Harley Davidson FLHR Road King 2004 Repair Service Manual

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Taper: Motorcycle

Distributeur:

UGS: 66609

Mots clés: 2004 Engines FLHR Harley Davidson King Air Motorcycle Road King

Variantes de produits

Description

The 2004 FLHR Road King is a premium large-displacement cruiser designed for riders who prioritize comfort, touring capability, and classic American motorcycle aesthetics. Powered by an air-cooled, Twin Cam 88 V-Twin engine with a 1450cc displacement, this model offers substantial torque and a smooth power delivery. Notable features include a detachable windshield, spacious saddlebags for storage, comfortable seating for long rides, and a 5-speed transmission with belt drive. The Road King line, with its heritage dating back to 1994, represents a dedication to traditional styling and rider comfort, making it a strong choice for touring enthusiasts and those who appreciate the open road experience. This comprehensive workshop repair service manual provides in-depth guidance for all aspects of the 2004 FLHR Road King, covering all models, engines, trims, and transmission types. It details maintenance procedures, troubleshooting steps, technical specifications, and safety guidelines essential for proper vehicle upkeep and repair. The manual covers a wide range of systems, including the engine, fuel system, brakes, electrical system, chassis, and transmission, offering detailed instructions for disassembly, assembly, cleaning, and reinstallation. This resource is invaluable for owners, mechanics, and technicians seeking to maintain, diagnose, and repair the vehicle to professional standards.

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

FLHR Road King

Year:

Generation

Model Generation:

Fifth Generation (1997-2008)

Codes

Vin Code Model Identifier:

FLHR (typically)

👋 Introduction

Market Position

Positioning:

Premium large-displacement cruiser, catering to riders who value comfort, touring capability, and classic Harley-Davidson styling.

Target Audience:

Touring riders, cruiser enthusiasts, and owners who appreciate classic American motorcycle design and a comfortable riding experience for long distances.

Competitive Analysis

Competitors:

Primary competitors in its class included models from Indian Motorcycle, and potentially some high-end offerings from Japanese manufacturers focusing on cruiser aesthetics and touring features. However, the Harley-Davidson identity and V-twin engine were strong differentiators.

Key Features

Features:

Detachable windshield, large saddlebags, comfortable seating, classic styling, V-twin engine, cruise control (often standard or optional depending on sub-model/package).

📋 Manual Details

Coverage Areas

Coverage:

All Models, Engines, Trim, Transmissions Types for 2004 FLHR Road King

Page Count

Page Count:

Hundreds of pages (specific count not provided, but implied to be comprehensive)

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

Zoom Functionality:

YES (Allows zooming in/out of PDF content for clarity)

Delivery

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader & WinZip

Compatibility

Operating System Compatibility:

All Versions of Windows & Mac

📖 Manual Coverage

Systems Covered

Covered Systems:

General Information, Maintenance, Chassis, Fuel System, Cooling System, Engine, Clutch, Engine Lubrication System, Engine Removal/Installation, Drive, Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Wiring Diagrams

Electrical System Details:

Comprehensive coverage including battery, charging system, ignition system, lighting, instruments, starter, and all related wiring with detailed diagrams.

Chassis Components:

Frame, front and rear suspension (forks, shocks), steering head, swingarm, wheels, tires, and related components.

Fuel System Details:

Carburetor assembly, fuel lines, fuel pump (if applicable for the specific model variant, though typically gravity-fed for this era), fuel filter, and related components.

Brake System Details:

Front and rear brake calipers, master cylinders, brake lines, rotors, brake pads, and bleeding procedures.

Procedures Included

Included Procedures:

Service, Maintenance, Troubleshooting, Diagnostic, Repair, Disassembly, Assembly, Cleaning, Reinstallation, Detailed substeps, Notes, Cautions, Warnings

Troubleshooting Methods:

Step-by-step troubleshooting guides integrated with diagnostic procedures and wiring diagrams for efficient problem identification and resolution.

Engine Rebuild Procedures:

Comprehensive engine disassembly, inspection, repair, and reassembly instructions, including piston and cylinder service, valve train maintenance, and crankshaft/connecting rod assembly.

Transmission Overhaul:

Detailed procedures for transmission disassembly, inspection of gears, bearings, shift components, and reassembly, including clutch servicing.

