Target Audience:
Harley-Davidson owners, independent repair shops, DIY enthusiasts
Value Proposition:
Provides factory-level repair and maintenance information, saving significant costs compared to dealership service.
Instructional Style:
Step-by-step instructions with detailed diagrams and exploded views for clarity.
Convenience:
Instant digital download, accessible on multiple devices for on-the-go troubleshooting.
Primary Coverage:
Full Service, Repair, Maintenance, Troubleshooting
Estimated Pages:
Extensive (typical for WSRM, often 500+ pages)
Type:
Factory Service Manual (FSM) / Workshop Service Repair Manual (WSRM)
Format:
PDF (Downloadable)
Engine Service:
Complete engine disassembly, assembly, troubleshooting, tuning (fuel injection, ignition)
Transmission Service:
Service and repair of the 6-speed cruise drive transmission
Drivetrain Service:
Primary drive, final drive belt inspection and replacement
Chassis Service:
Frame, swingarm, suspension (forks, rear shocks) maintenance and repair
Electrical System:
Wiring diagrams, component testing, battery, charging system, ignition system, lighting, accessories
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank service
Braking System:
Front and rear brake caliper service, master cylinders, hydraulic lines, bleeding procedures
Wheel Tire Service:
Wheel bearing replacement, tire mounting and balancing
Control Systems:
Handlebars, controls, cables, clutch and throttle operation
Bodywork Trim:
Fender removal/installation, fairing, saddlebag service
Maintenance Tasks:
Scheduled maintenance, oil changes, filter replacements, lubrication
Troubleshooting Diagnostics:
Systematic troubleshooting guides for common and uncommon issues, diagnostic codes
Repair Procedures:
Step-by-step instructions for component repair and replacement, including detailed exploded views
Diagnostic Capabilities:
Advanced diagnostics for EFI, ignition, and sensor systems
Rebuild Procedures:
Complete engine and transmission rebuild procedures
Calibration Procedures:
Fuel system and ignition calibration details
Engine Type:
Air-cooled, Twin Cam 96B (1584cc)
Bore X Stroke:
3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)
Torque:
92.6 ft-lbs @ 3500 RPM (125.5 Nm @ 3500 RPM) (typical for Twin Cam 96)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
91 octane or higher unleaded gasoline
Ignition Type:
Crankshaft position sensor, coil-over-plug
Transmission Type:
6-speed Cruise Drive
Gear Ratios:
1st: 9.312, 2nd: 6.445, 3rd: 4.774, 4th: 3.827, 5th: 3.143, 6th: 2.790
Clutch Type:
Clutched, hydraulically actuated, 9-plate, wet
Transmission Fluid Type:
Harley-Davidson Formula + transmission/primary chaincase lubricant
Initial Service:
1000 miles (1600 km) or 6 months, whichever comes first
Subsequent Service:
Every 5000 miles (8000 km) or 12 months, whichever comes first
Engine Oil:
Harley-Davidson SYN3 (Synthetic) SAE 20W50 or equivalent, 4.0 US qt. (3.8 L) capacity
Transmission Fluid:
Harley-Davidson Formula + transmission/primary chaincase lubricant
Primary Chaincase Oil:
Harley-Davidson Formula + transmission/primary chaincase lubricant, 2.8 US qt. (2.6 L) capacity
Timing Chain Tensioners:
Early Twin Cam models (pre-2007) were known for hydraulic tensioner wear, requiring replacement with updated components. Manual will detail inspection and replacement.
Crankshaft Position Sensor:
Potential for failure leading to starting or running issues. Manual provides testing procedures.
Starter Solenoid:
Intermittent engagement or failure can occur. Manual covers diagnostic steps.
Brand Legacy:
Harley-Davidson, established 1903, known for its V-twin engines and iconic cruiser styling.
Softail Platform:
The Softail chassis, introduced in 1984, mimics the appearance of a hardtail frame with hidden rear suspension.
Road King Lineage:
The Road King series is a popular touring and cruising model within the Harley-Davidson lineup, emphasizing comfort and classic styling.
Production Years Flhrsi:
2004-2006 (FLHRSI specifically)