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Harley Davidson FLHRCI Road King Classic Motorcycle 2005 Factory Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHRCI Road King Classic Year: 2005 Vehicle Type: Motorcycle Product Name: Harley Davidson FLHRCI Road King Classic Motorcycle 2005 Factory Service Repair Workshop...
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🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FLHRCI Road King Classic
Year:
2005
Vehicle Type:
Motorcycle
Product Name:
Harley Davidson FLHRCI Road King Classic Motorcycle 2005 Factory Service Repair Workshop Manual Download
👋 Introduction
Market Position
Market Segment:
Cruiser motorcycle, touring, classic styling.
Target Audience:
Harley-Davidson owners, independent repair shops, motorcycle enthusiasts.
Competitive Analysis
Comparable Models:
Other large-displacement V-twin cruisers from brands like Indian, Victory (later models), and some Japanese manufacturers.
Key Features
Vehicle Highlights:
Classic styling, comfortable touring capabilities, large V-twin engine, chrome accents, leather saddlebags.
Manual Value Proposition
Value:
Essential resource for maintaining and repairing the FLHRCI, saving time and money on dealership services.
Instructions Quality:
Easy-to-follow step-by-step instructions with visual aids.
📋 Manual Details
Coverage Areas
Primary Coverage:
All repairs and servicing for the 2005 Harley-Davidson FLHRCI Road King Classic
Page Count
Estimated Pages:
Over 700
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Downloadable Digital Format (Likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, including disassembly, assembly, component inspection, and tuning for Twin Cam 88B engine.
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, fuel lines, and fuel tank servicing.
Ignition System:
Ignition module, spark plugs, ignition coils, and troubleshooting of ignition faults.
Transmission:
Servicing and repair of the 5-speed constant mesh transmission, including clutch operation and maintenance.
Drivetrain:
Primary drive, final drive belt, chain adjustment (if applicable to specific sub-models or earlier versions of the frame), and wheel bearings.
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake fluid flushing, and troubleshooting brake system issues.
Suspension System:
Front fork (tele-fork) servicing, rear shock absorber replacement and adjustment, and related suspension components.
Electrical System:
Complete electrical system diagnostics, including battery, charging system (stator, regulator/rectifier), lighting, horn, and starter motor.
Wiring Diagrams:
Detailed, color-coded wiring diagrams for all electrical circuits, crucial for troubleshooting and repairs.
Bodywork And Frame:
Fairing removal and installation, fender servicing, fuel tank mounting, seat removal, and basic frame inspection.
Controls:
Handlebar controls, throttle cables, brake levers, and clutch lever adjustments and replacement.
Exhaust System:
Exhaust system removal, installation, and gasket replacement.
Procedures Included
Maintenance:
Scheduled maintenance tasks, including oil changes, filter replacements, lubrication, and general inspections.
Troubleshooting:
Step-by-step diagnostic procedures for identifying and resolving common and uncommon issues across all systems.
Repair:
Detailed repair instructions for component replacement, overhaul, and adjustment.
Disassembly And Assembly:
Comprehensive instructions for taking apart and reassembling various motorcycle components and sub-assemblies.
Special Tools:
Identification and usage instructions for any specialized tools required for specific repairs or adjustments.
Technical Depth
Depth Level:
Comprehensive, covering everything from basic checks to complete engine and transmission rebuilds.
Diagnostics:
Advanced diagnostic procedures, including interpretation of fault codes and electrical system analysis.
Specifications:
Includes torque specifications, clearances, fluid capacities, and electrical resistance values.
📊 Manual Specifications
File Format
Format:
Digital Download (PDF)
Searchability:
Likely searchable text, enabling quick access to specific information.
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity.
Binding Type
Binding:
Not applicable for digital download, but equivalent to a professionally bound workshop manual.
Paper Type
Paper Quality:
Not applicable for digital download, but the content is designed for clarity and durability in a workshop environment.
⚙️ Engine Specifications
Primary Engine
Engine Family:
Harley-Davidson Twin Cam 88B
Engine Type:
Air-cooled, 45-degree V-twin
Displacement:
1449 cc (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
Valvetrain:
Overhead valves (OHV), two valves per cylinder, pushrod-actuated.
Timing System:
Camshaft-driven, with automatic chain tensioners for the timing chain.
Performance
Horsepower Estimated:
~65-70 HP (at crankshaft, estimated)
Torque Estimated:
~75-80 lb-ft (at crankshaft, estimated)
Fuel System
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 87 octane.
Lubrication
Oil Capacity:
4.0 US quarts (3.8 liters) with filter change.
Oil Type Specification:
Harley-Davidson SYN3 (fully synthetic) or equivalent API CG-4 rated motorcycle oil (e.g., SAE 20W-50).
