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Harley Davidson FLHR FLHT Touring models 2005 Repair Service Manual

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Basic Information Identification Make: Harley-Davidson Model: FLHR Road King, FLHT Electra Glide Standard, FLHTCU Ultra Classic Electra Glide, FLTR Road Glide Year: 2005 Generation Platform: Touring Platform Codes Vin Prefix: 1HD1 Introduction Market Position Segment: Heavyweight touring motorcycles, premium segment. Competitive Analysis Competitors: Honda Gold Wing, Indian Roadmaster, Yamaha Star Venture. Key Features Touring Capability: Designed for long-distance comfort, cargo capacity, and passenger accommodation. Heritage: Built upon Harley-Davidson's iconic V-twin engine and classic cruiser styling. Customization: Extensive aftermarket support and customization options are a hallmark of the brand. Manual Details Coverage Areas Models Covered: FLHR Road King, FLHRCI Road King Classic, FLHRI Road King (EFI), FLHRS Road King Custom, FLHRSI Road King (EFI), FLHT Electra Glide Standard, FLHTC Electra Glide Classic, FLHTCI Electra Glide Classic (EFI), FLHTCSE2 Screamin Eagle Electra Glide, FLHTCUI Ultra Classic Electra Glide (EFI), FLHTI Electra Glide Standard (EFI), FLTRI Road Glide (EFI) Page Count Total Pages: 1334 Manual Type Type: Repair Service Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Electrical Diagnostics: Comprehensive electrical system diagnosis and troubleshooting, including wiring diagrams and component testing. Engine Overhaul: Complete engine tear-down, rebuild procedures, including cylinder head, piston, crankshaft, and camshaft servicing. Transmission And Drivetrain: Service and repair of the transmission, clutch, primary drive, and final drive systems. Suspension And Steering: Fork servicing, rear shock absorber replacement, and steering head bearing maintenance. Braking System: Brake caliper, rotor, master cylinder, and hydraulic system service. Fuel System: Fuel injection system (EFI) diagnostics, fuel pump, injectors, and throttle body service. Cooling System: Engine cooling system maintenance and repair (where applicable for specific models). Exhaust System: Exhaust component replacement and gasket service. Bodywork And Trim: Fairing, saddlebag, and cosmetic component removal and installation. Procedures Included Maintenance: Routine maintenance tasks, including oil changes, filter replacements, and lubrication schedules. Troubleshooting: Systematic approach to diagnosing and resolving common and uncommon faults. Repair: Detailed, step-by-step repair procedures for all major vehicle components. Rebuild: Complete engine and component rebuild instructions. Diagnostics: In-depth diagnostic procedures for electrical and mechanical systems. Technical Depth Depth: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Illustrations: Illustrated with clear, high-quality images and detailed part diagrams. Technical Data: Includes essential torque specifications, clearances, and fluid capacities. Manual Specifications File Format Format: PDF Print Quality Quality: High-resolution, ensuring clarity of text and images. Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) 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) Compression Ratio: 8.8:1 Performance Horsepower: Approximately 65-70 HP (estimate, varies by model and tuning) Torque: Approximately 75-80 lb-ft (estimate, varies by model and tuning) Fuel System Injection Type: Electronic Sequential Port Fuel Injection (ESPFI) for EFI models. Fuel Type: Unleaded gasoline, minimum 91 octane recommended. Ignition System Type: High-performance, electronic ignition with knock sensor. Lubrication System Oil Type: Harley-Davidson SYN3 Synthetic Motorcycle Oil (SAE 20W-50) or equivalent. Transmission Standard Transmission Type: 5-speed constant mesh, helical gear Clutch Type: Wet, multi-plate, diaphragm spring Features Primary Drive: Plated, heavy-duty, 36-tooth, 1.375-inch pitch, chain drive. Final Drive: Carbon fiber belt, 25mm width, 140-tooth count. Fluid Specifications Transmission Oil Type: Harley-Davidson Genuine Transmission Fluid or Formula+ (GL-4 rated, SAE 75W-90). Dimensions Exterior Length: Approx. 96.5 in. (2450 mm) - varies by model Width: Approx. 37.0 in. (940 mm) - varies by model Height: Approx. 54.5 in. (1385 mm) - varies by model Weights Dry Weight: Approx. 700-800 lbs (317-363 kg) - varies by model Gross Vehicle Weight Rating Gvwr: Approx. 1200 lbs (544 kg) - varies by model Fuel Capacity: 5.0 US gallons (18.9 L) Wheels And Tires Front Tire Size: MT90B16 (varies slightly by model) Rear Tire Size: 130/90B16 (varies slightly by model) Wheel Type: Cast aluminum or laced, depending on model and trim. Safety Features Ratings Safety Standards: Designed to meet or exceed applicable federal motorcycle safety standards. Active Features Braking System: Dual 32mm, 4-piston, fixed front caliper with dual 11.5 in. (292mm) discs; 32mm, 4-piston, floating rear caliper with 11.5 in. (292mm) disc. Lighting: Halogen headlight, LED tail light, front and rear turn signals. Passive Features Chassis Construction: Steel, triple-cradle frame for stability and rigidity. Anti Lock Braking System ABS: Optional on some models. Technology Features Infotainment Audio System: Factory-installed AM/FM/WB radio with cassette player or CD player, integrated speakers. Some models feature CB radio and intercom. Cruise Control: Standard on most touring models. Driver Assistance Security: Factory security system with siren and immobilizer. Connectivity Internal Diagnostics: On-board diagnostics with Harley-Davidson's Digital Technician (requires specific tools not included in manual). Maintenance Service Intervals Engine Oil Change: Every 5,000 miles (8,000 km) or 6 months, whichever comes first. Primary Chain Tensioner Inspection: Inspect at 10,000 miles (16,000 km), replace if necessary (especially with the early spring-loaded design). Spark...
