Market Position:
The Harley-Davidson FLHRSI Road King EFI 2004 is a flagship touring motorcycle known for its classic styling, comfortable ride, and V-twin engine performance, catering to riders who prioritize long-distance comfort and traditional cruiser aesthetics.
Competitive Analysis:
Competes with other large-displacement cruisers and touring motorcycles from manufacturers like Indian, Honda Gold Wing (in touring segment), and potentially some high-end Victory models, offering a distinct American V-twin experience.
Key Features:
Detachable windscreen, ample storage via saddlebags, comfortable rider and passenger seating, classic chrome styling, electronic fuel injection for consistent performance, and a robust V-twin engine.
Value Proposition:
Empowers owners to perform maintenance and repairs confidently, saving significantly on labor costs while ensuring the longevity and optimal performance of their Harley-Davidson FLHRSI Road King EFI.
Coverage Areas:
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
Page Count:
Hundreds (estimated 700-900 pages for a complete factory manual of this era)
Manual Type:
Factory Service Repair Manual
Printability:
Fully printable, allowing users to print specific pages or the entire manual.
Searchability:
PDF format allows for keyword searching within the document, enabling quick access to specific information.
Authenticity:
Genuine Factory Service Manual, not a third-party reproduction.
Systems Covered:
Engine Mechanical, Fuel Injection System (EFI), Ignition System, Lubrication System, Cooling System (if applicable, though typically air-cooled for this model), Clutch and Primary Drive, Transmission, Final Drive/Belt Drive, Suspension (Front and Rear), Brakes (Front and Rear), Electrical System (including lighting, charging, starting, diagnostics), Chassis and Frame, Wheels and Tires, Steering System, Bodywork and Accessories.
Procedures Included:
Routine Maintenance, Scheduled Service Intervals, Troubleshooting Fault Symptoms, Diagnostic Procedures for EFI System, Component Testing (sensors, actuators, ignition coils), Engine Rebuilding and Overhauling, Transmission Disassembly and Assembly, Clutch Service, Brake System Bleeding and Pad Replacement, Suspension Adjustments and Component Replacement, Electrical System Diagnostics and Repair, Wiring Harness Repair and Testing, Fork Seal Replacement, Wheel Bearing Service, Tire Mounting and Balancing, Frame Inspection, Accessory Installation and Troubleshooting.
Technical Depth:
Comprehensive factory-level detail, including step-by-step repair procedures, diagnostic flowcharts, detailed torque specifications, clearances, electrical schematics, and part identification for all major components. Suitable for professional technicians and experienced DIY enthusiasts.
Electrical System Detail:
Detailed schematics for lighting, ignition, charging system, starter, fuel injection, instrumentation, and accessories. Includes diagnostic procedures for electrical faults.
Troubleshooting Guide:
Advanced troubleshooting guide for diagnosing common and uncommon problems, including engine performance issues, electrical gremlins, and component failures.
Illustrations Diagrams:
Includes hundreds of detailed illustrations, drawings, and photographs to guide repair procedures, component identification, and assembly/disassembly sequences.
Diagnostic Techniques:
Provides techniques used by factory-trained technicians for accurate fault diagnosis, including electrical testing methods and engine performance checks.
Common Fixes:
Highlights common repair procedures and solutions for recurring issues, enabling owners to communicate effectively with mechanics or perform repairs themselves.
Frame And Suspension:
Detailed information on frame integrity checks, front fork service (oil changes, seal replacement), rear shock absorber service and adjustment, and wheel bearing maintenance.
Brake System:
Comprehensive coverage of front and rear brake caliper service, pad replacement, rotor inspection, brake line replacement, and bleeding procedures.
Fuel System Efi:
In-depth diagnosis of the Electronic Fuel Injection system, including troubleshooting sensors (MAP, IAT, TPS, O2), injectors, fuel pump, and ECU.
Engine Performance Tuning
Engine Performance Tuning:
Guidance on understanding engine management parameters and potential tuning considerations for optimal performance, though advanced tuning may require specialized tools not covered in a basic service manual.
Electrical Diagnostics:
Utilizes wiring diagrams and diagnostic flowcharts to trace electrical faults, test components, and repair wiring harness issues, covering everything from lighting to ignition.
Primary Engine:
Harley-Davidson Twin Cam 88 (Evolution Engine)
Engine Type:
Air-cooled, V-twin, 45-degree cylinder angle
Displacement:
1450 cc (88 cubic inches)
Bore X Stroke:
3.75 in x 4.00 in (95.25 mm x 101.6 mm)
Horsepower:
Approximately 67 HP (at crank, may vary)
Torque:
Approximately 86 ft-lbs @ 3200 RPM (at crank, may vary)
Fuel System:
Electronic Sequential Port Fuel Injection (ESPFI)
Ignition System:
High-performance electronic ignition
Lubrication System:
Dry-sump with oil tank separate from crankcase
Valve Train:
Overhead valves (OHV), pushrod actuated, two valves per cylinder
Cooling Method:
Air-cooled
Service Intervals:
Typically: Oil and filter change every 2,500-5,000 miles or annually. Primary chaincase oil change every 5,000 miles. Spark plug replacement every 10,000-20,000 miles. Brake fluid flush every 2 years. All data detailed in the manual.
Engine Oil:
Harley-Davidson recommended V-Twin oil (e.g., 20W50) or equivalent API SG or higher rated motorcycle oil. Capacity: Approx. 3.0 US quarts (2.8 L) with filter change. (Exact specifications in manual).
Primary Chaincase Oil:
Harley-Davidson primary lubricant or equivalent. Capacity: Approx. 1.0 US quart (0.95 L). (Exact specifications in manual).
Transmission Oil:
Harley-Davidson transmission lubricant or equivalent. Capacity: Approx. 24 US fluid ounces (0.7 L). (Exact specifications in manual).
Brake Fluid:
DOT 4 or DOT 5.1 (check specific model requirements in manual, DOT 5 silicone fluid was common on some Harley models, but DOT 4/5.1 is more typical for ABS if equipped, though this era ABS was less common on Road Kings). Manual will confirm.
Known Issues:
Common issues for this era can include: Cam chain tensioner wear (requiring upgrade to hydraulic tensioners), potential oil leaks from seals and gaskets, carburetor (if applicable on non-EFI models) or EFI component issues, and wheel bearing wear. The manual addresses diagnosis and repair for all these.
Oil Filter Part Number:
Examples include Harley-Davidson OEM 63796-77A or aftermarket equivalents like Harley-Davidson 63731-99, K&N KN-170C, or Wix 51358. (Manual will provide definitive OEM numbers).
Front Tire Pressure:
Typically 36 psi (2.5 bar) for front tire (check manual for specific recommendation)
Rear Tire Pressure:
Typically 40 psi (2.8 bar) for rear tire (check manual for specific recommendation)
Brand Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its distinctive V-twin engines, custom styling, and a rich history of performance and rider lifestyle.
Model Evolution:
The Road King model line, introduced in the early 1990s, evolved from Harley-Davidson's classic touring designs, offering a blend of traditional styling with modern amenities. The FLHRSI designation signifies the fuel-injected 'S' (Special) version of the Road King.
Production:
The Twin Cam 88 engine was introduced in 1999, and the FLHRSI Road King EFI was a popular variant throughout the early 2000s. Production spanned several years with minor updates.
