Positioning:
The Road King Classic and Custom models represent Harley-Davidson's premium cruiser segment, blending classic styling with modern performance. They appeal to riders seeking comfort, touring capability, and iconic American V-twin character.
Competitors:
Competed against other large-displacement cruiser motorcycles from brands like Indian, Victory, and to some extent, Japanese touring cruisers, though often distinguished by its distinct Harley-Davidson heritage and V-twin engine characteristics.
Features Classic:
Large windshield, classic whitewall tires, leather saddlebags, floorboards, chrome accents, iconic styling.
Features Custom:
Lower profile windshield or no windshield, custom wheels, two-up seating, often more aggressive styling cues compared to the Classic.
Value Proposition:
This manual is an indispensable resource for owners and technicians, providing the necessary information to maintain, troubleshoot, and repair these iconic motorcycles correctly, ensuring longevity and optimal performance.
Engine:
Detailed overhaul, tuning, diagnostics, specific engine components (e.g., Twin Cam 88, Twin Cam 96 variants if applicable within range).
Transmission:
Disassembly, assembly, troubleshooting, fluid types, shift mechanism.
Fuel System:
Carburetor (Keihin CV) or Fuel Injection (EFI) systems, fuel pump, lines, injectors, diagnostics.
Electrical System:
Wiring diagrams, lighting, ignition system, starter, charging system, battery, troubleshooting electrical faults, sensors.
Brakes:
Hydraulic system, caliper service, rotor replacement, bleeding procedures, ABS (if equipped).
Suspension:
Front fork service (including oil changes, seal replacement), rear shock absorber inspection and replacement, adjustments.
Chassis:
Frame inspection, steering head bearings, wheel bearings, swingarm service, general chassis components.
Bodywork:
Fairing removal/installation, fender service, fuel tank maintenance, seat removal, saddlebag specifics for Classic models.
Clutch:
Clutch operation, adjustment, replacement of plates and springs.
Exhaust System:
Inspection, replacement, gasket information.
Cooling System:
Air-cooled engine specifics, heat management.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs) for EFI models, common problems and solutions.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug service, brake fluid flushes, tire pressure checks, lubrication points.
Repair:
Engine rebuild, transmission overhaul, brake caliper rebuilding, suspension fork servicing, electrical component replacement, clutch service.
Troubleshooting:
Step-by-step diagnostic procedures for various symptoms (e.g., starting issues, running problems, electrical faults).
Adjustment:
Carburetor idle/mixture, clutch, throttle cables, brake levers, suspension settings.
Installation:
Accessory installation guidelines, component replacement procedures.
Depth:
Comprehensive: Covers everything from basic rider maintenance to full engine and transmission rebuilds.
Engine Type:
Air-cooled, 45-degree V-twin
Engine Displacement:
88 cubic inches (approx. 1450cc) for most models in this range. Later models in the range might feature the introduction of the Twin Cam 96 (96 cubic inches / 1584cc) which began appearing around 2007, but for 1999-2005, the primary engine is the Twin Cam 88.
Bore X Stroke:
Twin Cam 88: 3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Compression Ratio:
Twin Cam 88: Approximately 8.8:1
Horsepower:
Typically in the range of 60-70 HP (estimate, actual varies by year and tuning).
Torque:
Typically in the range of 70-85 ft-lbs (estimate, actual varies by year and tuning).
Carburetor:
Keihin CV 40mm (for carbureted models)
Fuel Injection:
Electronic Sequential Port Fuel Injection (ESPFI) on later models within this range.
Ignition Type:
Distributorless Electronic Ignition (DEI) with single fire coil.
Oil System:
Dry sump with oil tank separate from the crankcase.
Wheelbase:
Approximately 63.5 inches (1613 mm) - varies slightly by year/model.
Seat Height:
Approximately 28.0 - 29.0 inches (711 - 737 mm) unladen - varies by model and suspension.
Dry Weight:
Approximately 670 - 700 lbs (304 - 318 kg) - varies by model.
Gross Vehicle Weight Rating:
Typically around 1000-1100 lbs (454-499 kg).
Saddlebags Classic:
Leather-covered, hard-shell saddlebags with significant storage capacity.
Saddlebags Custom:
May have different styling or smaller capacity compared to Classic, or optional hard bags.
Safety Certifications:
Meets or exceeds all applicable federal safety standards for motorcycles of its era. ABS was an optional feature on some models within this range.
Brakes Type:
Dual-disc front, single-disc rear, hydraulic actuation. Some models offered ABS (Anti-lock Braking System).
Lighting:
Halogen headlight, integrated front and rear turn signals, brake lights.
Frame Construction:
Steel frame and swingarm for rigidity and durability.
Oil Change:
Every 5,000 miles or 12 months, whichever comes first (for engine oil and primary chaincase oil).
Air Filter:
Inspect every 10,000 miles, replace as needed or per manual recommendation.
Spark Plugs:
Replace every 10,000-20,000 miles depending on plug type.
Drive Belt:
Inspect tension and condition every 10,000 miles, adjust if necessary.
Brake Fluid:
Flush and replace every 24 months (DOT 4).
Engine Oil:
Harley-Davidson recommends SAE 20W50 (specific H-D 360 or similar V-twin specific oil).
Primary Chaincase Oil:
Harley-Davidson primary fluid or SAE 20W50 motorcycle oil.
Transmission Oil:
Harley-Davidson transmission fluid or SAE 90W gear oil.
Brake Fluid:
DOT 4 hydraulic fluid.
Fork Oil:
Specific Harley-Davidson fork oil or equivalent viscosity (e.g., 10W).
Cam Chain Tensioners:
Early Twin Cam 88 models are known for tensioner shoe wear; the manual will detail inspection and replacement procedures.
Oil Leaks:
Common areas include primary cover gasket, derby cover, crankcase seals. Manual details correct torque specs and gasket replacements.
Carburetor Tuning:
Keihin CV carbs may require adjustment for altitude or modifications; manual covers tuning procedures.
Idle Issues:
Can be related to vacuum leaks, carburetor, or ignition; manual provides diagnostic steps.
Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines, distinctive styling, and strong community. The Road King line has been a cornerstone of their touring and cruising offerings.
Road King Lineage:
The Road King was introduced in 1994 and has consistently evolved. The Classic variant emphasizes retro styling, while the Custom offers a sportier or more personalized appearance. This 1999-2005 period saw the transition and refinement of the Twin Cam 88 engine.
Manufacturing Location:
Primarily manufactured in the United States by Harley-Davidson Motor Company.
Key Production Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005.
