🏷️ Basic Information

Make:

Harley-Davidson

Model:

Electra Glide Road King

Year:

2002

Product Type:

Service Repair Workshop Manual

Vin Prefix:

1HD1

👋 Introduction

Vehicle Segment:

Full-size touring motorcycle, flagship model for long-distance comfort and cargo carrying.

Brand Perception:

Iconic American motorcycle brand, known for its V-twin engines, distinct styling, and rider community.

Key Competitors 2002:

Honda Gold Wing, Indian Chief, Kawasaki Vulcan, Yamaha Royal Star Venture.

Model Appeal:

Comfortable ride for rider and passenger, ample storage, classic styling, powerful V-twin engine.

Manual Value Proposition:

Provides comprehensive DIY service and repair capabilities, saving significant costs compared to dealership service.

📋 Manual Details

Manual Type:

Factory Service Repair Workshop Manual

Language:

English

Format:

Downloadable PDF

Completeness:

Complete Factory Service Information

Estimated Pages:

Approximately 700+

📖 Manual Coverage

Engine:

Detailed breakdown of Twin Cam 88 engine, including disassembly, inspection, reassembly, and troubleshooting for cylinders, pistons, crankshaft, camshafts, and valve train.

Fuel System:

Carburetor (CV carburetor) operation, adjustment, overhaul, and troubleshooting; fuel pump, fuel lines, and fuel tank servicing.

Ignition System:

Ignition timing, spark plugs, ignition coils, ignition module diagnostics and replacement.

Electrical System:

Wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), battery maintenance, lighting systems (headlights, taillights, turn signals), horn, instrumentation, and accessory wiring.

Transmission:

5-speed Cruise Drive transmission servicing, clutch operation, primary drive system, gearbox disassembly, inspection, and reassembly, gear shift linkage.

Drivetrain:

Belt drive system, rear pulley, front sprocket, drive belt inspection, adjustment, and replacement.

Suspension:

Front fork (showa) overhaul, seal replacement, oil levels, and adjustments; rear shock absorber servicing and replacement.

Brakes:

Front and rear brake system servicing, hydraulic lines, brake calipers, master cylinders, brake pads, brake fluid type and bleeding procedures.

Frame And Bodywork:

Frame inspection, fairing removal and installation, fuel tank mounting, seat assembly, fenders, saddlebags, and luggage rack procedures.

Wheels And Tires:

Wheel bearing inspection and replacement, tire inspection, pressure recommendations, and wheel mounting.

Scheduled Maintenance:

Detailed maintenance schedules for oil changes, filter replacements, spark plugs, drive belt inspection, brake checks, and other routine services.

Troubleshooting:

Comprehensive diagnostic procedures for common and uncommon issues, fault finding charts, and symptom-based troubleshooting guides.

Engine Rebuild:

Step-by-step instructions for complete engine disassembly, component inspection, measurement, machining recommendations, and precise reassembly.

Transmission Overhaul:

Detailed procedures for removing, disassembling, inspecting, and reassembling the 5-speed transmission, including gear inspection and bearing replacement.

Electrical Diagnostics:

In-depth troubleshooting of electrical faults using wiring diagrams, component testing, and diagnostic tools.

Brake System Repair:

Instructions for brake fluid replacement, caliper overhaul, master cylinder servicing, and bleeding the brake system.

Fork Rebuild:

Step-by-step guide for servicing front fork seals, replacing fork oil, and adjusting suspension settings.

Fuel System Cleaning:

Procedures for cleaning and rebuilding the CV carburetor, including jetting information and float bowl adjustments.

Level Of Detail:

Comprehensive, covering all aspects from basic checks to full engine and transmission rebuilds.

Diagnostic Capability:

Advanced diagnostic information including specifications, tolerances, and testing procedures for all major systems.

Torque Specifications:

Detailed torque specifications for all fasteners, critical for safe and correct assembly.

Special Tools:

Identification and usage instructions for specialized Harley-Davidson tools required for certain repair procedures.

📊 Manual Specifications

File Type:

PDF

Searchability:

Fully searchable text for quick information retrieval.

Image Resolution:

High-resolution images, diagrams, and schematics for clarity.

Printable:

Yes, pages are printable for workshop use.

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Air-cooled, 45-degree V-twin, 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:

8.3:1

Valve Train:

Overhead valves (OHV), two valves per cylinder, pushrod actuated.

Horsepower:

Approximately 65-70 HP (at crankshaft, estimated)

Torque:

Approximately 75-80 lb-ft (at crankshaft, estimated)

Fuel Delivery:

Keihin CV (Constant Velocity) carburetor, 40mm

Fuel Type:

Unleaded gasoline, minimum 91 octane recommended.

Engine Oil Capacity:

3.0 US qt (2.8 L) with filter change

Engine Oil Type:

Harley-Davidson SYN3 or equivalent SAE 20W50 API CI-4 or higher (check manual for specific approved viscosity grades based on ambient temperature).

