Harley Davidson FLHR Road King 2010 Repair Service Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHR Road King Year: 2010 Variant: All Models 👋 Introduction Market Position Market Position: The Harley-Davidson FLHR Road King is a flagship touring motorcycle known for its classic styling, comfortable ride, and powerful V-twin engine, appealing to riders who prioritize long-distance comfort and traditional cruiser aesthetics. Competitive Analysis Competitive Analysis: Competes with other large displacement touring cruisers from manufacturers like Indian Motorcycle, Victory Motorcycles (discontinued but relevant history), and other premium cruiser brands. Its strong brand heritage and iconic design are key differentiators. Key Features Key Features: Detachable windshield, spacious saddlebags, comfortable rider and passenger seating, powerful V-twin engine, classic chrome accents, touring-oriented suspension. 📋 Manual Details Coverage Areas Coverage Areas: Service, Maintenance, Troubleshooting Page Count Page Count: Estimated 500-700 pages (typical for this model and type of manual) Manual Type Manual Type: Workshop Repair Service Manual Manual Purpose: A practical guide for technicians and skilled DIY enthusiasts to perform all maintenance, repairs, and diagnostic procedures correctly and efficiently. Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Systems Covered: Engine, Fuel System, Ignition System, Electrical System, Transmission, Drive Train, Chassis, Suspension, Brakes, Clutch, Wheels and Tires, Bodywork, Lighting, Instruments, Diagnostic Trouble Codes (DTCs), Maintenance Procedures, Troubleshooting Charts, Wiring Diagrams. Procedures Included Procedures Included: Routine maintenance (oil changes, filter replacements, lubrication), engine overhaul, fuel injection system diagnosis and repair, ignition system troubleshooting, electrical component testing and replacement, transmission disassembly and assembly, clutch service, brake system bleeding and repair, suspension adjustments, wheel and tire servicing, body panel removal and installation, diagnostic procedures, torque specifications, specialized tool usage. Technical Depth Technical Depth: Comprehensive, covering from basic rider maintenance to complete engine and chassis rebuilds, including detailed diagnostic procedures and troubleshooting flowcharts. Diagnostic Trouble Codes DTC Coverage: Includes detailed information on Diagnostic Trouble Codes (DTCs) for the Electronic Control Module (ECM), enabling precise identification of system faults. Wiring Diagrams Wiring Diagrams Coverage: Comprehensive electrical wiring diagrams for all circuits, color-coded and detailed for easy troubleshooting of the electrical system. Special Tools Special Tools Coverage: Lists and describes required specialized Harley-Davidson tools for specific repair and maintenance procedures, essential for performing work to factory specifications. Bodywork Bodywork Procedures: Detailed instructions for the removal, installation, and adjustment of all body panels, including the front fairing, fenders, saddlebags, and console. Clutch System Clutch Procedures: Includes clutch adjustment, inspection of clutch plates, and service of the clutch release mechanism. Suspension System Suspension Procedures: Covers front fork service, rear shock absorber inspection and replacement, and suspension tuning for optimal ride quality. 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Print Quality Print Quality: High-resolution, printable pages with clear diagrams and legible text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Primary Engine: Harley-Davidson Twin Cam 96 (1584cc) Performance Horsepower: Approx. 75 HP (rated at crankshaft, actual wheel horsepower will be lower) Torque: Approx. 92 ft-lbs @ 3,500 RPM (rated at crankshaft) Fuel System Fuel System: Electronic Sequential Port Fuel Injection (ESPFI) Engine Type Engine Type: Air-cooled, 45-degree V-twin, pushrod-actuated valves Bore Stroke Bore Stroke: 3.75 in. x 4.38 in. (95.25 mm x 111.25 mm) Compression Ratio Compression Ratio: 9.2:1 Oil Capacity Oil Capacity: 5.0 US qt (4.7 L) Oil Type Spec Oil Type Spec: Harley-Davidson SYN3 or equivalent SAE 20W-50 Synthetic Motorcycle Oil Valve Train Valve Train Type: Overhead valves (OHV), 2 valves per cylinder, pushrod actuated. Ignition System Ignition System Type: Coil-on-plug, electronic spark control with knock sensor. 