Segment:
Cruiser Motorcycle
Target Audience:
Owners, independent repair shops, and Harley-Davidson enthusiasts seeking detailed maintenance and repair information
Manual Value Proposition:
Provides a comprehensive and authoritative resource, equivalent to official factory service manuals, enabling users to perform all maintenance and repair tasks.
Accessibility:
Instant download availability with no expiry dates offers immediate access to critical information.
Engine Systems:
Engine assembly, disassembly, inspection, tuning, lubrication, cooling system, fuel system (EFI), ignition system, exhaust system, oil pump
Transmission Drivetrain:
Transmission (5-speed Cruise Drive), primary drive, clutch, final drive, gearbox service, maintenance
Chassis Suspension:
Frame, front fork, rear suspension, swingarm, steering system, wheel bearings, alignment
Braking System:
Front and rear brake systems, hydraulic lines, calipers, master cylinders, ABS (if equipped), bleeding procedures
Electrical System:
Battery, charging system (alternator, regulator), ignition, starting system, lighting, instrumentation, ECM, wiring diagrams, diagnostics
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank, fuel lines
Body Fittings:
Fenders, fairings, saddlebags, seat, handlebars, controls, fairing components, trim pieces
Maintenance Procedures:
Regular scheduled maintenance, oil changes, filter replacements, spark plug service, chain adjustment (if applicable), brake pad replacement
Diagnostic Procedures:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs), wiring harness testing
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair for all major systems
Special Tools:
Identification and usage of specialized Harley-Davidson tools required for specific repairs
Depth:
In-depth, factory-level detail suitable for professional technicians and experienced DIY mechanics
Engine Type:
Air-cooled, Twin Cam 96 V-Twin
Displacement:
1584 cc (96 cubic inches)
Bore X Stroke:
3.75 in x 4.38 in (95.25 mm x 111.25 mm)
Fueling:
Electronic Sequential Port Fuel Injection (ESPFI)
Ignition:
Spark ignition, high-output ignition module
Torque Rating:
Approximately 92.6 ft-lbs (125.5 Nm) @ 3500 RPM (Varies slightly by year and tune)
Horsepower Rating:
Not typically published by Harley-Davidson, but estimated around 70-75 HP
Fuel Capacity:
6.0 US gallons (22.7 L)
Fuel Type:
Unleaded gasoline, minimum 91 octane (R+M)/2
Transmission Type:
6-speed Cruise Drive
Optional Transmissions:
N/A (Standard for this model and period)
Primary Drive:
Plated, heavy-duty,utschesch chain
Final Drive:
Carbon belt, 14mm pitch, 1400 mm length, 138-tooth
Clutch Type:
Hydraulic, assisted, multi-plate, wet
Safety Certifications:
DOT, EPA, CARB compliant where applicable
Braking System Type:
Hydraulic, four-piston caliper, dual front discs, single rear disc (ABS optional on some models/years)
Lighting:
Halogen headlight, LED tail light, front/rear turn signals
Frame Construction:
Steel, rigid backbone, large-diameter, cast-in-place neck
Audio System:
Often equipped with a factory-installed AM/FM/WB radio with CD player and handlebar-mounted controls. Later models might feature auxiliary input or compatibility for iPod/MP3 players.
Cruise Control:
Standard on FLHRC models for enhanced long-distance comfort.
ABS:
Anti-lock Braking System (ABS) was often an option and specified on certain build configurations. The manual would detail its maintenance and troubleshooting.
Diagnostics Port:
Proprietary diagnostic connector (e.g., 4-pin or 6-pin) for use with Harley-Davidson diagnostic tools (e.g., Digital Technician).
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Service Interval:
Every 5,000 miles (8,000 km) or 12 months thereafter (includes engine oil, primary lubricant, transmission lubricant changes)
Spark Plug Replacement:
Every 10,000 miles (16,000 km)
Engine Oil:
Harley-Davidson SYN3 (SAE 20W-50) or equivalent Harley-Davidson approved synthetic motorcycle oil
Primary Chain Case Oil:
Harley-Davidson primary chain case lubricant or genuine Harley-Davidson transmission fluid
Transmission Oil:
Harley-Davidson Formula + transmission lubricant or genuine Harley-Davidson transmission fluid
Brake Fluid:
DOT 4 (Note: Always check manual for specific recommendations and if ABS is present)
Common Wear Items:
Clutch plates, primary chain tensioner (early hydraulic tensioners can fail), fork seals, rear brake pads.
Electrical Considerations:
Potential for stator or regulator issues, though Twin Cam generally improved over earlier Twin Cam models. Check for any recall notices or service bulletins related to electrical components.
Heritage Significance:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its cruisers, touring bikes, and distinctive V-twin engines.
Road King Lineage:
The Road King series, introduced in 1994, evokes the classic styling of post-WWII touring bikes, offering comfort and style for long-distance riding.
Classic Variant:
The 'Classic' designation typically adds more retro styling cues such as full fenders, wide whitewall tires, and chrome accents.
Manufacturing Location:
USA (Primarily Milwaukee, Wisconsin and York, Pennsylvania)
