🏷️ Basic Information

Make:

Harley-Davidson

Model:

Electra Glide Road King

Year:

2002

Engine Family Code:

TBD (Specific code not provided, typically Twin Cam 88)

👋 Introduction

Segment:

Flagship touring motorcycle segment, known for comfort, long-distance capability, and classic Harley-Davidson styling.

Competitors 2002:

Honda Gold Wing, Indian Chief, Kawasaki Vulcan 1500 Classic, Yamaha Road Star.

Model Features:

Iconic styling, comfortable rider and passenger seating, large luggage capacity (saddlebags), stable chassis for touring, and the characteristic V-twin engine rumble.

Benefit:

Provides technicians and knowledgeable owners with dealership-level repair and maintenance information, ensuring accurate and efficient servicing of the 2002 Electra Glide Road King.

📋 Manual Details

Coverage:

All models and all repairs A-Z for 2002 Electra Glide Road King variants

Pages:

Not specified, but implied to be comprehensive for 'all repairs A-Z'

Type:

Service Repair Workshop Manual

Language:

English

Format:

Likely printed, but could be PDF; implied professional quality

📖 Manual Coverage

Engine Systems:

Fuel injection (EFI) or carburetor systems, ignition, lubrication, cooling (air-cooled), engine mechanical (internal components, timing, valve train), starting and charging systems.

Transmission Drivetrain:

5-speed manual transmission, clutch operation and adjustment, primary drive, final drive belt system, maintenance, and replacement procedures.

Chassis Suspension:

Front fork (including Telescopic or Springer options depending on specific Road King variant), rear shock absorbers, swingarm, wheel bearings, steering head bearings, chassis lubrication, and alignment.

Braking System:

Front and rear hydraulic disc brake systems, brake fluid specifications, bleeding procedures, caliper service, pad replacement, and rotor inspection.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlight, taillight, turn signals, auxiliary), instrumentation, horn, and wiring diagrams.

Fuel System:

Fuel tank, fuel lines, fuel pump (EFI models), carburetor (if applicable), fuel filters, and related components.

Exhaust System:

Exhaust pipes, mufflers, heat shields, and mounting hardware.

Bodywork Fittings:

Fairing (if equipped), windshield, saddlebags, fenders, fuel tank mounting, seat mounting, and trim components.

Routine Maintenance:

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

Engine Repair:

Top-end rebuild (cylinder head, valves, pistons), bottom-end rebuild (crankshaft, connecting rods), timing chain/belt service, oil pump replacement.

Transmission Repair:

Clutch plate replacement, gear set inspection and replacement, shift drum and fork service, transmission fluid changes.

Suspension Service:

Fork seal replacement, fork oil changes, shock absorber replacement, swingarm bearing service.

Brake Overhaul:

Master cylinder rebuild, caliper rebuilding, brake line replacement, ABS system troubleshooting (if equipped).

Electrical Troubleshooting:

Diagnostic procedures for ignition, charging, starting, and lighting systems, using wiring diagrams to trace faults.

Fuel System Diagnostics:

Carburetor cleaning and adjustment, fuel injector testing, fuel pump pressure testing, EVAP system checks (if applicable).

Bodywork Refinishing:

Removal and installation of body panels, fairings, and luggage systems.

Depth:

Comprehensive, covering routine maintenance to full engine and transmission rebuilds, with detailed diagnostics and component specifications.

Diagnostic Capabilities:

Includes troubleshooting charts, symptom-based diagnostics, and specific component testing procedures.

Specifications Data:

Provides torque values, tolerances, clearances, fluid capacities, and electrical specifications critical for accurate repair.

📊 Manual Specifications

Format Type:

Likely printed paper format. If digital, likely PDF with searchable text.

Quality:

Professional dealership quality, with clear diagrams and legible text.

Binding:

Likely spiral-bound or perfect-bound for durability and ease of use in a workshop environment.

Paper:

Durable, possibly coated paper stock to resist grease and shop elements.