🔧 Transmission Standard Transmission Type: 6-speed Cruise Drive Optional Optional Transmission: N/A Features Features: Constant mesh, helical gears, integrated oil bath primary chain case. Primary Fluid Primary Fluid Spec: Harley-Davidson Formula+ or equivalent SAE 50 transmission oil Primary Fluid Capacity Primary Fluid Capacity: 2.75 US qt (2.6 L) 📐 Dimensions Exterior Length: 93.3 in. (2370 mm) Width: 37.6 in. (955 mm) Height: 54.1 in. (1375 mm) Seat Height Laden: 27.1 in. (688 mm) Wheelbase: 63.7 in. (1618 mm) Ground Clearance: 5.1 in. (130 mm) Rake Trail: 26° / 6.2 in. (157 mm) Weights Dry Weight: 712 lbs (323 kg) Wet Weight: Approx. 750 lbs (340 kg) (with fluids and rider) Gross Vehicle Weight Rating: 1260 lbs (572 kg) Cargo Saddlebag Capacity: Approx. 2.24 cu ft (63.5 L) Fuel Capacity Fuel Tank Capacity: 5.0 US gal (18.9 L) 🛡️ Safety Features Ratings Safety Ratings: Not applicable for motorcycles in the same manner as automobiles, but designed with robust braking and handling characteristics for its class. Active Features Active Safety Features: Dual front disc brakes with 4-piston calipers, single rear disc brake with 4-piston caliper, often available with optional ABS (Anti-lock Braking System). Passive Features Passive Safety Features: Heavy-duty frame construction, integrated lighting, prominent rider visibility. Braking System Front Brake Spec: Dual 32 mm, 4-piston, fixed front...
The Harley-Davidson FLHR Road King is a flagship touring motorcycle known for its classic styling, comfortable ride, and powerful V-twin engine, appealing to riders who prioritize long-distance comfort and traditional cruiser aesthetics.
Competitive Analysis
Competitive Analysis:
Competes with other large displacement touring cruisers from manufacturers like Indian Motorcycle, Victory Motorcycles (discontinued but relevant history), and other premium cruiser brands. Its strong brand heritage and iconic design are key differentiators.
Estimated 500-700 pages (typical for this model and type of manual)
Manual Type
Manual Type:
Workshop Repair Service Manual
Manual Purpose:
A practical guide for technicians and skilled DIY enthusiasts to perform all maintenance, repairs, and diagnostic procedures correctly and efficiently.
Routine maintenance (oil changes, filter replacements, lubrication), engine overhaul, fuel injection system diagnosis and repair, ignition system troubleshooting, electrical component testing and replacement, transmission disassembly and assembly, clutch service, brake system bleeding and repair, suspension adjustments, wheel and tire servicing, body panel removal and installation, diagnostic procedures, torque specifications, specialized tool usage.
Technical Depth
Technical Depth:
Comprehensive, covering from basic rider maintenance to complete engine and chassis rebuilds, including detailed diagnostic procedures and troubleshooting flowcharts.
Diagnostic Trouble Codes
DTC Coverage:
Includes detailed information on Diagnostic Trouble Codes (DTCs) for the Electronic Control Module (ECM), enabling precise identification of system faults.
Wiring Diagrams
Wiring Diagrams Coverage:
Comprehensive electrical wiring diagrams for all circuits, color-coded and detailed for easy troubleshooting of the electrical system.
Special Tools
Special Tools Coverage:
Lists and describes required specialized Harley-Davidson tools for specific repair and maintenance procedures, essential for performing work to factory specifications.
Bodywork
Bodywork Procedures:
Detailed instructions for the removal, installation, and adjustment of all body panels, including the front fairing, fenders, saddlebags, and console.
Clutch System
Clutch Procedures:
Includes clutch adjustment, inspection of clutch plates, and service of the clutch release mechanism.
Suspension System
Suspension Procedures:
Covers front fork service, rear shock absorber inspection and replacement, and suspension tuning for optimal ride quality.
