The 2004 FLHR Road King represents a pinnacle of American cruiser design, blending classic aesthetics with robust touring capabilities. Powered by the then-new 1450cc Twin Cam 88 V-twin engine, this model is renowned for its iconic V-twin character, comfortable riding position, and extensive customization potential. Engineered for both spirited rides and long-distance journeys, the Road King has consistently been a favorite among riders seeking the authentic experience, characterized by its enduring style and reliable performance. This comprehensive service manual provides detailed instructions and specifications for the maintenance, repair, and troubleshooting of the 2004 FLHR Road King. Covering all major systems, including the engine, fuel, ignition, transmission, braking, and electrical systems, it offers step-by-step procedures for routine servicing, component overhauls, and diagnostic analysis. Essential information such as torque specifications, wiring diagrams, and special tool requirements are included to assist professional technicians and experienced enthusiasts in maintaining the optimal performance and longevity of their motorcycle. 🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHR Road King Year: 2004 Codes Chassis Code: FLHR 👋 Introduction Market Position Target Audience: Professional motorcycle technicians, experienced DIY mechanics, and Harley-Davidson enthusiasts. Vehicle Segment: Full-size cruiser motorcycle, touring capability. Competitive Analysis Market Competitors Era: Indian Chief, Victory Cruisers, custom motorcycles. Key Features Model Appeal: Classic styling, comfortable touring, V-twin engine character, customization potential. 📋 Manual Details Coverage Areas Manual Type: Service Manual / Workshop Manual / Repair Manual Language: English Format: PDF Download Page Count Estimated Page Count: Over 500 pages (typical for this era's full service manuals) 📖 Manual Coverage Systems Covered Engine Overhaul: Complete teardown, inspection, repair, and reassembly of Twin Cam 88 engine. Fuel System: Carburetor (Keihin CV) tuning, cleaning, and rebuilding; fuel tank, lines, and pump inspection. Ignition System: Ignition module, coil, spark plugs, wiring diagnostics, and timing adjustments. Transmission And Drivetrain: 5-speed gearbox overhaul, clutch adjustment and replacement, primary drive, and belt drive maintenance. Frame And Suspension: Fork assembly, rear shock absorber replacement and adjustment, steering head bearing maintenance, wheel bearing service. Braking System: Front and rear brake caliper service, brake pad replacement, master cylinder overhaul, hydraulic system bleeding. Electrical System: Wiring diagrams, charging system (alternator, regulator), starting system (starter, solenoid), lighting, and accessory circuits. Bodywork And Fittings: Fairing removal and installation, fender maintenance, seat, saddlebags, and fuel tank servicing. Diagnostics And Troubleshooting: Systematic troubleshooting guides for common performance and operational issues. Procedures Included Scheduled Maintenance: Detailed procedures for routine services like oil changes, filter replacements, and lubrication. Component Rebuilding: Step-by-step instructions for rebuilding major components like the carburetor, brake calipers, and transmission. Wiring Diagrams: Comprehensive, clearly labeled electrical schematics for all circuits. Torque Specifications: Essential torque values for all critical fasteners and bolts. Special Tools: Identification and usage of specialized tools required for specific repair tasks. Technical Depth Level Of Detail: Comprehensive; covers everything from basic maintenance to complete engine and transmission rebuilds. Diagnostic Capabilities: Advanced diagnostic procedures and troubleshooting flowcharts for identifying root causes of problems. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Print Quality Resolution: High-resolution scans for clear text and diagrams. Readability: Designed for clear viewing on digital devices and printable for workshop use. Binding Type Digital Format: Downloadable PDF (no physical binding). ⚙️ Engine Specifications Primary Engine Engine Family: Harley-Davidson Twin Cam 88 Configuration: 45-degree V-twin, air-cooled Displacement: 1450 cc (88 cubic inches) Bore X Stroke: 3.75 in x 4.00 in (95.25 mm x 101.6 mm) Compression Ratio: 8.9:1 Performance Horsepower Est: Approximately 65-70 HP (at crank, varies by tuning) Torque Est: Approximately 75-80 lb-ft @ 3500 RPM (at crank) Fuel System Carburetor Model: Keihin CV (Constant Velocity) 40mm Fuel Type: Unleaded gasoline, 91 octane (or higher) recommended Fuel Capacity: 4.2 gallons (15.9 liters) Maintenance Notes Valve Adjustment: Requires periodic adjustment per service schedule. Oil Type: Harley-Davidson 20W50 SYN3 (or equivalent) recommended for engine, primary, and transmission. 🔧 Transmission Standard Type: 5-speed constant mesh, helical gears Primary Drive: Chain drive (wet clutch, 36T primary sprocket, 31T clutch sprocket) Final Drive: Belt drive (29T motor pulley, 66T rear sprocket) Features Clutch Type: Wet, multi-plate, diaphragm spring Gear Ratios Est: 1st: 9.34, 2nd: 6.70, 3rd: 5.02, 4th: 3.93, 5th: 3.15 Maintenance Notes Transmission Fluid Type: Harley-Davidson Formula + (or equivalent heavy-duty gear oil) Primary Chain Tension: Requires periodic adjustment. 📐 Dimensions Exterior Length: 94.0 inches (2388 mm) Width: 38.0 inches (965 mm) Height: 55.3 inches (1405 mm) Wheelbase: 63.5 inches (1613 mm) Weights Dry Weight: 665 lbs (301.6 kg) Gross Vehicle Weight Rating Gvwr: 1100 lbs (500 kg) Load Capacity: 435 lbs (197 kg) Cargo Saddlebag Capacity: Approx. 2 cubic feet total Specifications Ground Clearance: 5.2 inches (132 mm) Seat Height: 28.2 inches (716 mm) 🛡️ Safety Features Ratings Crash Testing: Motorcycles typically not subjected to standardized crash testing like automobiles. Focus is on rider protection through design and component integrity....