🔧 Transmission

Transmission Type:

5-speed constant mesh, sequential manual gearbox

Primary Drive:

Primary chain, 34/46 tooth, 1.353:1 ratio

Final Drive:

Belt drive, 32/66 tooth, 2.06:1 ratio

Clutch Type:

Wet, multi-plate, diaphragm spring

Transmission Oil Type:

Harley-Davidson Formula + or equivalent SAE 80W-90 API GL-5 gear oil.

Transmission Oil Capacity:

24 US fl oz (0.71 L)

📐 Dimensions

Length:

Approx. 98.5 in. (2499 mm)

Width:

Approx. 37.0 in. (940 mm)

Height:

Approx. 56.0 in. (1422 mm)

Dry Weight:

Approx. 720 lbs (327 kg)

Gross Vehicle Weight Rating:

1260 lbs (571 kg)

Fuel Capacity:

5.0 US gal (18.9 L)

Oil Capacity:

3.0 US qt (2.8 L)

Wheelbase:

63.5 in. (1613 mm)

🛡️ Safety Features

Safety Ratings:

Motorcycles are not typically rated by agencies like NHTSA or IIHS in the same manner as passenger cars. Safety is primarily rider-dependent.

Braking System:

Dual disc front brakes, single disc rear brake with hydraulic actuation.

Lighting:

Halogen headlamp, auxiliary passing lamps, full LED taillight and turn signals (later models) or incandescent.

Frame Construction:

Steel cradle frame designed for stability and rigidity.

Ergonomics:

Designed for rider comfort on long journeys, reducing fatigue.

💡 Technology Features

Audio System:

Optional AM/FM stereo with cassette player, often integrated into the fairing. Some models may have CB radio or intercom features.

Cruise Control:

Not typically standard on the 2002 Road King, but available as an option or aftermarket addition.

Diagnostic Ports:

OBD-II diagnostic port not present on this model. Diagnostics are typically performed using specialized Harley-Davidson tools and procedures outlined in the manual.

🔧 Maintenance

First Service:

1000 miles (1600 km) or 6 months (whichever comes first): Check all fasteners, engine oil and filter change, primary chain adjustment, inspection of all controls and cables, brake adjustment and fluid check.

Subsequent Service:

Every 5000 miles (8000 km) or 12 months: Engine oil and filter change, inspect drive belt, check brake pads and fluid, inspect all cables and controls, lubricate cables, inspect and adjust clutch and throttle controls, check tire pressure and condition.

Spark Plug Replacement:

Every 10,000 miles (16,000 km)

Drive Belt Inspection:

Every 5000 miles (8000 km) for tension and condition. Replacement typically around 30,000-50,000 miles depending on conditions.

Brake Fluid Type:

DOT 4

Primary Chain Case Oil:

Harley-Davidson Formula + or equivalent SAE 80W-90 API GL-5 gear oil (shared with transmission).

Primary Chain Case Capacity:

24 US fl oz (0.71 L)

Cam Chain Tensioners:

Early Twin Cam 88 engines used spring-loaded hydraulic tensioners that could wear out, leading to a rattling noise. Upgraded tensioners or conversion kits are available. (This manual would detail inspection and replacement procedures.)

Carburetor Performance:

The stock CV carburetor can be sensitive to altitude and temperature changes, sometimes requiring adjustment or re-jetting for optimal performance. (Manual provides adjustment procedures.)

Oil Leaks:

Common on older Harleys, leaks can originate from base gaskets, pushrod tube seals, or transmission seals. The manual details how to identify and repair these.

📚 Vehicle History

Manufacturer Founding:

1903, Milwaukee, Wisconsin.

Iconic Status:

Harley-Davidson is an American icon, synonymous with freedom and the open road.

Electra Glide Introduction:

The Electra Glide lineage dates back to 1965, evolving significantly over the decades.

Road King Introduction:

The Road King was introduced in 1994, offering a blend of classic styling with modern touring capabilities, often seen as a more stripped-down touring option compared to the full-dress Electra Glide.

Twin Cam 88 Introduction:

The Twin Cam 88 engine was introduced in 1999, replacing the Evolution Big Twin, and became standard across most Harley-Davidson Big Twin models.

Manufacturing Location:

United States (primarily York, Pennsylvania, and Milwaukee, Wisconsin).

🏆 Awards & Recognition

Industry Awards:

Harley-Davidson motorcycles, particularly the Touring line, have consistently received positive reviews from motorcycle publications for their comfort, style, and long-distance capability.

Rider Satisfaction:

High rider satisfaction due to brand loyalty and the unique Harley-Davidson riding experience.

Emissions Compliance:

Compliant with U.S. EPA and California Air Resources Board (CARB) emissions standards for its model year. Manual would include relevant emissions control system information.