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Harley Davidson FLHRI Road King EFi Complete Workshop Service Repair Manual 2005

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHRI Road King Year: 2005 Variant: Road King EFI Codes Vin Decoder Notes: Vehicle Identification Number (VIN) for Harley-Davidson models typically starts with...
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Harley Davidson FLHRI Road King EFi Complete Workshop Service Repair Manual 2005
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FLHRI Road King
Year:
2005
Variant:
Road King EFI
Codes
Vin Decoder Notes:
Vehicle Identification Number (VIN) for Harley-Davidson models typically starts with '1HD'. Specific digits denote model, engine, and manufacturing details.
👋 Introduction
Market Position
Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson owners, independent repair shops, enthusiasts seeking to perform their own maintenance and repairs.
Competitive Analysis
Key Competitors 2005:
Indian Chief, Victory Kingpin, Honda Shadow, Kawasaki Vulcan, Yamaha Road Star.
Key Features Vehicle
Distinctive Features:
Iconic styling, comfortable riding position, large-displacement V-twin engine, detachable windscreen, hard-shell saddlebags.
📋 Manual Details
Coverage Areas
Manual Type:
Complete Workshop Service Repair Manual
Language:
English
Format:
Downloadable Digital Format (likely PDF)
Page Count:
Estimated 500+ pages (typical for a complete workshop manual)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (disassembly, assembly, inspection, troubleshooting), Fuel System (EFI, fuel pump, injectors, throttle body), Ignition System, Exhaust System.
Drivetrain:
Transmission (disassembly, assembly, inspection, adjustment), Clutch System, Primary Drive, Final Drive (Belt Drive).
Chassis:
Frame, Suspension (Front Fork, Rear Shocks), Steering System, Wheels, Tires, Brakes (Front & Rear, Hydraulic System, Calipers, Master Cylinders, ABS if applicable).
Electrical:
Wiring Diagrams, Battery, Charging System (Alternator, Regulator), Starting System (Starter Motor), Lighting System, Gauges, Indicators, ECU (Engine Control Unit) and related sensors, Security System.
Bodywork And Accessories:
Fairings, Fenders, Seat, Saddlebags, Fuel Tank, Handlebars, Controls, Instrument Panel, Accessories Installation and Troubleshooting.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, brake fluid flushes, tire pressure checks, chain/belt adjustment, spark plug replacement.
Troubleshooting:
Diagnostic procedures for common issues, fault codes interpretation, electrical system diagnostics, engine performance problems.
Repair And Rebuild:
Step-by-step instructions for engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, electrical component replacement.
Special Tools:
Identification and usage instructions for specialized tools required for specific procedures.
Technical Depth
Diagnostic Capabilities:
Includes detailed diagnostic flowcharts, component testing procedures, and specifications for diagnosing malfunctions.
Rebuild Specifications:
Provides critical clearance, torque, and measurement specifications for internal engine and transmission components during rebuilds.
Wiring Diagrams:
Comprehensive and detailed electrical wiring schematics for all vehicle systems.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Text-searchable for quick access to specific information.
Printability:
Printable, allowing for physical reference.
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity.
Binding Type
Binding Type Physical:
N/A (Digital Format)
Paper Type
Paper Type Physical:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-Cooled, Twin Cam 88
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.75 in x 4.00 in (95.25 mm x 101.6 mm)
Compression Ratio:
8.9:1
Performance
Horsepower:
Approximately 65-70 HP (est.)
Torque:
Approximately 80-85 ft-lbs (est.) at 3500 RPM
Fuel System
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded Gasoline, minimum 89 Octane
Fuel Capacity:
5.0 US gallons (18.9 L)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Constant Mesh
Clutch Type:
Multi-plate, Wet Clutch
Primary Drive:
Duplex Chain, 34/46 ratio
Final Drive:
Belt Drive, 32/66 ratio
Features
Transmission Fluid Type:
Harley-Davidson Syn3 (or equivalent SAE 20W-50) for engine and transmission.
📐 Dimensions
Exterior
Length:
93.1 in (2365 mm)
Width:
39.6 in (1006 mm)
Height:
57.1 in (1450 mm)
Wheelbase:
63.7 in (1618 mm)
Weights
Dry Weight:
Approx. 723 lbs (328 kg)
Gross Vehicle Weight Rating:
1250 lbs (567 kg)
Gvwr Payload Capacity:
Approx. 527 lbs (239 kg)
Cargo
Saddlebag Capacity:
Approx. 2.2 cu ft total
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycles are not subjected to standardized crash testing like automobiles).
Active Features
Braking System:
Hydraulic disc brakes front and rear. Optional ABS (Anti-lock Braking System) may be present on FLHRI models.
Lighting:
Halogen headlight, taillight, brake light, front and rear turn signals.
Passive Features
Frame Construction:
Steel frame and swingarm designed for stability and handling.
Security System:
Factory-installed H-D® Immobilizer security system with siren and two hand-held transmitters (key fobs).
💡 Technology Features
Infotainment
Audio System:
Optional radio and speaker system (often integrated into fairing or handlebar controls on touring models).
Gauges And Instruments:
Speedometer, tachometer, fuel gauge, voltmeter, oil pressure indicator, engine diagnostic indicator, turn signal indicators, high beam indicator.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an option for the FLHRI Road King in 2005.
Connectivity
Diagnostic Ports:
Proprietary diagnostic connector for use with Harley-Davidson diagnostic tools (e.g., Digital Technician).
🔧 Maintenance
Service Intervals
Initial Service Mileage:
1,000 miles (1,600 km)
Subsequent Service Mileage:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first.
Fluid Specifications
Engine Oil:
Harley-Davidson SAE 20W-50 Genuine Motorcycle Oil (SYN3) or equivalent. Check manual for specific API classification.
Transmission Oil:
Harley-Davidson SAE 20W-50 Genuine Motorcycle Oil (SYN3) or equivalent.
Primary Chain Case Oil:
Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant (or equivalent SAE 90 gear oil for non-clutch lubrication).
Brake Fluid:
DOT 4 Hydraulic Brake Fluid.
Known Issues
Common Wear Items:
Clutch plates, brake pads, tires, belt drive components, wheel bearings, fork seals.
Potential Engine Concerns:
Some Twin Cam 88 engines can experience issues with cam chain tensioners (especially early versions) and oil leaks. Rocker box seals and exhaust gaskets can also be sources of leaks.
Electrical System Considerations:
Wiring harness chafing, regulator/rectifier failures, and battery charging system issues can occur.
Fuel System Considerations:
Fuel pump reliability, injector clogging, and throttle position sensor (TPS) issues can affect performance.
📚 Vehicle History
Brand Heritage
Brand Founding:
Harley-Davidson Motor Company founded in 1903.
Model Evolution
Road King Introduction:
The Road King model line was introduced in 1994, evolving from earlier touring models and emphasizing a classic cruiser aesthetic.
Twin Cam Engine Introduction:
The Twin Cam 88 engine was introduced in 1999, replacing the Evolution Big Twin engine.
Production
Manufacturing Location:
York, Pennsylvania, USA and Milwaukee, Wisconsin, USA
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the 2005 FLHRI Road King might not be readily documented, the Road King model line has consistently been recognized for its blend of classic styling and touring capability, contributing to Harley-Davidson's strong market presence.
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