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Harley Davidson FLHR Road King Motorcycle 1995-1998 Factory Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHR Road King Years Covered: 1995, 1996, 1997, 1998 👋 Introduction Market Position Segment: Full-size V-twin cruiser motorcycle, renowned for touring comfort and...
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Harley Davidson FLHR Road King Motorcycle 1995-1998 Factory Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FLHR Road King
Years Covered:
1995, 1996, 1997, 1998
👋 Introduction
Market Position
Segment:
Full-size V-twin cruiser motorcycle, renowned for touring comfort and classic styling.
Competitive Analysis
Competitors:
Other large displacement cruisers from American manufacturers and some Japanese brands of the era.
Key Features
Model Identity:
The FLHR Road King is characterized by its classic styling, comfortable ride, detachable windshield, and saddlebags, making it a versatile touring machine.
Manual Value Proposition
Utility:
Essential for owners and technicians to maintain, diagnose, and repair the FLHR Road King, ensuring longevity and optimal performance.
📋 Manual Details
Coverage Areas
Primary Coverage:
Factory Service Repair Workshop Manual
Page Count
Estimated Page Count:
Approximately 500-700 pages (typical for this era's comprehensive service manuals)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital Download (likely PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (Evolution V-Twin), Transmission, Primary Drive, Final Drive
Chassis:
Frame, Suspension (Front Forks, Rear Shocks), Steering, Wheels, Tires
Electrical:
Ignition System, Lighting System, Charging System, Starting System, Gauges, Switches, Wiring Diagrams
Brakes:
Front and Rear Brake Systems (Hydraulic Disc)
Fuel System:
Carburetor (likely Keihin CV), Fuel Tank, Fuel Lines, Fuel Filter
Exhaust:
Exhaust System Components and Mounting
Bodywork:
Fairing (if equipped), Fenders, Saddlebags, Seat, Handlebars, Controls
Procedures Included
Maintenance:
Routine Service, Oil Changes, Filter Replacements, Spark Plug Service, Chain/Belt Adjustment (if applicable), Lubrication Points
Repair:
Engine Overhaul, Transmission Rebuild, Clutch Service, Brake Caliper Overhaul, Suspension Component Replacement, Electrical Component Diagnosis and Repair
Troubleshooting:
Diagnostic Flowcharts, Symptom-Based Troubleshooting Guides, Common Issues and Solutions
Technical Data:
Specifications, Tolerances, Torque Values, Fluid Capacities, Electrical Schematics
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls.
📊 Manual Specifications
File Format
Digital Format:
PDF (typically with searchable text and high-resolution images/diagrams)
Print Quality
Image Resolution:
High-resolution for clear viewing of diagrams, photos, and schematics.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Harley-Davidson Evolution (commonly known as the 'Evo' engine)
Configuration:
Air-cooled, 45-degree V-twin
Displacement:
1337cc (80 cubic inches)
Bore X Stroke:
3.493 in x 4.25 in (88.7 mm x 108 mm)
Compression Ratio:
8.5:1 (typical for this era)
Valvetrain:
Overhead valves (OHV), 2 valves per cylinder, operated by pushrods
Performance
Horsepower:
Approx. 60-70 HP (at crankshaft, estimate based on typical tuning)
Torque:
Approx. 75-85 ft-lbs (at crankshaft, estimate based on typical tuning)
Fuel System
Fuel Delivery:
Carbureted (Keihin CV 40mm common)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Lubrication
Oil Type:
Harley-Davidson 20W50 Motorcycle Oil or equivalent API SG or higher
Oil Capacity:
Approx. 4 US quarts (3.8 Liters) with filter change
🔧 Transmission
Standard
Transmission Type:
5-speed manual constant mesh
Clutch Type:
Wet, multi-plate, diaphragm spring
Features
Primary Drive:
Multi-plate clutch, 34/46 gear ratio
Final Drive:
Belt drive, 32/65 gear ratio
Transmission Oil Type:
Harley-Davidson Syn3 or equivalent SAE 75W90 Synthetic Gear Oil
Transmission Oil Capacity:
Approx. 24 US fluid ounces (0.71 Liters)
📐 Dimensions
Exterior
Wheelbase:
Approx. 63.5 inches (1613 mm)
Length:
Approx. 94.0 inches (2388 mm)
Seat Height:
Approx. 28.0 inches (711 mm) unladen
Weights
Dry Weight:
Approx. 680 lbs (308 kg)
Gross Vehicle Weight Rating:
Approx. 1160 lbs (526 kg)
Cargo
Saddlebag Capacity:
Detachable leather or hard saddlebags (capacity varies by specific model/option).