📊 Manual Specifications
File Format
File Format:
Portable Document Format (PDF)
Print Quality
Print Quality:
High-resolution, printable pages with clear diagrams and legible text.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Primary Engine:
Harley-Davidson Twin Cam 96 (1584cc)
Performance
Horsepower:
Approx. 75 HP (rated at crankshaft, actual wheel horsepower will be lower)
Torque:
Approx. 92 ft-lbs @ 3,500 RPM (rated at crankshaft)
Harley-Davidson Formula+ or equivalent SAE 50 transmission oil
Primary Fluid Capacity
Primary Fluid Capacity:
2.75 US qt (2.6 L)
📐 Dimensions
Exterior
Length:
93.3 in. (2370 mm)
Width:
37.6 in. (955 mm)
Height:
54.1 in. (1375 mm)
Seat Height Laden:
27.1 in. (688 mm)
Wheelbase:
63.7 in. (1618 mm)
Ground Clearance:
5.1 in. (130 mm)
Rake Trail:
26° / 6.2 in. (157 mm)
Weights
Dry Weight:
712 lbs (323 kg)
Wet Weight:
Approx. 750 lbs (340 kg) (with fluids and rider)
Gross Vehicle Weight Rating:
1260 lbs (572 kg)
Cargo
Saddlebag Capacity:
Approx. 2.24 cu ft (63.5 L)
Fuel Capacity
Fuel Tank Capacity:
5.0 US gal (18.9 L)
🛡️ Safety Features
Ratings
Safety Ratings:
Not applicable for motorcycles in the same manner as automobiles, but designed with robust braking and handling characteristics for its class.
Active Features
Active Safety Features:
Dual front disc brakes with 4-piston calipers, single rear disc brake with 4-piston caliper, often available with optional ABS (Anti-lock Braking System).
Dual 32 mm, 4-piston, fixed front brake calipers with 11.8 in. (300 mm) front brake rotors.
Rear Brake Spec:
Single 32 mm, 4-piston, floating rear brake caliper with 11.8 in. (300 mm) rear brake rotor.
💡 Technology Features
Infotainment
Infotainment System:
Basic audio system (AM/FM/WB) with fairing-mounted speakers. Often includes cruise control integration. May have provision for aftermarket iPod/MP3 connectivity.
Driver Assistance
Driver Assistance Features:
Optional ABS (Anti-lock Braking System).
Connectivity
Connectivity Features:
Limited by modern automotive standards. Focus is on rider ergonomics and basic audio control.
Instruments
Instrument Cluster:
Analog speedometer and tachometer, fuel gauge, voltmeter, oil pressure gauge, and indicator lights integrated into the tank console and fairing.
🔧 Maintenance
Service Intervals
Initial Service:
First service recommended at 1,000 miles (1,600 km).
Subsequent Service Intervals:
Every 5,000 miles (8,000 km) or annually, whichever comes first, for most routine checks and fluid changes. More in-depth services are scheduled at higher mileage intervals. (Refer to manual for precise schedule).
Tire Pressure Recommendations:
Front: 36 PSI (2.5 bar), Rear: 40 PSI (2.8 bar) - always check manual for exact specs for loaded conditions.
Harley-Davidson proved gear oil or equivalent SAE 85W-140 gear oil.
Brake Fluid Spec:
DOT 4 recommended.
Coolant Spec:
N/A (Air-cooled engine)
Known Issues
Known Issues:
Potential for primary chain tensioner wear (especially earlier Twin Cam models, though improved in later years), starter clutch issues, and occasional electrical gremlins. The manual will detail inspection and replacement procedures for common wear items.
Filter Part Numbers
Oil Filter Part Number:
Likely 63796-77A or similar Harley-Davidson oil filter (verify in manual).
Air Filter Part Number:
Varies by specific configuration, but typically Harley-Davidson part numbers beginning with 29000 series or similar (verify in manual).
📚 Vehicle History
Brand Heritage
Brand Heritage:
Harley-Davidson, founded in 1903, boasts over a century of motorcycle manufacturing, known for its iconic V-twin engines, distinctive styling, and strong association with American culture and freedom.
Model Evolution
Model Evolution:
The Road King line, introduced in 1994, evolved from earlier touring models, emphasizing a retro aesthetic with modern performance. It has consistently offered a comfortable, large-displacement touring platform.
Production
Production Location:
United States (various Harley-Davidson assembly plants)
Production Years For Twin Cam 96:
2007-2011 (for the Twin Cam 96 engine platform, adapted across various models including FLHR).
🏆 Awards & Recognition
Recognitions
Recognitions:
While specific awards for the 2010 model year may not be widely documented, the Harley-Davidson brand and the Road King model line consistently receive acclaim for their build quality, rider comfort, and enduring classic style. Often cited in 'best touring bikes' lists.