HOME

MAINTENANCE SCHEDULE

MAINTENANCE TASK
AND SERVICE DATA

1.1

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P
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D
E

1
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M

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1
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Engine oil
Oil level:
Separate hot and cold checks
Engine filter
Hand tighten oil filter 1/2 to 3/4 turn
after gasket surface contacts filter
mounting surface
Battery
Brake fluid level and condition
Brake fluid type:
D.O.T. 5 SILICONE BRAKE FLUID
Part No. 99902-77 (12 oz.) or
99901-77 (gallon)

Brake pads and discs for wear

Minimum pad thickness:
0.04 in. (1.02 mm)

Maximum brake disc lateral runout:

0.008 in. (0.2 mm)
Tire pressure and inspect tire for
wear/damage
Primary chain adjustment
Deflection:
Cold: 5/8-7/8 in. (15.9-22.2 mm)
Hot: 3/8-5/8 in. (9.5-15.9 mm)

Table Code:
A - Adjust.
I - Inspect, and if necessary, correct, adjust, clean or replace.
L - Lubricate with specified lubricant.

R - Replace or change.
T - Tighten to proper torque.
X - Perform.
D - Disassemble, lubricate and inspect.

2003 FLT Police: Maintenance

1-1

HOME

MAINTENANCE TASK
AND SERVICE DATA

P
R
E
R
I
D
E

1
0
0
0
M
I

2
5
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5
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7
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1
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M
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1
2
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1
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1
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M
I

2
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I

2
2
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0
M
I

2
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I

2
7
5
0
0
M
I

3
0
0
0
0
M
I

3
2
5
0
0
M
I

3
5
0
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0
M
I

3
7
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0
0
M
I

4
0
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0
0
M
I

4
2
5
0
0
M
I

4
5
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0
M
I

4
7
5
0
0
M
I

5
0
0
0
0
M
I

1
6
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K
M

4
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K
M

8
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M

1
2
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M

1
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M

2
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2
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M

2
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3
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Primary chain lubricant

Lubricant level:
Bottom edge of diaphragm spring
with vehicle upright
Lubricant type:
Part No. 99887-84 (quart) or
99886-84 (gallon)
Clutch adjustment
X

Hand lever free play:

1/16-1/8 in. (1.6-3.2 mm)

Transmission lubricant
Lubricant level:
Bottom edge of FULL mark on dipstick with vehicle upright.
R

Lubricant type:
Part No. 99892-84 (quart)
Drain plug:
14-21 ft-lbs (19.0-28.5 Nm)
Rear belt deflection inspection
Deflection:
Vehicle on ground without rider5/16-3/8 in. (7.9-9.5 mm);
bottom strand with 10 lb. (4.5 kg)
upward force.

Specialty tool:
Part No. HD-35381
Rear belt and sprocket

Steering head bearing

AL

AL

AL

AL

Front fork oil

Check air suspension pressure,
operation and leakage

R
I

Table Code:
A - Adjust.
I - Inspect, and if necessary, correct, adjust, clean or replace.
L - Lubricate with specified lubricant.

1-2

2003 FLT Police: Maintenance

R
I

R - Replace or change.
T - Tighten to proper torque.
X - Perform.
D - Disassemble, lubricate and inspect.

HOME

MAINTENANCE TASK
AND SERVICE DATA

P
R
E
R
I
D
E

1
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1
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1
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1
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4
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1
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1
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2
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2
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2
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3
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3
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4
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7
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M

8
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M

Spark plugs
Plug type:
No. 6R12
Plug gap:
0.038-0.043 (0.97-1.09 mm)

Plug torque:
12-18 ft-lbs (16-24 Nm)
Air cleaner filter
Cover screw torque:
36-60 in-lbs (4.1-6.8 Nm)

Lubricate controls
Front brake hand lever, clutch hand
lever, throttle control cables, clutch
control cable and jiffy stand
Operation of throttle controls

Engine idle speed

Idle speed:
950-1050 RPM

Fuel system lines and fittings

Fuel tank filter

Rear swingarm pivot shaft nuts

Torque:
40-45 ft-lbs (54-61 Nm)

Hinges, latches - saddlebags,

fuel door

Check oil and brake lines for

leaks

I
I

Table Code:
A - Adjust.
I - Inspect, and if necessary, correct, adjust, clean or replace.
L - Lubricate with specified lubricant.