Cooling System
Cooling Method:
Air-cooled
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Clutch Type:
Wet, multi-plate
Primary Drive:
Duplex chain
Final Drive:
Belt drive
Features
Gear Ratios:
1st: 9.315, 2nd: 6.650, 3rd: 4.948, 4th: 3.818, 5th: 3.150 (approximate, refer to manual for exact figures)
Transmission Fluid Type:
Harley-Davidson Formula + (or equivalent primary lubricant)
Transmission Fluid Capacity:
2.7 US quarts (2.55 liters)
📐 Dimensions
Exterior
Wheelbase:
63.5 inches (1612.9 mm)
Length:
93.7 inches (2380 mm)
Width:
37.0 inches (939.8 mm)
Height:
52.4 inches (1330.9 mm)
Weights
Dry Weight:
706 lbs (320 kg)
Wet Weight:
743 lbs (337 kg) (estimated)
Gross Vehicle Weight Rating Gvwr:
1160 lbs (526 kg)
Cargo
Saddlebag Capacity:
Approx. 2.5 cubic feet total
🛡️ Safety Features
Ratings
Safety Certifications:
Meets or exceeds all applicable federal safety standards for motorcycles.
Active Features
Braking System Type:
Hydraulic disc brakes, front and rear.
Front Brake Spec:
Dual 292mm (11.5 inch) discs, 4-piston calipers.
Rear Brake Spec:
Single 292mm (11.5 inch) disc, 2-piston caliper.
Lighting:
Halogen headlamp, integrated front and rear turn signals, brake light, tail light.
Passive Features
Chassis Type:
Steel, sectionally-welded, single downtube, backbone structure.
💡 Technology Features
Infotainment
Audio System:
Optional or standard AM/FM radio with cassette or CD player (depending on specific trim/options), often integrated into the fairing or handlebar.
Speakers:
Usually integrated fairing speakers.
Driver Assistance
Cruise Control:
Often equipped with electronic cruise control.
Connectivity
Connectivity Features:
Limited by modern standards; typically focused on the audio system and basic vehicle functions.
🔧 Maintenance
Service Intervals
First Service:
1,000 miles (1,600 km) or 6 months, whichever comes first.
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months thereafter. Check manual for specific tasks at each interval.
Engine Oil Change:
Every 5,000 miles (8,000 km) or 12 months, or more frequently under severe service conditions.
Transmission Oil Change:
Every 10,000 miles (16,000 km) or 24 months.
Primary Chain Tensioner Inspection:
Inspect at 1,000 miles (1,600 km) and every 10,000 miles (16,000 km) thereafter. Replace if worn.
Fluid Specifications
Engine Oil Specification:
Harley-Davidson SYN3 (Fully Synthetic) or equivalent SAE 20W-50 motorcycle oil.
Primary Lubricant Specification:
Harley-Davidson Formula + (or equivalent primary lubricant).
Brake Fluid Specification:
DOT 4 brake fluid.
Fork Oil Specification:
Refer to manual, typically SAE 10W or 15W fork oil, capacity specified per fork leg.
Known Issues
Primary Chain Tensioner:
The original hydraulic tensioner can wear out, leading to noise and potential damage. Upgrade to a revised or aftermarket manual tensioner is common.
Cam Chain Tensioners:
The internal cam chain tensioners in the Twin Cam 88B are known to wear and can cause engine damage if not replaced.
Exhaust Gaskets:
Exhaust port gaskets can sometimes leak, causing exhaust leaks and ticking noises.
Rear Cylinder Cooling:
Rear cylinders on air-cooled V-twins can run hotter, especially in traffic or hot weather, potentially leading to performance issues or premature wear.
📚 Vehicle History
Brand Heritage
Brand Origin:
Founded in Milwaukee, Wisconsin, USA in 1903.
Brand Reputation:
Iconic American motorcycle manufacturer known for V-twin engines and cruiser/touring motorcycles.
Model Evolution
Road King Introduction:
The Road King line was introduced in 1994, blending classic styling with touring comfort.
Flhrci Specifics:
The 'CI' designation typically indicates fuel injection (EFI), which became standard on many Harley-Davidson models in the late 1990s and early 2000s.
Production
Production Period:
The Twin Cam 88B engine was used in Harley-Davidson motorcycles from 1999 through 2006.
Manufacturing Location:
Typically manufactured at Harley-Davidson's York, Pennsylvania, or Kansas City, Missouri plants.
🏆 Awards & Recognition
Recognitions
Brand Awards:
Harley-Davidson has a long history of awards and recognition for its motorcycles and brand heritage.
Model Recognition:
The Road King line is consistently praised for its comfort, classic styling, and touring capability, making it a perennial favorite among Harley-Davidson riders.