2

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SPECIFICATIONS

2.1

FUEL TANK
TOTAL

MODEL

FLHTP
FLHP

OIL TANK
W/FILTER

TRANSMISSION
(APPROX.)

PRIMARY
CHAINCASE

gal.

liter

gal.

liter

qt.

liter

oz.

liter

oz.

liter

5.0

18.92

4.0

3.79

24

0.71

32

0.95

WHEEL BASE
MODEL
in.

FUEL TANK
RESERVE

mm

OVERALL
LENGTH

OVERALL
WIDTH

in.

in.

mm

in.

mm

mm

ROAD
CLEARANCE

OVERALL
HEIGHT

SADDLE
HEIGHT

in.

mm

in.

mm

FLHTP

63.5

1612.9

93.70

2379.9

39.0

990.6

5.1

129.5

61.0

1549.4

28.5

723.9

FLHP

63.5

1612.9

93.70

2379.9

34.45

875.0

5.1

129.5

55.06

1398.5

28.5

723.9

DRY WEIGHT

GVWR

GAWR FRONT

GAWR REAR

lb.

lb.

MODEL
lb.

kg

lb.

kg

kg

kg

FLHTP

778.0

352.9

1200

544.3

500

226.8

770

349.3

FLHP

721.0

327.0

1200

544.3

500

226.8

770

349.3

NOTE
Gross vehicle weight rating (GVWR) (maximum allowable
loaded vehicle weight) and corresponding gross axle weight
rating (GAWR) are printed on a label fixed to the bottom of
the right front frame downtube.

NOTE
See Section 2.3 TIRES for important information regarding
tire data and tire inflation.

2003 FLT Police: Chassis

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VEHICLE IDENTIFICATION NUMBER

2.2

GENERAL

is stamped between the front and rear cylinders on the left

side of the crankcase.

A 17-digit serial number, or Vehicle Identification Number

(VIN), is stamped on the right side of the frame backbone at
the rear of the steering head (and under the main harness
conduit). A label bearing the VIN code is also affixed to the
bottom of the right front frame downtube. An abbreviated VIN

NOTE
Always give the complete VIN when ordering parts or making
an inquiry about your motorcycle.

Market Designation
1 = Domestic
5 = International (HDI)

Manufacturer and Make

Harley-Davidson
Motorcycle Type
1 - Heavyweight

Engine Type
V - Carbureted
W - Fuel Injected

Model Designation
FH - FLHPI
FM - FLHTPI
FT - FLHPEI

Vin Check Digit

Varies; can be 0 thru 9, or X.

Introduction Date/Special Models

1 = Regular introduction date
2 = Mid-year introduction date
3 = California model
4 = Anniversary model
Model Year
3 - 2003

Assembly Plant
Y - York, PA
K - Kansas City, MO

Serial Number

HD

FM

110000

Sample VIN as it appears on the steering head - 1HD1FMW133Y110000

Sample abbreviated VIN as it appears on the engine - FMW3110000
Figure 2-1. Vehicle Identification Number (VIN)

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2003 FLT Police: Chassis

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TIRES

2.3

GENERAL

NOTE

The rear tire on FL police motorcycles is fit for solo riding

only. If converted to a two-up bike, that is, configured for passenger use (with luggage), then the rear tire needs to be
changed to one with a higher weight rating. Since it has long
been Harley-Davidson policy not to mix different types of tires
on the same vehicle, we strongly recommend that both front
and rear tires be replaced. In order to alert the customer to
this safety issue, the following warning appears on a label fitted to the rear fender (approximately 1/4 inch behind the
domestic seat mounting hole).

11
1WARNING
WARNING

Use the tires recommended for civilian/pleasure vehicles of

the same year and model family.

11
1WARNING
WARNING
The Dunlop front and rear tires on Harley-Davidson
motorcycles are not interchangeable. DO NOT put a front
tire at the rear of the vehicle or a rear tire at the front.
Improper placement of tires can adversely affect motorcycle stability and handling, which may lead to loss of
vehicle control resulting in death or serious injury.
Tire size, manufacturers description and inflation pressure
are listed below.

This vehicle has tires with weight ratings for one person
operation. If this vehicle is modified to carry two people,
the tires must be changed. See your local Harley-Davidson dealer for the proper replacement tires. Failure to follow this warning could cause tire failure which could
result in death or serious injury.

