Segment:
Flagship Touring/Cruiser Motorcycle
Target Audience:
Owners seeking to perform their own maintenance, repairs, and customizations, as well as independent repair shops.
Key Competitors:
Indian Chief, Honda Gold Wing, BMW R 1250 RT (in the broader touring category, though Road King is more classic cruiser)
Vehicle Usp:
Classic styling, comfortable ride, powerful V-Twin engine, touring capability with removable windscreen and saddlebags.
Manual Value Proposition:
Empowers owners with the knowledge and procedures to maintain and repair their high-value motorcycle, saving time and money compared to dealership services.
Engine:
Twin Cam 103 Engine: Top End (Cylinder Heads, Valves, Camshafts), Bottom End (Crankcase, Crankshaft, Connecting Rods), Lubrication System, Cooling System (Airflow Management), Fuel System (EFI Components, Injectors, Throttle Body)
Transmission:
6-Speed Cruise Drive Transmission: Gearbox Internals, Clutch Assembly, Primary Drive, Final Drive
Electrical System:
Wiring Diagrams, Lighting Systems (Headlight, Taillight, Turn Signals), Ignition System, Charging System (Stator, Regulator/Rectifier), Starting System (Starter Motor, Solenoid), Battery Management, ECM (Engine Control Module) and Sensors
Chassis Suspension Brakes:
Frame and Bodywork, Front Suspension (Fork Internals, Seals), Rear Suspension (Shocks, Swingarm), Braking System (Front and Rear Calipers, Rotors, Master Cylinders, ABS Components where applicable), Wheels and Tires
Fuel System:
Fuel Tank, Fuel Pump, Fuel Lines, Fuel Injectors, Throttle Control System, Emissions Control Components
Exhaust System:
Exhaust Headers, Mufflers, Catalytic Converter (if applicable), Lambda Sensors
Controls And Instruments:
Handlebar Controls, Foot Controls, Instrument Cluster, Indicators, Diagnostic Codes
Bodywork And Fittings:
Fenders, Fairings (if applicable), Saddlebags, Seat, Handlebars, Controls, Mirrors
Engine Repair:
Engine Disassembly and Reassembly, Valve Adjustment, Piston and Cylinder Replacement, Crankshaft and Connecting Rod Service, Camshaft Timing and Replacement
Transmission Repair:
Transmission Gear Inspection and Replacement, Clutch Service, Primary Drive Chain Adjustment and Replacement, Final Drive Belt Inspection and Adjustment
Electrical Diagnostics:
Troubleshooting Electrical Faults using Wiring Diagrams, Sensor Testing, Component Testing (Ignition Coils, Fuel Injectors, etc.), Diagnostic Trouble Code (DTC) Retrieval and Interpretation
Suspension And Brakes:
Fork Seal Replacement, Shock Absorber Replacement, Brake Pad and Rotor Replacement, Brake Bleeding, ABS System Diagnostics and Service
Fuel System Service:
Fuel Injector Cleaning and Replacement, Fuel Pump Pressure Testing, Throttle Body Cleaning and Adjustment
Maintenance Tasks:
Oil and Filter Changes, Air Filter Replacement, Spark Plug Replacement, Drive Belt Adjustment and Replacement, Tire Maintenance
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon issues
Depth:
Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds, including detailed electrical troubleshooting.
Diagnostics Level:
Advanced: Includes diagnostic codes, sensor data interpretation, and component-level testing procedures.
Wiring Diagrams:
Detailed, component-level wiring schematics
Engine Type:
Air-Cooled, Twin Cam 103, 45-degree V-Twin
Bore X Stroke:
3.875 in. x 4.380 in. (98.4 mm x 111.3 mm)
Displacement:
103 cu. in. (1690 cc)
Valve Train:
Overhead Valves (OHV), 2 valves per cylinder
Camshafts:
High Output Twin Cam 103 Camshafts
Ignition:
Electronic Sequential Port Fuel Injection (ESPFI)
Torque Rating:
Approximately 97.3 ft-lbs @ 3,000 RPM (Specific figures may vary slightly by year)
Horsepower Rating:
Approximately 78 HP @ 5,000 RPM (Specific figures may vary slightly by year)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Fuel Tank Capacity:
6.0 US gallons (22.7 L)
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months thereafter
Engine Oil Change:
Every 5,000 miles (8,000 km)
Primary Chain Tensioner:
Inspect every 10,000 miles (16,000 km)
Drive Belt Tension:
Check and adjust every 10,000 miles (16,000 km)
Engine Oil:
Harley-Davidson SYN3 (Synthetic) SAE 20W50 or other approved motorcycle oil (Refer to manual for specific API classification and Harley-Davidson approvals)
Transmission Fluid:
Harley-Davidson Formula+ or equivalent SAE 85W-140
Primary Chain Case Oil:
Harley-Davidson Formula+ or equivalent SAE 85W-140
Brake Fluid:
DOT 4 (refer to manual for specific recommendations, especially if ABS equipped)
Fork Oil:
Harley-Davidson recommended fork oil (Type E or equivalent, check manual for viscosity)
Twin Cam 103 Cam Chain Tensioner:
Hydraulic cam chain tensioners can wear out, leading to rattling noises. Recommended upgrade to the '96 up cam chain tensioner upgrade kit.
Primary Drive Clutch Friction Plates:
Wear can occur over time, affecting clutch engagement. Regular inspection and adjustment are key.
Electrical Connections:
Corrosion or loose connections can cause intermittent electrical issues, particularly on older models or those exposed to harsh weather.
Rear Air Suspension:
The air-adjustable suspension can develop leaks over time, affecting ride height and comfort. Regular checks of air lines and shocks are advised.
Founding:
1903, Milwaukee, Wisconsin
Legacy:
Iconic American motorcycle manufacturer known for V-twin engines and custom styling.
Road King Introduction:
The Road King lineage began in the early 1990s, evolving from the Electra Glide platform to offer a more classic, stripped-down touring experience.
Engine Transition:
The 1690cc Twin Cam 103 engine became a staple for Harley-Davidson touring models in this era, offering increased displacement and torque over previous Evolution engines.
Manufacturing Location:
United States (primarily York, Pennsylvania and Milwaukee, Wisconsin assembly plants)
