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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...
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Harley Davidson FLHR Road King 2004 Repair Service Manual
🏷️ 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 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).
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, brake pads, fork seals, drive belt.
Potential Twin Cam Issues:
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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