Model:
Road King / Road Glide
Sub Model:
FLHR (Road King), FLTR (Road Glide)
Generation Designation:
1999-2005 Harley-Davidson Big Twin Touring Models
Chassis Codes Covered:
FLHR, FLHRCI, FLHRI, FLHT, FLHTC, FLHTCI, FLHTI, FLHTPI, FLHX, FLHTCSE, FLTR, FLTRI, FLTRSEI
Target Audience:
Harley-Davidson owners, independent repair shops, motorcycle technicians servicing 1999-2005 Road King and Road Glide models.
Manual Value Proposition:
Provides detailed, factory-level information essential for maintaining and repairing these specific Harley-Davidson touring motorcycles, offering a cost-effective alternative to official dealership service.
Manual Strength:
Extensive coverage of engine variants, electrical systems, and model-specific differences for a broad range of years within a single manual.
Engine Systems:
Engine assembly, disassembly, tuning, lubrication, cooling system, fuel system (carbureted & EFI), ignition system, exhaust system, engine performance tuning, component testing, troubleshooting
Transmission Drivetrain:
Transmission assembly/disassembly (5-speed, including 'Cruise Drive' if applicable to later models), clutch operation and adjustment, primary drive, final drive, drive belt maintenance, troubleshooting
Chassis Suspension Brakes:
Frame, front fork (including telescopic forks and potentially Tele-Guide), rear suspension (shock absorbers), wheel bearings, steering head bearings, brake system (front & rear hydraulic disc brakes), brake fluid specifications, bleeding procedures, ABS (if equipped), troubleshooting
Electrical System:
Wiring diagrams (detailed), battery service, charging system (alternator/stator, regulator/rectifier), starting system (starter motor), lighting system (headlights, taillights, turn signals), ignition switches, instrument cluster, fuel injection system diagnostics (EFI models), security system (if equipped), horn, troubleshooting electrical faults
Bodywork And Trim:
Fairings (Road Glide), saddlebags, windshields, fenders, seat installation, fuel tank removal/installation, handlebars, controls, trim pieces, fairing maintenance and repair
Maintenance Procedures:
Routine service, oil changes, filter replacement, spark plug replacement, air filter cleaning/replacement, brake pad inspection and replacement, chain/belt adjustment (if applicable), battery charging and maintenance, tire pressure checks, lubrication points
Repair Procedures:
Engine rebuilds, transmission overhauls, fork seal replacement, brake caliper rebuilds, electrical component replacement, fuel system repair, clutch service, wheel and tire mounting
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides, electrical diagnostic charts, engine performance issues, drivability problems
Special Tool Requirements:
Identification and usage of specialized tools required for specific repair and maintenance tasks
Technical Depth:
Comprehensive, covering everything from basic fluid checks and adjustments to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
Engine Family:
Harley-Davidson Twin Cam 88
Engine Displacement:
1450cc (88 cubic inches)
Engine Configuration:
Air-cooled, 45-degree V-twin
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Compression Ratio:
8.8:1 (typical, may vary slightly by year/model)
Horsepower:
Approx. 65-70 HP (at crankshaft, varies by tuning and year)
Torque:
Approx. 85-90 lb-ft (at crankshaft, varies by tuning and year)
Carbureted Models:
Keihin CV (Constant Velocity) carburetor, 40mm
Efi Models:
Electronic Fuel Injection (EFI) with single-injector throttle body
Fuel Type:
Unleaded gasoline, minimum 87 octane (91 AKI)
Transmission Type:
5-speed constant mesh, helical gears
Primary Drive:
Duplex chain
Final Drive:
Belt drive, 32mm wide
Clutch Type:
Wet, multi-plate, diaphragm spring
Transmission Fluid Capacity:
Approx. 1 quart (0.95 L)
Transmission Fluid Specification:
Harley-Davidson Formula+ or equivalent API GL-4 gear oil (check specific manual for precise spec)
Wheelbase:
Approx. 63.5 inches (1613 mm)
Length:
Approx. 93.0 inches (2362 mm)
Ground Clearance:
Approx. 5.1 inches (130 mm)
Dry Weight:
Approx. 700 lbs (317.5 kg) (varies by model and options)
Gvwr:
Not typically published for motorcycles, but implies safe operating load including rider, passenger, and luggage.
Fuel Tank Capacity:
5.0 US gallons (18.9 L)
Oil Tank Capacity:
3.5 US quarts (3.3 L)
Front Tire:
Dunlop MH90-21 (or similar, consult manual for exact OEM spec)
Rear Tire:
Dunlop MU85B16 (or similar, consult manual for exact OEM spec)
Safety Features General:
Robust frame construction, disc brakes, integrated lighting.
Braking System:
Dual front disc brakes, single rear disc brake, hydraulic actuation. Some models may offer optional ABS (Anti-lock Braking System) from 2003 onwards.
Lighting:
Halogen headlamp, full lighting suite (headlight, taillight, brake light, turn signals).
Security:
Optional factory alarm system and immobilizer on some models.
Oil Change Interval:
Every 5,000 miles (8,000 km) or annually, whichever comes first (check manual for specific conditions).
Primary Chain Tensioner Inspection:
Recommended inspection at 10,000-mile intervals due to potential wear on early hydraulic tensioners.
Drive Belt Check:
Inspect for wear and tension at every service interval.
Brake Fluid Flush:
Every 2 years, regardless of mileage.
Engine Oil Type:
Harley-Davidson SYN3 Synthetic Motorcycle Oil (20W-50) or equivalent V-Twin specific motorcycle oil.
Engine Oil Capacity:
3.0 US quarts (2.8 L) with filter change.
Brake Fluid Type:
DOT 4, Low Viscosity.
Primary Chain Tensioner Wear:
Early models (pre-2007) with the original hydraulic tensioner system are prone to wear, which can lead to noise and potential damage if not addressed. Upgrade to an improved tensioner or the later Twin Cam 96 primary setup is often recommended.
Cam Chain Tensioner Wear:
Similar to the primary tensioner, the cam chain tensioners can wear, requiring inspection and potential replacement.
Crank Position Sensor Failure:
Can lead to starting issues or engine stalling.
Fuel Injector Issues:
On EFI models, potential for clogging or failure can affect performance.
Brand Legacy:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its cruiser and touring motorcycles, embodying freedom, individuality, and a distinct riding culture.
Road King Introduction:
The Road King was introduced in 1994 as a modern interpretation of the classic FL-series 'Electra Glide' models, emphasizing a stripped-down, retro touring aesthetic.
Road Glide Introduction:
The Road Glide, characterized by its frame-mounted fairing, debuted in 1980 and has evolved significantly, becoming a staple for riders seeking wind protection and integrated audio.
Engine Transition:
The 1999 model year marked a significant transition for Harley-Davidson's touring line with the introduction of the Twin Cam 88 engine, replacing the Evolution (Evo) engine.
Production Era:
These models represent the early to mid-production years of the Twin Cam 88 engine, a period of refinement and adaptation for Harley-Davidson's touring platforms.
