Harley Davidson FLHR Road King 2004 Repair Service Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHR Road King Year: 2004 Generation Model Generation: Fifth Generation (1997-2008) Codes Vin Code Model Identifier: FLHR (typically) 👋 Introduction Market Position Positioning: Premium large-displacement cruiser, catering to riders who value comfort, touring capability, and classic Harley-Davidson styling. Target Audience: Touring riders, cruiser enthusiasts, and owners who appreciate classic American motorcycle design and a comfortable riding experience for long distances. Competitive Analysis Competitors: Primary competitors in its class included models from Indian Motorcycle, and potentially some high-end offerings from Japanese manufacturers focusing on cruiser aesthetics and touring features. However, the Harley-Davidson identity and V-twin engine were strong differentiators. Key Features Features: Detachable windshield, large saddlebags, comfortable seating, classic styling, V-twin engine, cruise control (often standard or optional depending on sub-model/package). 📋 Manual Details Coverage Areas Coverage: All Models, Engines, Trim, Transmissions Types for 2004 FLHR Road King Page Count Page Count: Hundreds of pages (specific count not provided, but implied to be comprehensive) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download Zoom Functionality: YES (Allows zooming in/out of PDF content for clarity) Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader & WinZip Compatibility Operating System Compatibility: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Covered Systems: General Information, Maintenance, Chassis, Fuel System, Cooling System, Engine, Clutch, Engine Lubrication System, Engine Removal/Installation, Drive, Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Wiring Diagrams Electrical System Details: Comprehensive coverage including battery, charging system, ignition system, lighting, instruments, starter, and all related wiring with detailed diagrams. Chassis Components: Frame, front and rear suspension (forks, shocks), steering head, swingarm, wheels, tires, and related components. Fuel System Details: Carburetor assembly, fuel lines, fuel pump (if applicable for the specific model variant, though typically gravity-fed for this era), fuel filter, and related components. Brake System Details: Front and rear brake calipers, master cylinders, brake lines, rotors, brake pads, and bleeding procedures. Procedures Included Included Procedures: Service, Maintenance, Troubleshooting, Diagnostic, Repair, Disassembly, Assembly, Cleaning, Reinstallation, Detailed substeps, Notes, Cautions, Warnings Troubleshooting Methods: Step-by-step troubleshooting guides integrated with diagnostic procedures and wiring diagrams for efficient problem identification and resolution. Engine Rebuild Procedures: Comprehensive engine disassembly, inspection, repair, and reassembly instructions, including piston and cylinder service, valve train maintenance, and crankshaft/connecting rod assembly. Transmission Overhaul: Detailed procedures for transmission disassembly, inspection of gears, bearings, shift components, and reassembly, including clutch servicing. Technical Depth Depth: Professional Technician Level; Complete Diagnostic, Repair, and Maintenance Information Diagnostic Tools: Information on using diagnostic tools and interpreting fault codes for troubleshooting engine and electrical issues. 📊 Manual Specifications File Format File Format: PDF Searchability: Implied to be searchable due to PDF format, aiding in quick information retrieval. Print Quality Print Quality: Full Printable Binding Type Binding Type: Digital Download (Printable) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, Twin Cam 88 V-Twin Displacement: 1450cc (88 cubic inches) Bore X Stroke: 3.75 in. x 4.00 in. (95.25 mm x 101.6 mm) Performance Horsepower: Approx. 67 hp @ 5200 rpm (est. - actual figures can vary slightly by source) Torque: Approx. 85 ft-lbs @ 3500 rpm (est. - actual figures can vary slightly by source) Fuel System Fuel Delivery: Carbureted (Keihin CV Carburetor) Fuel Tank Capacity: 5.0 gallons (18.9 L) 🔧 Transmission Standard Transmission Type: 5-speed, Constant Mesh Optional Optional Transmissions: N/A for this model year and variant Features Clutch Type: Wet, multi-plate Final Drive Type: Belt Drive 📐 Dimensions Exterior Overall Length: Approx. 93.5 inches (2375 mm) Wheelbase: Approx. 63.5 inches (1613 mm) Seat Height: Approx. 28.2 inches (716 mm) Weights Dry Weight: Approx. 687 lbs (311 kg) Gross Vehicle Weight Rating: Approx. 1040 lbs (472 kg) Gvwr Load Capacity: Approx. 353 lbs (160 kg) payload capacity (Gross Vehicle Weight Rating minus Dry Weight). 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle safety is typically assessed through independent testing of components and overall design principles, not standardized crash test ratings like automobiles). Active Features Active Safety: Front and rear disc brakes with dual-piston calipers, Hydraulic clutch Passive Features Passive Safety: Sturdy frame construction, rider ergonomics designed for stability 💡 Technology Features Infotainment Audio System: Optional, often dealer-installed aftermarket or factory radio systems were available, typically AM/FM with cassette or CD player. Driver Assistance Cruise Control: Available, often standard on certain trims or as an option. Electronic cruise control enhances highway comfort. Connectivity Connectivity Features: Limited by modern standards; focused on basic audio system integration if equipped. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000 miles or 6 months, whichever comes first (refer to specific manual for exact interval and oil type). Primary Chain Adjust: As per manual, typically at 1000 mile service and then as needed. Brake Fluid Flush Interval: Recommended every 2 years or as...
Premium large-displacement cruiser, catering to riders who value comfort, touring capability, and classic Harley-Davidson styling.
Target Audience:
Touring riders, cruiser enthusiasts, and owners who appreciate classic American motorcycle design and a comfortable riding experience for long distances.
Competitive Analysis
Competitors:
Primary competitors in its class included models from Indian Motorcycle, and potentially some high-end offerings from Japanese manufacturers focusing on cruiser aesthetics and touring features. However, the Harley-Davidson identity and V-twin engine were strong differentiators.
