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Harley Davidson FLHR Road King Complete Workshop Service Repair Manual 2005

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHR Road King Year: 2005 Generation Model Generation: Second Generation (1999-2006) Codes Chassis Code: FLHR 👋 Introduction Market Position Model Segment: Full-size touring...
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Harley Davidson FLHR Road King Complete Workshop Service Repair Manual 2005
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FLHR Road King
Year:
2005
Generation
Model Generation:
Second Generation (1999-2006)
Codes
Chassis Code:
FLHR
👋 Introduction
Market Position
Model Segment:
Full-size touring cruiser, iconic Harley-Davidson styling.
Competitive Analysis
Competitors:
Indian Chief, Victory Kingpin, other large-displacement cruiser motorcycles.
Key Features
Defining Features:
Detachable windscreen, leather-covered saddlebags, comfortable touring ergonomics, classic V-twin engine sound and performance.
📋 Manual Details
Coverage Areas
Service Coverage:
Comprehensive
Page Count
Estimated Page Count:
Approximately 800-1000 pages (typical for full workshop manuals)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable Digital Format (PDF)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine disassembly, assembly, troubleshooting, fuel system (carbureted and EFI variations where applicable), ignition system, cooling system (air-cooled), lubrication system, exhaust system.
Drivetrain Systems:
Transmission (5-speed, including clutch, gearbox internals, primary drive), final drive (belt drive system, adjustments).
Chassis Systems:
Frame, front suspension (forks, steering head), rear suspension (shock absorbers, swingarm), brakes (front and rear hydraulic systems, master cylinders, calipers, rotors), wheels, tires, bearings.
Electrical Systems:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), lighting system (headlight, taillight, turn signals), instrumentation, ignition switch, security system (if equipped), accessory wiring.
Bodywork And Trim:
Fairing, saddlebags, fenders, seat, fuel tank, handlebars, controls, mirrors, mounting hardware.
Procedures Included
Maintenance Procedures:
Routine checks (oil, brakes, tires), fluid changes (engine oil, transmission oil, primary chaincase oil), filter replacements (oil filter, air filter), spark plug service, brake pad replacement, cable adjustments.
Repair Procedures:
Engine rebuilds, transmission overhauls, brake system bleeding and repair, electrical component troubleshooting and replacement, suspension servicing, fork seal replacement, wheel bearing replacement, clutch adjustment and replacement.
Troubleshooting Guides:
Diagnostic charts for common symptoms, electrical fault finding, engine performance issues, starting problems.
Technical Depth
Depth Of Coverage:
Complete rebuild and diagnostic information, suitable for professional technicians and experienced DIY mechanics.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Image Resolution:
High-resolution, clear diagrams and text for readability and accurate component identification.
Binding Type
Binding Style:
Not applicable (digital download)
Paper Type
Paper Quality:
Not applicable (digital download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, Twin Cam 88 V-twin
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
Performance
Horsepower Est:
Approx. 65-70 HP (at crank, depending on tuning)
Torque Est:
Approx. 85-90 lb-ft @ 3200 RPM (at crank, depending on tuning)
Fuel System
Fuel Delivery:
Carburetor (e.g., Keihin CV 40mm) or Electronic Fuel Injection (EFI) depending on specific build/market. Manual will cover both if applicable.
Fuel Type:
Unleaded gasoline, minimum 87 octane
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh, helical gears
Features
Clutch Type:
Multi-plate, wet clutch
Primary Drive Type:
Primary chain, enclosed in oil bath
Final Drive Type:
Enclosed primary chain drive to transmission, then belt drive to rear wheel
📐 Dimensions
Exterior
Length:
Approx. 99.3 in. (2522 mm)
Height:
Approx. 53.9 in. (1370 mm)
Width:
Approx. 37.6 in. (955 mm)
Weights
Dry Weight Est:
Approx. 700 lbs (317.5 kg)
Gross Vehicle Weight Rating Gvwr:
Not typically specified as a strict GVWR, but a maximum load capacity is implied.
