Positioning:
Premium cruiser motorcycle with classic styling and touring capability
Key Competitors:
Other large-displacement V-twin cruisers, touring motorcycles from Japanese and American manufacturers
Design Philosophy:
Blend of classic Harley-Davidson aesthetics with modern touring comfort and performance
Manual Utility:
Enables owners to perform comprehensive maintenance, diagnostics, and repairs, saving on labor costs and ensuring proper upkeep.
Diagnostic Capability:
Provides the technical foundation for identifying and resolving complex issues, reducing downtime.
Accessibility:
Instant digital access facilitates on-the-spot problem-solving, especially during breakdowns.
Engine:
Detailed coverage of Twin Cam 96 engine (disassembly, assembly, timing, lubrication, cooling, fuel and ignition systems)
Transmission:
Six-speed Cruise Drive transmission (disassembly, assembly, lubrication, internal components)
Fuel System:
Fuel injection (EFI) system, throttle body, fuel pump, fuel injectors, diagnostic procedures
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), ignition system, lighting, instrumentation, security system
Brakes:
Hydraulic brake systems (front and rear calipers, master cylinders, brake lines, fluid replacement, bleeding, troubleshooting)
Suspension:
Front forks (telescopic, disassembly, seals, fluid), rear suspension (shock absorbers, adjustments)
Chassis Frame:
Frame inspection, steering head, swingarm, wheel bearings
Bodywork:
Fairing, saddlebags, fenders, fuel tank, seat, control levers, cables
Exhaust System:
Exhaust pipes, mufflers, gasket replacement
Cooling System:
Air-cooled engine specifics, heat dissipation strategies
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug service, lubrication points
Troubleshooting:
Diagnostic charts, common problems and solutions, electrical system diagnostics
Repair:
Complete disassembly and reassembly procedures for all major components
Engine Rebuild:
Detailed steps for engine overhaul, piston and cylinder service, valve adjustments, cam timing
Transmission Service:
Gearbox inspection, clutch service, primary drive maintenance
Electrical Diagnostics:
Fault finding for ignition, charging, lighting, and accessory systems
Brake System Service:
Brake pad replacement, caliper service, hydraulic system maintenance
Suspension Overhaul:
Fork seal replacement, shock absorber servicing
Depth:
Comprehensive (covers routine maintenance to complete engine and transmission rebuilds)
Target Audience:
Professional mechanics and experienced DIY enthusiasts
Engine Type:
Air-cooled, Twin Cam 96 V-Twin
Displacement:
96 cubic inches (1584 cc)
Bore X Stroke:
3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)
Valve Train:
Overhead valve (OHV), 2 valves per cylinder
Horsepower:
Estimated 60-70 HP (specific figures vary by dyno and tuning, manual will provide detailed specs)
Torque:
Estimated 80-90 ft-lbs @ 3200 RPM (specific figures vary, manual will provide detailed specs)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, 91 octane or higher recommended
Oil Type:
Harley-Davidson recommended V-Twin 20W-50 or equivalent synthetic
Oil Capacity:
Approximately 4 quarts (3.8 L) with filter change (verify in manual)
Transmission Type:
6-speed Cruise Drive
Primary Drive:
Constantly engaged, single-row, chain drive (46/34 ratio)
Final Drive:
Belt drive (53/55 ratio)
Clutch:
Hydraulic, multi-plate wet clutch
Transmission Fluid Type:
Harley-Davidson Formula + Transmission Fluid or equivalent
Transmission Fluid Capacity:
Approximately 1 quart (0.95 L) (verify in manual)
Safety Features:
Disc brakes (front and rear), comprehensive wiring with fuses and circuit breakers
Brakes:
Dual 32mm front piston calipers with 300mm discs, 32mm rear piston caliper with 300mm disc
Lighting:
Halogen headlight, LED tail light and brake light, amber front and rear turn signals
Frame Construction:
Mild steel, tubular, square section, backbone with pressed and welded backbone and downtube
Audio System:
Optional premium audio system (often with AM/FM radio, CD player, or later MP3/auxiliary input capability, depending on specific factory options).
Cruise Control:
Often equipped with electronic cruise control.
Security System:
Factory-installed security system with immobilizer and key fob.
Diagnostic Port:
Features a diagnostic connector for use with Harley-Davidson Electronic<bos>Troubleshooting (H-D E.T.) or similar diagnostic tools.
First Service:
Typically at 1,000 miles (1600 km) - includes engine oil and filter change, primary chain tension check, clutch adjustment, and inspection of all critical fasteners and components.
Subsequent Service:
Generally every 5,000 miles (8,000 km) or annually, whichever comes first. This includes engine oil and filter, transmission oil, primary lubricant, spark plugs (as needed), inspection of brakes, tires, and all functional systems.
Engine Oil:
Harley-Davidson V-Twin 20W-50 Synthetic or equivalent.
Transmission Oil:
Harley-Davidson Formula + Transmission Fluid or equivalent.
Primary Chain Case Oil:
Harley-Davidson Formula + Transmission Fluid or equivalent (same as transmission).
Brake Fluid:
DOT 4 specification hydraulic brake fluid.
Fork Oil:
Specific weight and type (e.g., Harley-Davidson Type E or equivalent) – manual will specify exact type and quantity.
Common Wear Items:
Clutch plates, brake pads, tires, wheel bearings, fork seals, starter drive components.
Potential Diagnostics:
Fueling issues (idle quality, hesitation), charging system faults (regulator/rectifier), occasional electrical gremlins, primary chain adjustment requirements.
Brand Origin:
Founded in Milwaukee, Wisconsin, USA, in 1903.
Brand Identity:
Iconic American motorcycle manufacturer known for its V-twin engines and cruiser/touring motorcycles.
Road King Lineage:
The Road King line has been a staple of Harley-Davidson's touring segment, evolving from earlier FL models.
Custom Variant:
The 'Custom' designation (FLHRSI) typically indicates specific styling cues like different handlebars, seats, and paint schemes compared to the standard Road King.
Production Era:
The Twin Cam 88 and later Twin Cam 96 engines were in production from 1999 to 2017.
Manufacturing Location:
Harley-Davidson motorcycles are primarily manufactured in the United States.