Table 2-1. Tire Data

MODEL

TIRE
LOCATION

SIZE

MANUFACTURERS
DESIGNATION

TIRE
PRESSURE
(Cold)

Front

MT90B1671H

Dunlop
D402 PTF

36 psi
(248 kPa)

Rear

MT90B1674H

Dunlop
D402 PT

36 psi
(248 kPa)

FLHTP/FLHP

2003 FLT Police: Chassis

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SEAT

2.4

FLHTP/FLHP
5872

Quick Release
Pin

OPERATION
CAUTION
Maximum seat air pressure is 100 psi (689 kPa). Normal
air pressure is between 30-45 psi (207-310 kPa). Minimum
air pressure is determined by rider weight. Do not operate with pressure so low that system bottoms out on
bumpy roads.

Support
Post

Rear Seat
Bracket

NOTE
To set minimum air pressure, have rider sit on seat and
bounce to simulate riding conditions. Visually check for any
contact between air spring and frame components. Add air as
necessary.
1.

Standing on left side of vehicle, press down on rear of

seat and pull quick release pin from hole in support post.
See Figure 2-2. Raise seat toward fuel tank console.

2.

To lock seat in place, move seat down until support post

engages hole in rear seat bracket.

Figure 2-2. Seat Latch

3.

While pressing down on rear of seat, insert quick release

pin into hole of support post.
NOTE
The seat does not adjust forward or backward.

11

10
9
8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

Air spring hose

Air spring
Screw (2) @ 15-20 ft-lbs (20.3-27.1 Nm)
6
Trim panel
Seat faring
Screw
Rivnut (4)
Screw
5
Bushing
Seat support bracket
Nut @ 15-20 ft-lbs (20.3-27.1 Nm)
Seat
Seat mount bracket (2)
Washer
Screw @ 15-20 ft-lbs (20.3-27.1 Nm)
Screw (4) @ 15-20 ft-lbs (20.3-27.1 Nm)
Rubber bumper
Flange locknut (2) @ 15-20 ft-lbs (20.3-27.1 Nm)
Quick release pin
Flange nut (2) @ 8-12 ft-lbs (10.8-16.3 Nm)
Washer (2)
Rear seat bracket
Set screw (2)
Nut (2) @ 8-12 ft-lbs (10.8-16.3 Nm)
Quick release fitting

13
14

12

16 15

19

17
18
20

21

3
2
1

22
23
24
25

Figure 2-3. Air Seat Support

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2003 FLT Police: Chassis

p0047c2x

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AIR SEAT RESERVOIR

f1842x2x

Air Pressure
Gauge

Air
Reservoir

REMOVAL
1.

Remove luggage rack. See Section 2.6 LUGGAGE

RACK, REMOVAL, steps 1-5.

2.

Alternately loosen screws on each side of motorcycle to

release ends of luggage rack from frame tube weldments. Continue loosening screws until luggage rack can
be raised high enough to remove air reservoir.

3.

Remove two Phillips screws (with lockwashers) from luggage rack to release top of air reservoir bracket.

4.

Remove two Phillips screws from license plate bracket to

free rear of air reservoir bracket. Be sure to hold reservoir as the last screw is removed or damage to fender
paint may occur when assembly is released.

5.

Raise luggage rack and remove air reservoir from motorcycle.

6.

Remove tee fittings from reservoir, if necessary.

Air Valve

Figure 2-4. Air Seat Reservoir Air Valve

3.

Slide Phillips screws through two holes in license plate

bracket and two holes in luggage rack engaging weld
nuts in air reservoir bracket. Alternately tighten screws
until snug.

4.

Alternately tighten screws on each side of motorcycle to

secure ends of luggage rack to frame tube weldments.

5.

Install luggage rack. See Section 2.6 LUGGAGE RACK,

INSTALLATION, steps 1-4 and 6-13.

INSTALLATION
1.

Install tee fittings to air reservoir, if removed.

2.

Position air reservoir beneath luggage rack exercising

caution to avoid scratching fender paint.