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Harley Davidson FLHR FLHT Touring models 2005 Repair Service Manual
Basic Information
Identification
Make: Harley-Davidson
Model: FLHR Road King, FLHT Electra Glide Standard, FLHTCU Ultra Classic Electra Glide, FLTR Road Glide
Year: 2005
Generation
Platform: Touring Platform
Codes
Vin Prefix: 1HD1
Introduction
Market Position
Segment: Heavyweight touring motorcycles, premium segment.
Competitive Analysis
Competitors: Honda Gold Wing, Indian Roadmaster, Yamaha Star Venture.
Key Features
Touring Capability: Designed for long-distance comfort, cargo capacity, and passenger accommodation.
Heritage: Built upon Harley-Davidson's iconic V-twin engine and classic cruiser styling.
Customization: Extensive aftermarket support and customization options are a hallmark of the brand.
Manual Details
Coverage Areas
Models Covered: FLHR Road King, FLHRCI Road King Classic, FLHRI Road King (EFI), FLHRS Road King Custom, FLHRSI Road King (EFI), FLHT Electra Glide Standard, FLHTC Electra Glide Classic, FLHTCI Electra Glide Classic (EFI), FLHTCSE2 Screamin Eagle Electra Glide, FLHTCUI Ultra Classic Electra Glide (EFI), FLHTI Electra Glide Standard (EFI), FLTRI Road Glide (EFI)
Page Count
Total Pages: 1334
Manual Type
Type: Repair Service Manual
Language
Language: English
Format
Format: PDF Download
Manual Coverage
Systems Covered
Electrical Diagnostics: Comprehensive electrical system diagnosis and troubleshooting, including wiring diagrams and component testing.
Engine Overhaul: Complete engine tear-down, rebuild procedures, including cylinder head, piston, crankshaft, and camshaft servicing.
Transmission And Drivetrain: Service and repair of the transmission, clutch, primary drive, and final drive systems.
Suspension And Steering: Fork servicing, rear shock absorber replacement, and steering head bearing maintenance.
Braking System: Brake caliper, rotor, master cylinder, and hydraulic system service.
Fuel System: Fuel injection system (EFI) diagnostics, fuel pump, injectors, and throttle body service.
Cooling System: Engine cooling system maintenance and repair (where applicable for specific models).
Exhaust System: Exhaust component replacement and gasket service.
Bodywork And Trim: Fairing, saddlebag, and cosmetic component removal and installation.
Procedures Included
Maintenance: Routine maintenance tasks, including oil changes, filter replacements, and lubrication schedules.
Troubleshooting: Systematic approach to diagnosing and resolving common and uncommon faults.
Repair: Detailed, step-by-step repair procedures for all major vehicle components.
Rebuild: Complete engine and component rebuild instructions.
Diagnostics: In-depth diagnostic procedures for electrical and mechanical systems.
Technical Depth
Depth: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts.
Illustrations: Illustrated with clear, high-quality images and detailed part diagrams.
Technical Data: Includes essential torque specifications, clearances, and fluid capacities.
Manual Specifications
File Format
Format: PDF
Print Quality
Quality: High-resolution, ensuring clarity of text and images.
