🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLHR Road King

Year:

2004

Manual Product Name:

Harley Davidson FLHR Road King 2004 Workshop Service Manual PDF Download

Vehicle Chassis Code:

FLHR

Engine Code Family:

Twin Cam 88

👋 Introduction

Vehicle Segment:

Full-size Cruiser Motorcycle

Target Audience:

Harley-Davidson enthusiasts, owners seeking self-maintenance or repair capabilities, independent repair shops.

Key Competitors:

Indian Chief, Victory Kingpin, Honda Gold Wing (though different style), various Japanese cruiser offerings.

Road King Defining Features:

Classic touring capability with removable windscreen, comfortable ergonomics for long-distance riding, iconic Harley-Davidson styling.

Manual Value Proposition:

Empowers owners to maintain and repair their 2004 FLHR Road King, saving on dealership costs and ensuring proper service.

📋 Manual Details

Manual Type:

Workshop Service Repair Manual

Manual Completeness:

Complete Official Factory Service Manual

Page Count Estimated:

Hundreds (exact count not specified, but indicates comprehensive nature)

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Systems:

Engine assembly, disassembly, inspection, repair, tuning, Twin Cam 88 specifics, fuel injection (EFI) system, ignition system, lubrication system, cooling system (air-cooled components).

Transmission Systems:

Transmission assembly, disassembly, inspection, repair, clutch operation, primary drive, final drive.

Electrical Systems:

Wiring diagrams, ignition system, charging system (alternator, regulator), starting system (starter, solenoid), lighting systems (headlight, taillight, turn signals), instrumentation, accessory circuits, troubleshooting electrical faults.

Chassis Systems:

Frame inspection and repair, front fork assembly and service, rear suspension (shocks, swingarm), wheel bearings, steering head bearings, brake systems (front and rear calipers, master cylinders, lines, rotors), wheel and tire service.

Bodywork And Fittings:

Fairing removal and installation, saddlebag service, fuel tank removal and installation, seat service, fenders, handlebars, controls (throttle, clutch, brake levers).

Maintenance Procedures:

Oil changes, filter replacement, spark plug service, brake fluid flush, tire pressure checks, drive belt inspection and adjustment, air filter cleaning/replacement.

Diagnostic Procedures:

Troubleshooting guides for common mechanical and electrical issues, fault code diagnostics (if applicable to the era), performance tuning diagnostics.

Repair Procedures:

Step-by-step instructions for engine rebuilds, transmission overhauls, brake system repairs, suspension component replacement, electrical component diagnosis and replacement.

Adjustment Procedures:

Carburetor (if applicable, though 2004 is EFI) or fuel injection system adjustments, clutch cable adjustment, throttle cable adjustment, suspension adjustments.

Special Tool Requirements:

Identification of specific Harley-Davidson tools required for various procedures (e.g., bearing pullers, torque wrenches, engine alignment tools).

Depth Of Information:

Comprehensive rebuild and overhaul procedures, detailed technical specifications, torque values, clearances, diagnostic flowcharts.

Diagnostic Capabilities:

Advanced troubleshooting for fuel, ignition, and sensor systems, electrical system fault tracing.

📊 Manual Specifications

File Format:

PDF

Searchable Text:

Typically includes searchable text for efficient information retrieval.

Print Quality:

High resolution, suitable for printing individual pages or the entire manual.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Family:

Harley-Davidson Twin Cam 88

Engine Type:

Air-cooled, 45-degree V-twin, pushrod actuated overhead valves

Displacement:

1450cc (88 cubic inches)

Bore X Stroke:

3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)

Compression Ratio:

8.8:1 (typical for Twin Cam 88)

Horsepower Estimate:

Approximately 65-70 HP (manufacturer not specifying exact figures for this era, service manual will have detailed performance tuning data)

Torque Estimate:

Approximately 80-85 ft-lbs at 3500 RPM (manufacturer not specifying exact figures for this era, service manual will have detailed performance tuning data)

Fuel Delivery:

Electronic Fuel Injection (EFI) - Sequential Port Fuel Injection (SPFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane recommended

Ignition Type:

Electronic Ignition

Oil Type:

Harley-Davidson SYN3 Full Synthetic or equivalent SAE 20W50 motorcycle oil meeting Harley-Davidson specifications.