5
7

2
4
1. Air seat reservoir and
bracket
2. Lockwasher (2)
3. Screw (2)
4. Air pressure gauge
5. Air tube
6. Compression fitting
7. Air valve
8. Protective cap
9. Tee fitting (2)
10. Screw (2)

10

p0048b2x

Figure 2-5. Air Seat Reservoir

2003 FLT Police: Chassis

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FOOTBOARDS
FLHTP/FLHP

4.

GENERAL
FLHTP and FLHP models are equipped with adjustable footboards.

At footboard rear bracket, slide upper hex bolt through

frame weldment, jiffy stand bracket and foot-board
bracket thru hole. Install lockwasher and locknut. Slide
lower hex bolt (with lockwasher) through frame weldment
and jiffy stand bracket into threaded hole of footboard
bracket. Alternately tighten rear bracket fasteners.
NOTE

Perform a visual check to verify that both footboards are at

the same height.

ADJUSTMENT
RIGHT SIDE
1.

Loosen two allen head socket screws (with lockwashers

and flat washers) to release right side footboard brackets
from frame weldment. For best results, approach from
left side of vehicle using a 3/8 inch ball allen with extension.

2.

Move the footboard to one of two positions. Alternately

tighten allen head socket screws to 30-35 ft-lbs (40.747.5 Nm).

11
1WARNING
WARNING
Rear brake will not operate properly if brake pedal cannot be fully depressed. After adjusting right footboard,
check for minimum clearance of 2.25 inches (57 mm)
between bottom of brake pedal and top of footboard.
Failure to allow for proper clearance can lead to loss of
braking performance, which could result in death or serious injury.

LEFT SIDE
1.

Loosen the allen head socket screw (with lockwasher

and flat washer) to release the footboard forward bracket
from frame weldment. For best results, approach from
opposite side of vehicle using a 3/8 inch ball allen.

2.

To free footboard rear bracket from frame weldment and

jiffy stand bracket, remove lower hex bolt (with lockwasher) and upper hex bolt (with lockwasher and locknut).

3.

Move the footboard to one of two positions. Alternately

tighten allen head socket screw to 30-35 ft-lbs (40.7-47.5
Nm).

2-6

2.5

2003 FLT Police: Chassis

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LUGGAGE RACK

2.6

FLHTP/FLHP

6046

REMOVAL
1.

Remove both saddlebags.

2.

On the right side of the motorcycle, locate the air seat

reservoir air valve under the luggage rack, and on the left
side, the rear shock air valve just below the chrome
frame cover. See Figure 2-6.

11
1WARNING
WARNING
Exercise caution when bleeding air from the air valves.
Moisture combined with lubricant (either from shock
assembly or drip oiler in the air compressor lines) may
be ejected onto the rear wheel, tire and/or brake components and adversely affect traction and/or braking efficiency, which could result in death or serious injury.

f1842x2x

Air Seat
Reservoir
Air Valve

Figure 2-7. Remove Luggage Rack

Rear Shock
Air Valve

3.

Remove protective cap from each air valve and depress

pin to bleed air from both reservoir and shocks. To purge
rear air suspension lines of any oil, add 3-5 psi (20.734.5 kPa) before releasing air. Depress collar on each
compression fitting and pull out air tube.

4.

Remove bolt (with flat washer) to remove saddlebag front

mounting bracket from chrome frame cover. Remove
Phillips screw and then remove frame cover. Repeat step
on opposite side of motorcycle.

5.

Remove two bolts to free license plate bracket from bottom support tube.

6.

Remove screws (with spacers) on each side of motorcycle to release ends of luggage rack from frame tube
weldments.

7.

Remove pole lamp. See Section 8.5 POLE LAMP.

8.

Slide luggage rack toward rear of motorcycle to clear

front bushings, and then rotate rack upward to clear
frame tubes. See Figure 2-7.

INSTALLATION

f2018x2x

1.

Place luggage rack into position inboard of frame tubes.

Figure 2-6. Air Valves

2003 FLT Police: Chassis

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2.

Install screws (with spacers) on each side of motorcycle

to secure ends of luggage rack to frame tube weldments.

3.

Install two bolts to fasten license plate bracket to bottom

support tube.

4.

Position chrome frame cover on frame tube and install

Phillips screw. Install bolt (with flat washer) to install saddlebag front mounting bracket, but do not tighten. Repeat
step on opposite side of motorcycle.

