and are usually
installed with the sealing lip facing the contained lubricant.
Seal orientation, however, may vary under different applica-
tions.
Seals should not be removed unless necessary. Only remove
seals if required to gain access to other parts or if seal dam-
age or wear dictates replacement.
Leaking oil or grease usually means that a seal is damaged.
Replace leaking seals to prevent overheated bearings.
Always discard seals after removal. Do not use the same
seal twice.
O-Rings (Preformed Packings)
Always discard O-rings after removal. Replace with new O-
rings. To prevent leaks, lubricate the O-rings before installa-
tion. Apply the same type of lubricant as that being sealed.
Be sure that all gasket, O-ring and seal mating surfaces are
thoroughly clean before installation.
Gears
Always check gears for damaged or worn teeth.
Remove burrs and rough spots with a honing stone or crocus
cloth before installation. Lubricate mating surfaces before
pressing gears on shafts.
Shafts
If a shaft does not come out easily, check that all nuts, bolts
or retaining rings have been removed. Check to see if other
parts are in the way before using force.
Shafts fitted to tapered splines should be very tight. If shafts
are not tight, disassemble and inspect tapered splines. Dis-
card parts that are worn. Be sure tapered splines are clean,
dry and free of burrs before putting them in place. Press mat-
ing parts together tightly.
Clean all rust from the machined surfaces of new parts.
Part Replacement
Always replace worn or damaged parts with new parts.
CLEANING
Part Protection
Before cleaning, protect rubber parts (such as hoses, boots
and electrical insulation) from cleaning solutions. Use a
grease-proof barrier material. Remove the rubber part if it
cannot be properly protected.
Cleaning Process
Any cleaning method may be used as long as it does not
result in parts damage. Thorough cleaning is necessary for
proper parts inspection. Strip rusted paint areas to bare
metal before repainting.
2003 Touring: Maintenance 1-7
HOME
Rust or Corrosion Removal
Remove rust and corrosion with a wire brush, abrasive cloth,
sand blasting, vapor blasting or rust remover. Use buffing
crocus cloth on highly polished parts that are rusted.
Bearings
Remove shields and seals from bearings before cleaning.
Clean bearings with permanent shields and seals in solution.
Clean open bearings by soaking them in a petroleum clean-
ing solution. Never use a solution that contains chlorine.
Let bearings stand and dry. Do not dry using compressed air.
Do not spin bearings while they are drying.
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2003 Harley-Davidson Touring Service Manual SET FLHR FLHT FLTR Electra Glide Road King Ultra Glide Road Glide Screamin Eagle Pol
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Description
These comprehensive manuals cover a range of 2003 Touring models from Harley-Davidson, including the FLTRI Road Glide, FLHTPI Electra Glide Police, FLHTI Electra Glide Standard, FLHTCUI Ultra Classic Electra Glide, FLHTCI Electra Glide Classic, FLHTC Electra Glide Classic, FLHT Electra Glide Standard, FLHRSEI Screamin Eagle Road King, FLHRI Road King, FLHRCI Road King Classic, and FLHR Road King.
The service manual includes detailed chapters on maintenance, chassis, engine, fuel system, drive, transmission, and electrical systems. The electrical diagnostics manual covers starting/charging, instruments, TSM/HFSM, and engine management, along with numerous subsections, troubleshooting guides, detailed diagrams, illustrations, photos, exploded views, and step-by-step instructions.
These manuals are invaluable resources for both professional mechanics and DIY enthusiasts. They are available in a file format compatible with all versions of Windows and Mac, and can be viewed using Adobe Reader. With the ability to print any page, these manuals offer significant cost savings compared to dealership labor charges. Whether you're looking to save on maintenance costs or simply prefer having these resources at your fingertips, these manuals are a must-have for anyone working with these Harley-Davidson models.