Oil Capacity:

Approximately 4.0 US quarts (3.8 liters) with filter change.

Cooling Method:

Air-cooled

🔧 Transmission

Transmission Type:

5-speed constant mesh

Primary Drive:

Duplex chain, wet clutch

Final Drive:

Belt drive

Clutch Type:

Hydraulic clutch actuation

Transmission Oil Type:

Harley-Davidson Formula + Transmission and Primary Chaincase Lubricant or equivalent.

Transmission Oil Capacity:

Approximately 24-28 US fluid ounces (0.71-0.83 liters).

📐 Dimensions

Length:

Approx. 93.7 in. (2380 mm)

Width:

Approx. 37.0 in. (940 mm)

Height:

Approx. 54.7 in. (1390 mm)

Wheelbase:

Approx. 63.5 in. (1613 mm)

Dry Weight:

Approx. 683 lbs (309.8 kg)

Gross Vehicle Weight Rating:

Not explicitly stated, but typically around 1000+ lbs.

Fuel Tank Capacity:

4.9 US gallons (18.5 liters)

🛡️ Safety Features

Safety Certification:

Meets DOT and applicable federal motor vehicle safety standards for motorcycles.

Braking System:

Dual 300mm discs with 4-piston calipers (front), Single 292mm disc with 2-piston caliper (rear). Hydraulic actuation.

Lighting:

Halogen headlight, LED taillight, amber front and rear turn signals.

Frame Construction:

Steel, longitudinal members and cast sections.

Tires:

Tubeless, typically Dunlop or Dunlop-derived tires. Specific sizes will be in manual (e.g., 130/90B16 front, 150/80B16 rear).

💡 Technology Features

Audio System:

Optional factory radio with AM/FM and CB/Intercom capabilities on some models. Manual covers operation and basic troubleshooting.

ABS Availability:

Anti-lock Braking System (ABS) was an optional feature on the 2004 FLHR Road King. Manual will cover ABS system components and diagnostics if equipped.

Diagnostic Ports:

The manual will detail the location and use of diagnostic connectors for any onboard diagnostics (OBD) or diagnostic tools available for the era.

🔧 Maintenance

Initial Service:

First service typically at 1,000 miles (1,600 km) - includes engine oil change, primary chaincase oil change, and inspection.

Regular Oil Change:

Every 5,000 miles (8,000 km) or annually, whichever comes first.

Spark Plug Replacement:

Refer to manual, typically every 10,000-15,000 miles (16,000-24,000 km).

Drive Belt Inspection:

Inspect at every service, check tension every 5,000 miles.

Brake Fluid Type:

DOT 4, compatible with ABS if equipped (though unlikely for 2004 standard FLHR).

Fork Oil Type:

Refer to manual, typically SAE 15W or 20W fork oil.

Common Wear Items:

Clutch plates, brake pads, wheel bearings, fork seals, drive belt. Battery aging is also common.

Twin Cam 88 Considerations:

Some early Twin Cam 88 engines had issues with cam chain tensioners; manual will detail inspection and potential upgrades/replacements.

📚 Vehicle History

Harley Davidson Legacy:

Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer with a rich history of V-twin engines and distinctive styling.

Road King Heritage:

The Road King model was introduced in 1994, reviving classic styling cues from the post-war era. It's known for its comfort and touring capability without the full fairing of other touring models.

Twin Cam 88 Introduction:

The Twin Cam 88 engine was introduced in 1999, replacing the Evolution engine, offering increased displacement and a revised engine mounting system for improved vibration isolation.

Manufacturing Location:

Milwaukee, Wisconsin, USA (and York, Pennsylvania, USA for assembly).

🏆 Awards & Recognition

Model Accolades:

While specific awards for the 2004 model are not readily cited, the Road King has consistently been praised for its comfort, style, and touring capability within the cruiser market. The Twin Cam 88 engine was a significant advancement for Harley-Davidson.

Industry Reputation:

Highly regarded for its classic cruiser appeal and long-distance comfort. A benchmark model in the touring cruiser segment.