Key Features
Features:
Detachable windshield, large saddlebags, comfortable seating, classic styling, V-twin engine, cruise control (often standard or optional depending on sub-model/package).
📋 Manual Details
Coverage Areas
Coverage:
All Models, Engines, Trim, Transmissions Types for 2004 FLHR Road King
Page Count
Page Count:
Hundreds of pages (specific count not provided, but implied to be comprehensive)
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
Zoom Functionality:
YES (Allows zooming in/out of PDF content for clarity)
Comprehensive coverage including battery, charging system, ignition system, lighting, instruments, starter, and all related wiring with detailed diagrams.
Chassis Components:
Frame, front and rear suspension (forks, shocks), steering head, swingarm, wheels, tires, and related components.
Fuel System Details:
Carburetor assembly, fuel lines, fuel pump (if applicable for the specific model variant, though typically gravity-fed for this era), fuel filter, and related components.
Brake System Details:
Front and rear brake calipers, master cylinders, brake lines, rotors, brake pads, and bleeding procedures.
Step-by-step troubleshooting guides integrated with diagnostic procedures and wiring diagrams for efficient problem identification and resolution.
Engine Rebuild Procedures:
Comprehensive engine disassembly, inspection, repair, and reassembly instructions, including piston and cylinder service, valve train maintenance, and crankshaft/connecting rod assembly.
Transmission Overhaul:
Detailed procedures for transmission disassembly, inspection of gears, bearings, shift components, and reassembly, including clutch servicing.
Technical Depth
Depth:
Professional Technician Level; Complete Diagnostic, Repair, and Maintenance Information
Diagnostic Tools:
Information on using diagnostic tools and interpreting fault codes for troubleshooting engine and electrical issues.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Implied to be searchable due to PDF format, aiding in quick information retrieval.
Print Quality
Print Quality:
Full Printable
Binding Type
Binding Type:
Digital Download (Printable)
Paper Type
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, Twin Cam 88 V-Twin
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Performance
Horsepower:
Approx. 67 hp @ 5200 rpm (est. - actual figures can vary slightly by source)
Torque:
Approx. 85 ft-lbs @ 3500 rpm (est. - actual figures can vary slightly by source)
Fuel System
Fuel Delivery:
Carbureted (Keihin CV Carburetor)
Fuel Tank Capacity:
5.0 gallons (18.9 L)
🔧 Transmission
Standard
Transmission Type:
5-speed, Constant Mesh
Optional
Optional Transmissions:
N/A for this model year and variant
Features
Clutch Type:
Wet, multi-plate
Final Drive Type:
Belt Drive
📐 Dimensions
Exterior
Overall Length:
Approx. 93.5 inches (2375 mm)
Wheelbase:
Approx. 63.5 inches (1613 mm)
Seat Height:
Approx. 28.2 inches (716 mm)
Weights
Dry Weight:
Approx. 687 lbs (311 kg)
Gross Vehicle Weight Rating:
Approx. 1040 lbs (472 kg)
Gvwr Load Capacity:
Approx. 353 lbs (160 kg) payload capacity (Gross Vehicle Weight Rating minus Dry Weight).
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety is typically assessed through independent testing of components and overall design principles, not standardized crash test ratings like automobiles).
Active Features
Active Safety:
Front and rear disc brakes with dual-piston calipers, Hydraulic clutch
Passive Features
Passive Safety:
Sturdy frame construction, rider ergonomics designed for stability
💡 Technology Features
Infotainment
Audio System:
Optional, often dealer-installed aftermarket or factory radio systems were available, typically AM/FM with cassette or CD player.
Driver Assistance
Cruise Control:
Available, often standard on certain trims or as an option. Electronic cruise control enhances highway comfort.
Connectivity
Connectivity Features:
Limited by modern standards; focused on basic audio system integration if equipped.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 miles or 6 months, whichever comes first (refer to specific manual for exact interval and oil type).
Primary Chain Adjust:
As per manual, typically at 1000 mile service and then as needed.
Brake Fluid Flush Interval:
Recommended every 2 years or as per manual instructions.
Fluid Specifications
Engine Oil Type:
Harley-Davidson Syn3 or equivalent (e.g., V-Twin specific SAE 20W-50 synthetic oil recommended by many owners).
Transmission Fluid Type:
Harley-Davidson Formula + or equivalent heavy-duty motorcycle transmission lubricant.
Primary Chain Case Oil:
Harley-Davidson Formula + or equivalent heavy-duty motorcycle transmission lubricant.
Brake Fluid Type:
DOT 4 (Check manual for specific recommendations).
Fork Oil Type:
Harmonic Dampening Fluid (refer to manual for viscosity and quantity).
While the Twin Cam 88 is generally robust, some early models could experience cam bearing wear or oil pressure issues if not properly maintained. Upgrades were available.
📚 Vehicle History
Brand Heritage
Heritage:
Harley-Davidson, founded in 1903, is one of the most iconic American motorcycle manufacturers, renowned for its V-twin engines, distinctive styling, and association with freedom and the open road.
Model Evolution
Evolution:
The Road King line, introduced in 1994, represented Harley-Davidson's commitment to classic styling and touring comfort, evolving from earlier FL models with modern updates like the Twin Cam engine.
Engine Introduction:
The Twin Cam 88 engine was introduced in 1999, becoming standard across most Harley-Davidson models by 2000, including the Road King. This engine offered a significant improvement in torque and a smoother power delivery compared to its predecessor, the Evolution engine.
Production
Manufacturing Location:
United States (Various Harley-Davidson assembly plants)
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