Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson owners, independent repair shops, enthusiasts seeking to perform their own maintenance and repairs.
Key Competitors 2005:
Indian Chief, Victory Kingpin, Honda Shadow, Kawasaki Vulcan, Yamaha Road Star.
Distinctive Features:
Iconic styling, comfortable riding position, large-displacement V-twin engine, detachable windscreen, hard-shell saddlebags.
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.
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.
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.
๐ Manual Specifications
File Type:
PDF (Portable Document Format)
Searchability:
Text-searchable for quick access to specific information.
Printability:
Printable, allowing for physical reference.
Image Resolution:
High-resolution images and diagrams for clarity.
Binding Type Physical:
N/A (Digital Format)
Paper Type Physical:
N/A (Digital Format)
โ๏ธ Engine Specifications
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)
Horsepower:
Approximately 65-70 HP (est.)
Torque:
Approximately 80-85 ft-lbs (est.) at 3500 RPM
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded Gasoline, minimum 89 Octane
Fuel Capacity:
5.0 US gallons (18.9 L)
Crash Test Ratings:
N/A (Motorcycles are not subjected to standardized crash testing like automobiles).
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.
Frame Construction:
Steel frame and swingarm designed for stability and handling.
Security System:
Factory-installed H-Dยฎ Immobilizer security system with siren and two hand-held transmitters (key fobs).
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.
ABS:
Anti-lock Braking System (ABS) was an option for the FLHRI Road King in 2005.
Diagnostic Ports:
Proprietary diagnostic connector for use with Harley-Davidson diagnostic tools (e.g., Digital Technician).
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.
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.
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.
Brand Founding:
Harley-Davidson Motor Company founded in 1903.
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.
Manufacturing Location:
York, Pennsylvania, USA and Milwaukee, Wisconsin, USA