Table 2-2. Rear Air Suspension Pressures

Shock Loading

Recommended
Pressures
PSI

Solo rider up to 150 lbs. (68 kg)

0-35

kPa
0-241

Solo rider 150-200 lbs. (68-91 kg)

0-10

0-69

5.

Install pole lamp. See Section 8.5 POLE LAMP.

Solo rider 200-250 lbs. (91-113 kg)

5-15

35-103

6.

Depress collar on compression fitting of air seat reservoir, and insert air tube until it bottoms. Gently tug on
tube to verify that it is locked in place.

Maximum GVWR (see Section 2.1

SPECIFICATIONS)

20-35

138-241

11
1WARNING
WARNING
CAUTION
Maximum seat air pressure is 100 psi (689 kPa). Normal
air pressure is between 30-45 psi (207-310 kPa). Minimum
air pressure is determined by rider weight. Do not operate with pressure so low that system bottoms out on
bumpy roads.
7.

Fill air reservoir to desired pressure. Install protective

cap on air valve. See upper frame of Figure 2-6.

Use this table as a starting point in determining suitable rear air suspension pressures. Do not exceed
maximum GVWR when loading vehicle and do not
pressurize system in excess of 35 psi (241 kPa).
Excessive load weight and/or air suspension pressure can adversely affect handling and lead to loss
of vehicle control, which could result in death or serious injury.

NOTE
To set minimum air pressure, have rider sit on seat and
bounce to simulate riding conditions. Visually check for any
contact between air spring and frame components. Add air as
necessary.

11. Observe air pressure gauge while filling. If leakage

occurs, remove tubes and inspect ends for burrs or damage. If either condition is found, snip off end of tube and
insert back into fitting.

8.

12. When air pressure remains constant, install protective

cap on air valve.

9.

Observe air pressure gauge. If leakage occurs, then

remove tube and inspect end for burrs or damage. If
either condition is found, snip off end of tube and insert
back into fitting.
Depress collar on compression fitting of each shock and
insert air tube until it bottoms. Gently tug on tube to verify
that it is locked in place.

10. Fill shocks to desired pressure. See Table 2-2.

CAUTION
All air components fill rapidly. Use a small hand or foot
operated air pump to avoid possible damage to shocks
or air suspension components.
NOTE
An AIR SUSPENSION PUMP AND GAUGE (Part No. HD34633) is available at your Harley-Davidson dealer.

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2003 FLT Police: Chassis

13. Install saddlebags. Using an open end/box wrench,

tighten saddlebag front mounting bracket bolts.

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INSTRUMENT MOUNTING BRACKET

2.7

FLHP

8
7

GENERAL
9
The Instrument Mounting Bracket relocates the tachometer to
allow for the addition of a radio and speaker.

NOTE

10

The two rear holes in the handlebar clamp shroud allow the
rider to adjust the handlebars without having to remove the
shroud. To keep out moisture and debris, be sure to install
plastic plugs back into holes after handlebar adjustment.

INSTALLATION
1.

Remove windshield. See Section 2.29 WINDSHIELD/

HEADLAMP NACELLE (FLHR/C), REMOVAL, in the
2003 Touring Models Service Manual (Part No. 9948303).

2.

Remove Phillips screw at the bottom of the headlamp

door (chrome ring). Remove the headlamp door.

3.

Remove the eight Phillips screws to free the headlamp

housing from the headlamp nacelle.

4.

Squeeze the two external tabs (if present) to remove the

wire connector at the back of the headlamp bulb.
Remove headlamp housing assembly from the vehicle.

5.

Reaching inside the headlamp nacelle, remove flange

nut to release the chrome strip at the top of the nacelle.
See Figure 2-8.

6.

Carefully pry off the fork lock plate at the rear of the handlebar clamp shroud. Remove two Phillips screws
beneath the lock plate.

7.

Loosen the Phillips screw from tab at the front of the handlebar clamp shroud (but do not remove).

8.

Remove two acorn nuts from the left side fork studs.
Remove acorn nuts from the right side fork studs.

9.

Cover front fender with suitable material to protect fender

paint. Remove the passing lamp bracket from the left and
right side fork studs and carefully set on front fender.