Technical Depth

Depth:

Professional Technician Level; Complete Diagnostic, Repair, and Maintenance Information

Diagnostic Tools:

Information on using diagnostic tools and interpreting fault codes for troubleshooting engine and electrical issues.

📊 Manual Specifications

File Format

File Format:

Searchability:

Implied to be searchable due to PDF format, aiding in quick information retrieval.

Print Quality

Print Quality:

Full Printable

Binding Type

Binding Type:

Digital Download (Printable)

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, Twin Cam 88 V-Twin

Displacement:

1450cc (88 cubic inches)

Bore X Stroke:

3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)

Performance

Horsepower:

Approx. 67 hp @ 5200 rpm (est. - actual figures can vary slightly by source)

Torque:

Approx. 85 ft-lbs @ 3500 rpm (est. - actual figures can vary slightly by source)

Fuel System

Fuel Delivery:

Carbureted (Keihin CV Carburetor)

Fuel Tank Capacity:

5.0 gallons (18.9 L)

🔧 Transmission

Standard

Transmission Type:

5-speed, Constant Mesh

Optional

Optional Transmissions:

N/A for this model year and variant

Features

Clutch Type:

Wet, multi-plate

Final Drive Type:

Belt Drive

📐 Dimensions

Exterior

Overall Length:

Approx. 93.5 inches (2375 mm)

Wheelbase:

Approx. 63.5 inches (1613 mm)

Seat Height:

Approx. 28.2 inches (716 mm)

Weights

Dry Weight:

Approx. 687 lbs (311 kg)

Gross Vehicle Weight Rating:

Approx. 1040 lbs (472 kg)

Gvwr Load Capacity:

Approx. 353 lbs (160 kg) payload capacity (Gross Vehicle Weight Rating minus Dry Weight).

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle safety is typically assessed through independent testing of components and overall design principles, not standardized crash test ratings like automobiles).

Active Features

Active Safety:

Front and rear disc brakes with dual-piston calipers, Hydraulic clutch

Passive Features

Passive Safety:

Sturdy frame construction, rider ergonomics designed for stability

💡 Technology Features

Infotainment

Audio System:

Optional, often dealer-installed aftermarket or factory radio systems were available, typically AM/FM with cassette or CD player.

Driver Assistance

Cruise Control:

Available, often standard on certain trims or as an option. Electronic cruise control enhances highway comfort.

Connectivity

Connectivity Features:

Limited by modern standards; focused on basic audio system integration if equipped.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 miles or 6 months, whichever comes first (refer to specific manual for exact interval and oil type).

Primary Chain Adjust:

As per manual, typically at 1000 mile service and then as needed.

Brake Fluid Flush Interval:

Recommended every 2 years or as per manual instructions.

Fluid Specifications

Engine Oil Type:

Harley-Davidson Syn3 or equivalent (e.g., V-Twin specific SAE 20W-50 synthetic oil recommended by many owners).

Transmission Fluid Type:

Harley-Davidson Formula + or equivalent heavy-duty motorcycle transmission lubricant.

Primary Chain Case Oil:

Harley-Davidson Formula + or equivalent heavy-duty motorcycle transmission lubricant.

Brake Fluid Type:

DOT 4 (Check manual for specific recommendations).

Fork Oil Type:

Harmonic Dampening Fluid (refer to manual for viscosity and quantity).

Known Issues

Common Wear Items:

Clutch plates, wheel bearings, brake pads, fork seals, drive belt.

Potential Twin Cam Issues:

While the Twin Cam 88 is generally robust, some early models could experience cam bearing wear or oil pressure issues if not properly maintained. Upgrades were available.

📚 Vehicle History

Brand Heritage

Heritage:

Harley-Davidson, founded in 1903, is one of the most iconic American motorcycle manufacturers, renowned for its V-twin engines, distinctive styling, and association with freedom and the open road.

Model Evolution

Evolution:

The Road King line, introduced in 1994, represented Harley-Davidson's commitment to classic styling and touring comfort, evolving from earlier FL models with modern updates like the Twin Cam engine.

Engine Introduction:

The Twin Cam 88 engine was introduced in 1999, becoming standard across most Harley-Davidson models by 2000, including the Road King. This engine offered a significant improvement in torque and a smoother power delivery compared to its predecessor, the Evolution engine.

Production

Manufacturing Location:

United States (Various Harley-Davidson assembly plants)