Cargo
Saddlebag Capacity:
Approx. 2.24 cu ft total (63.4 liters)
Wheels And Tires
Front Tire Size:
130/90B16 67H
Rear Tire Size:
140/90B16 71H
Wheelbase:
Approx. 63.5 in. (1613 mm)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Motorcycles are not subject to the same standardized crash testing as automobiles. Safety is assessed through design and rider input.
Active Features
Braking System:
Dual front disc brakes, single rear disc brake with hydraulic actuation. ABS was an optional feature for some Harley-Davidson models in this era but was not standard on all FLHR models in 2005.
Lighting:
Halogen headlight, LED taillight, amber front and rear turn signals.
Passive Features
Chassis Design:
Steel frame, substantial weight for stability.
Security:
Factory-installed security system with key fob (optional or standard depending on trim).
💡 Technology Features
Infotainment
Audio System:
Optional AM/FM radio and CD player integrated into the fairing (if equipped), or a simpler sound system.
Cruise Control:
Standard on most FLHR Road King models for 2005, providing electronic cruise control.
Driver Assistance
ABS Availability:
Anti-lock Braking System (ABS) was an optional feature for the 2005 FLHR Road King, not standard on all units.
Connectivity
Phone Integration:
No integrated smartphone connectivity or Bluetooth in 2005 models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or annually (whichever comes first), as per typical Harley-Davidson recommendations for this era.
Primary Chaincase Oil Change:
Every 10,000 miles or annually.
Transmission Oil Change:
Every 10,000 miles or annually.
Spark Plug Replacement:
Every 10,000 miles or as needed based on inspection.
Fluid Specifications
Engine Oil Type:
Harley-Davidson 20W-50 SYN3 or equivalent motorcycle-specific 20W-50 API CI-4 or higher.
Engine Oil Capacity:
3.5 US quarts (3.3 liters) with filter change.
Primary Chaincase Oil Type:
Harley-Davidson primary fluid or motorcycle-specific primary lubricant.
Primary Chaincase Oil Capacity:
Approximately 1 quart (0.95 liters), level should be to the bottom of the clutch basket splines.
Transmission Oil Type:
Harley-Davidson transmission lubricant or SAE 80W-90 API GL-5 gear oil (check manual for specific H-D recommendations).
Transmission Oil Capacity:
Approximately 20-24 US fluid ounces (0.6 - 0.7 liters).
Brake Fluid Type:
DOT 4 compatible, meeting specified Harley-Davidson requirements.
Known Issues
Common Wear Items:
Clutch plates, primary chain tensioner (early hydraulic tensioners can fail), wheel bearings, fork seals, exhaust gaskets.
Engine Notes:
Twin Cam 88 engines are generally robust, but issues like oil leaks, cam chain tensioner wear (on earlier models), and valve guide wear can occur with mileage.
Electrical Notes:
Battery health, voltage regulator/rectifier failure are common points of attention on older Harley-Davidsons.
📚 Vehicle History
Brand Heritage
Brand History:
Harley-Davidson is an iconic American motorcycle manufacturer with a legacy dating back to 1903, known for its V-twin engines and cruiser/touring motorcycles.
Model Evolution
Road King Lineage:
The Road King line debuted in 1994, evolving from earlier FL models, emphasizing a classic touring style with detachable luggage and windscreen.
Twin Cam Era:
The 2005 model features the Twin Cam 88 engine, introduced in 1999, which offered more power and reliability than previous Evolution Big Twin engines.
Production
Manufacturing Location:
United States (various Harley-Davidson plants)
🏆 Awards & Recognition
Recognitions
Industry Recognition:
Harley-Davidson motorcycles, particularly the Road King model, consistently receive high marks for rider satisfaction and classic styling from automotive and motorcycle publications.
Ratings
Owner Satisfaction:
High owner satisfaction ratings are typical for the Harley-Davidson brand due to brand loyalty and the iconic riding experience.
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