🛡️ Safety Features
Ratings
Safety Certifications:
N/A (Motorcycles are typically not rated by consumer safety organizations in the same way as cars).
Active Features
Braking System:
Dual front disc brakes, Single rear disc brake. Mechanical actuation with hydraulic assist. (ABS was not common on these models).
Lighting:
Halogen headlight, taillight, brake light, turn signals.
Passive Features
Frame Construction:
Steel tube cradle frame provides rigidity and stability.
Suspension Design:
Telescopic front fork, dual rear shock absorbers for rider comfort and control.
💡 Technology Features
Infotainment
Audio System:
Optional AM/FM radio with CB/Intercom and cassette player was available on some models, often integrated into the fairing.
Gauges:
Analogue speedometer, tachometer, voltmeter, fuel gauge, oil pressure gauge (location and availability may vary).
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was not a standard or commonly available option on these model years.
Connectivity
Connectivity Features:
Limited by modern standards. Primarily mechanical and electrical systems with no digital connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first.
Primary Chain Tensioner Inspection:
Check at 10,000 miles and every 10,000 miles thereafter. (Hydraulic tensioners introduced later, manual models may have adjusters).
Spark Plug Replacement:
Every 10,000 miles
Air Filter Cleaning/Replacement:
Inspect every 5,000 miles, clean or replace as needed.
Brake Fluid Flush:
Every 24 months or as specified by manual.
Fluid Specifications
Engine Oil:
Harley-Davidson 20W50 Motorcycle Oil or equivalent API SG or higher.
Transmission Oil:
Harley-Davidson Syn3 or equivalent SAE 75W90 Synthetic Gear Oil.
Primary Chain Case Oil:
Harley-Davidson Primary Chaincase Lubricant or equivalent SAE 80W90 gear oil (approx. 1 quart).
Brake Fluid:
DOT 4 brake fluid (for clutch and brake master cylinders).
Known Issues
Cam Chain Tensioners:
Early Evolution engines are known for wear on the cam chain tensioner pads, which can lead to engine damage if not addressed. Later models often had upgrades.
Carburetor Tuning:
Keihin CV carburetors can sometimes require periodic adjustment or cleaning for optimal performance.
Electrical Connectors:
Corrosion or loose connections in electrical connectors can lead to intermittent issues.
Belt Drive Tension:
Proper belt tension is critical to prevent premature wear of the belt and sprockets.
📚 Vehicle History
Brand Heritage
Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer known for its V-twin engines and classic styling.
Model Evolution
Road King Lineage:
The Road King was introduced in 1994 as a nod to the classic FL models of the 1940s and 1950s, combining vintage aesthetics with modern V-twin technology.
Production
Manufacturing Location:
York, Pennsylvania, USA (primary manufacturing facility for Harley-Davidson touring models)
Production Era:
The 1995-1998 models represent a key period in the Evolution engine's development and the touring line's refinement.
🏆 Awards & Recognition
Recognitions
Model Recognition:
The FLHR Road King is widely recognized as a quintessential American cruiser, praised for its ride comfort, touring capability, and timeless styling.
Ratings
Customer Satisfaction:
Consistently high customer satisfaction for its blend of classic appeal and touring functionality.
Certifications
Historical Significance:
Represents a significant era for Harley-Davidson, building on the success of the Evolution engine and solidifying the touring cruiser segment.
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