I
I

I
I

I
R

Engine mounts
Operation of all electrical
equipment and switches

I
I

I
I

R - Replace or change.
T - Tighten to proper torque.
X - Perform.
D - Disassemble, lubricate and inspect.

2003 FLT Police: Maintenance

1-3

HOME

MAINTENANCE TASK
AND SERVICE DATA

P
R
E
R
I
D
E

All critical fasteners except

engine head bolts

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1
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1
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6
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7
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8
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M

Inspect FLHP windshield

grommets
Road test

Table Code:
A - Adjust.
I - Inspect, and if necessary, correct, adjust, clean or replace.
L - Lubricate with specified lubricant.

1-4

2003 FLT Police: Maintenance

R - Replace or change.
T - Tighten to proper torque.
X - Perform.
D - Disassemble, lubricate and inspect.

HOME

BROADSIDES

1.2

8518

4
3

5
6

8
7

10

18 17
1.
2.
3.
4.
5.
6.
7.

Front turn signal/running lamp

Pursuit lamp
Headlamp
Ignition/light key switch/fork lock
Clutch hand lever
Ignition coil
Horn

16
14 13
15
12

11

8.

Main 40 amp circuit breaker

(under seat)
9. System fuses/relays
(under side cover)
10. Rear suspension air valve
(behind saddlebag)

11.
12.
13.
14.
15.
16.
17.
18.

Primary drain plug

Clutch inspection cover
Primary chain inspection cover
Jiffy stand
Footrest
Engine oil filter
Voltage regulator
Gear shifter lever

Figure 1-1. FLHTP (Left Side View)

8519

11
10

5
6

3
4

12

8
7
13

2
1

1.
2.
3.
4.
5.
6.
7.
8.

Rear turn signal lamp

Tail/stop lamp
Seat air valve/gauge
ECM, EFI fuses/relay
(under side cover)
Battery (under seat)
Accessory connector
(under seat)
Air cleaner
Fuel filler cover

21

20 19 18 17
16

9.
10.
11.
12.
13.
14.
15.

Throttle control grip

Front brake hand lever
Front brake master cylinder/reservoir
Speedometer/tachometer
Front turn signal/running lamp
Rear brake pedal
Rear brake master cylinder/reservoir

15
16.
17.
18.
19.
20.
21.

14
Footrest
Engine oil pan drain
Transmission fill plug
Transmission drain plug
Engine oil fill plug/dipstick
Electric starter motor

Figure 1-2. FLHTP (Right Side View)

2003 FLT Police: Maintenance

1-5

HOME

8526

10

6 7

11

12

20
1.
2.
3.
4.
5.
6.
7.
8.

Front turn signal/running lamp

Pursuit lamp
Headlamp
Fork lock
Clutch hand lever
Fuel gauge
Ignition coil
Ignition/light key switch

18
15
17 16 14

19

13

13.
14.
15.
16.
17.
18.
19.
20.

9. Horn
10. Main 40 amp circuit breaker
(under seat)
11. System fuses/relays
(under side cover)
12. Rear suspension air valve
(behind saddlebag)

Primary drain plug

Clutch inspection cover
Primary chain inspection cover
Jiffy stand
Footrest
Engine oil filter
Voltage regulator
Gear shifter lever

Figure 1-3. FLHP (Left Side View)

11 12

8527

5
3

13

10
9

6
7

8
14

2
1

22
1.
2.
3.
4.
5.
6.
7.
8.

Rear turn signal lamp

Tail/stop lamp
Seat air valve/gauge
ECM, EFI fuses/relay
(under side cover)
Battery (under seat)
Accessory connector
(under seat)
Air cleaner
Fuel filler cap

20 19 18 17
21

9.
10.
11.
12.

Speedometer
Throttle control grip
Front brake hand lever
Front brake
master cylinder/reservoir
13. Tachometer
14. Front turn signal/running lamp
15. Rear brake master cylinder/
reservoir
Figure 1-4. FLHP (Right Side View)

1-6

2003 FLT Police: Maintenance

15

16

16.
17.
18.
19.
20.
21.
22.

Rear brake pedal

Footrest
Engine oil pan drain
Transmission fill plug
Transmission drain plug
Engine oil fill plug/dipstick
Electric starter motor