Binding Type
Type: N/A (Digital Download)
Paper Type
Type: N/A (Digital Download)
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)
Compression Ratio: 8.8:1
Performance
Horsepower: Approximately 65-70 HP (estimate, varies by model and tuning)
Torque: Approximately 75-80 lb-ft (estimate, varies by model and tuning)
Fuel System
Injection Type: Electronic Sequential Port Fuel Injection (ESPFI) for EFI models.
Fuel Type: Unleaded gasoline, minimum 91 octane recommended.
Ignition System
Type: High-performance, electronic ignition with knock sensor.
Lubrication System
Oil Type: Harley-Davidson SYN3 Synthetic Motorcycle Oil (SAE 20W-50) or equivalent.
Transmission
Standard
Transmission Type: 5-speed constant mesh, helical gear
Clutch Type: Wet, multi-plate, diaphragm spring
Features
Primary Drive: Plated, heavy-duty, 36-tooth, 1.375-inch pitch, chain drive.
Final Drive: Carbon fiber belt, 25mm width, 140-tooth count.
Fluid Specifications
Transmission Oil Type: Harley-Davidson Genuine Transmission Fluid or Formula+ (GL-4 rated, SAE 75W-90).
Dimensions
Exterior
Length: Approx. 96.5 in. (2450 mm) - varies by model
Width: Approx. 37.0 in. (940 mm) - varies by model
Height: Approx. 54.5 in. (1385 mm) - varies by model
Weights
Dry Weight: Approx. 700-800 lbs (317-363 kg) - varies by model
Gross Vehicle Weight Rating Gvwr: Approx. 1200 lbs (544 kg) - varies by model
Fuel Capacity: 5.0 US gallons (18.9 L)
Wheels And Tires
Front Tire Size: MT90B16 (varies slightly by model)
Rear Tire Size: 130/90B16 (varies slightly by model)
Wheel Type: Cast aluminum or laced, depending on model and trim.
Safety Features
Ratings
Safety Standards: Designed to meet or exceed applicable federal motorcycle safety standards.
Active Features
Braking System: Dual 32mm, 4-piston, fixed front caliper with dual 11.5 in. (292mm) discs; 32mm, 4-piston, floating rear caliper with 11.5 in. (292mm) disc.
Lighting: Halogen headlight, LED tail light, front and rear turn signals.
Passive Features
Chassis Construction: Steel, triple-cradle frame for stability and rigidity.
Anti Lock Braking System ABS: Optional on some models.
Technology Features
Infotainment
Audio System: Factory-installed AM/FM/WB radio with cassette player or CD player, integrated speakers. Some models feature CB radio and intercom.
Cruise Control: Standard on most touring models.
Driver Assistance
Security: Factory security system with siren and immobilizer.
Connectivity
Internal Diagnostics: On-board diagnostics with Harley-Davidson's Digital Technician (requires specific tools not included in manual).
Maintenance
Service Intervals
Engine Oil Change: Every 5,000 miles (8,000 km) or 6 months, whichever comes first.
Primary Chain Tensioner Inspection: Inspect at 10,000 miles (16,000 km), replace if necessary (especially with the early spring-loaded design).
Spark Plug Replacement: Inspect every 10,000 miles (16,000 km), replace as needed.
Drive Belt Inspection: Inspect tension and condition every 10,000 miles (16,000 km).
Fluid Specifications
Engine Oil Capacity: 4.0 US quarts (3.8 L) with filter change.
Brake Fluid Type: DOT 4 synthetic brake fluid.
Coolant Type: N/A (Air-cooled engine)
Known Issues
Primary Chain Tensioner: Early models utilized a spring-loaded tensioner which could wear prematurely; upgrade to the hydraulic tensioner is a common modification.
Cam Chain Tensioners: Internal cam chain tensioners can also wear; inspection and potential upgrade to the hydraulic tensioner is recommended.
Crankshaft Runout: While generally robust, checking crankshaft runout during engine rebuilds is crucial for long-term reliability.
Vehicle History
Brand Heritage
Legacy: Harley-Davidson boasts over a century of motorcycle manufacturing, synonymous with American freedom and craftsmanship.
Model Evolution
Touring Lineage: The FLHT/FLHR platforms have evolved from the early Electra Glide models, consistently refining comfort and performance for touring riders.
Twin Cam 88 Introduction: The Twin Cam 88 engine, introduced in 1999, represented a significant technological advancement for Harley-Davidson, offering increased power and reliability.
Production
Manufacturing Location: York, Pennsylvania, USA and Milwaukee, Wisconsin, USA.
Awards & Recognition
Recognitions
Iconic Status: The Harley-Davidson Touring platform is widely recognized for its enduring style and capability in the cruiser market.
Ratings
Customer Satisfaction: Consistently high customer satisfaction ratings within the Harley-Davidson owner community.
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