10. Remove grommets (and clutch cable clamp) from the left
and right side fork studs.
11. Reaching inside the headlamp nacelle, disconnect
tachometer connector [108], 3-place Deutsch.
12. Remove the handlebar clamp shroud from the vehicle,
while gently pulling the tachometer conduit and connector out of the headlamp nacelle. See Figure 2-9.

11

1
f1458d2x

1.
2.
3.
4.
5.
6.

Headlamp Nacelle 7. Tachometer Bracket

8. Acorn Nut (2)
Nut
9. Fork Lock Plate
Flat Washer
10. Handlebar Clamp Shroud
Flange Nut
11. Stud Plate
Chrome Strip
Phillips Screw (2)
Figure 2-8. Headlamp Nacelle Assembly

13. Remove two acorn nuts and flat washers to release

tachometer bracket from the handlebar clamp shroud.
14. A peel and stick foam tape on the stud plate holds it in
place on the inboard side of the handlebar clamp shroud,
Place the instrument mounting bracket over the studs
and secure using hardware provided by manufacturer.
See upper frame of Figure 2-11.

2003 FLT Police: Chassis

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5531

f1458e2x

Figure 2-9. Handlebar Clamp Shroud

Install instrument mounting bracket on stud plate.

p0044x5x
5532

Install instrument mounting bracket front bolt.

5530

1. Acorn Nut
2. Instrument Mounting
Bracket
3. Handlebar Clamp Shroud

4. Stud Plate
5. Screw
6. Nut

Figure 2-10. Instrument Mounting Bracket Assembly

15. Secure slotted tab of instrument mounting bracket to

front of handlebar clamp shroud using nut and bolt provided by manufacturer. See middle frame of Figure 2-11.
16. Place tachometer bracket over studs on instrument
mounting bracket and install two acorn nuts with flat
washers. See lower frame of Figure 2-11.
17. Part the halves of the headlamp nacelle slightly. With the
flat washer on the handlebar clamp shroud facing the
inside surface of the nacelle, slide the Phillips screw
down the gap until the shroud is in position at top of
nacelle. See Figure 2-9.

2-10

2003 FLT Police: Chassis

Install tachometer bracket.

Figure 2-11. Install Instrument Mounting Bracket

18. Raising handlebar clamp shroud slightly, feed tachometer connector and conduit into the headlamp nacelle.
Install shroud over mating flange while routing tachometer conduit through opening for left side handlebar.
Reaching inside headlamp nacelle, mate pin and socket
halves of tachometer connector.

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19. With the halves of the nacelle mated, tighten the Phillips
screw in the tab of the handlebar clamp shroud to 10-20
in-lbs (1.1-2.3 Nm). If necessary, temporarily install a
small cable strap into holes at the bottom of the nacelle
(headlamp housing flange) to hold the halves together.

25. Install wire connector at the back of headlamp bulb.

20. Install two Phillips screws to fasten handlebar clamp

shroud to the fork lock mechanism. Install fork lock plate.

27. Fit the square-shaped portion of the headlamp door

spring into the slot at the top of the headlamp housing
and then snap the headlamp door (chrome ring) into
place. Install Phillips screw at the bottom of the headlamp door.

21. Inserting weld stud on chrome strip into hole at the top of
the headlamp nacelle, reach inside the nacelle to install
flange nut. Tighten flange nut to 15-20 in-lbs (1.7-2.3
Nm).
22. Install grommets on the left and right side fork studs.
23. Slide passing lamp bracket onto the left and right side
fork studs. Verify that four grommets are positioned on
the inboard side of the passing lamp brackets.

26. Align holes in headlamp housing with those in headlamp

nacelle (headlamp door bracket at bottom). Install the
eight Phillips screws.

28. Install windshield. See Section 2.29 WINDSHIELD/

HEADLAMP NACELLE (FLHR/C), INSTALLATION, in
the 2003 Touring Models Service Manual (Part No.
99483-03).

24. Install acorn nuts on the fork studs and tighten to 18 ftlbs (24.4 Nm). Be sure to capture the clutch cable clamp
on the upper left stud before installing the acorn nut.

2003 FLT Police: Chassis

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NOTES

2-12

2003 FLT Police: Chassis