⚙️ Engine Specifications

Engine Type:

Air-cooled, 45-degree V-twin

Engine Displacement:

1449cc (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

Horsepower:

Approx. 65-70 HP (Varies slightly by specific tuning and model year variation)

Torque:

Approx. 78-82 ft-lbs @ 3200 RPM (Varies slightly)

Fuel Delivery Efi:

Sequential Electronic Fuel Injection (ESPFI)

Fuel Delivery Carburetor:

Keihin CV Carburetor (on some variants or prior to EFI rollout)

Fuel Type:

Unleaded gasoline, minimum 87 octane

🔧 Transmission

Type:

5-speed constant mesh, helical gear transmission

Primary Drive:

Duplex chain, wet clutch

Final Drive:

Belt drive

Clutch Type:

Hydraulic, multi-plate wet clutch

Gear Ratios:

Specific ratios available in detailed manual, but typically: 1st: 9.59, 2nd: 6.78, 3rd: 4.88, 4th: 3.91, 5th: 3.15

Transmission Fluid:

Harley-Davidson Syn 3 (SAE 20W-50) or equivalent motorcycle-specific oil.

📐 Dimensions

Length:

Approx. 92.5 inches (2350 mm)

Width:

Approx. 35.0 inches (889 mm)

Height:

Approx. 56.0 inches (1422 mm)

Wheelbase:

Approx. 63.5 inches (1613 mm)

Dry Weight:

Approx. 705 lbs (319.8 kg)

Gross Vehicle Weight Rating:

Not explicitly provided, but designed for rider + passenger + luggage.

Saddlebag Capacity:

Integrated hard saddlebags, capacity varies based on internal dimensions.

🛡️ Safety Features

Crash Safety:

Motorcycles are not typically rated by agencies like NHTSA or IIHS in the same way cars are. Safety relies on rider skill and vehicle design features.

Braking System:

Dual front disc brakes, single rear disc brake. ABS was optional on some Harley-Davidson touring models around this time but not standard on all Electra Glide Road Kings.

Lighting:

Halogen headlight, taillight, brake light, turn signals.

Frame Construction:

Steel frame designed for stability and rigidity.

Ergonomics:

Comfortable riding position designed to reduce fatigue on long rides.

💡 Technology Features

Audio System:

Many 2002 Electra Glides featured an AM/FM/WB stereo radio with cassette player, often integrated into the fairing or dashboard. CB radio and intercom options were sometimes available.

Display:

Analog gauges for speedometer, tachometer, fuel level, oil pressure, and voltmeter.

Cruise Control:

Electronic cruise control was often an option on touring models by 2002.

ABS Availability:

Anti-lock Braking System (ABS) was an optional feature for certain Harley-Davidson touring models in 2002, not standard on all. Manual would cover diagnosis and service if equipped.

Connectivity Features:

Limited by modern standards. Primarily focused on the onboard audio system and optional intercom/CB features.

🔧 Maintenance

First Service:

1000 miles (1600 km) or 6 months, whichever comes first. Includes engine oil and filter change, primary chain tension adjustment, inspection of all controls, cables, fasteners, etc.

Subsequent Service:

Every 5000 miles (8000 km) or 12 months, whichever comes first. Includes engine oil and filter change, primary chain tension adjustment, spark plug inspection/replacement, brake fluid check, drive belt inspection/adjustment.

Transmission Fluid Change:

Typically every 10,000 miles (16,000 km) or as specified in the manual.

Engine Oil:

Harley-Davidson Genuine Motor Oil SAE 20W-50 (Syn 3) or equivalent motorcycle-specific synthetic/mineral blend.

Primary Chain Case Oil:

Harley-Davidson Genuine Formula + Transmission/Primary Fluid (or SAE 50 motorcycle oil).

Brake Fluid:

DOT 4 hydraulic brake fluid.

Fork Oil:

Specific viscosity (e.g., Spectro HD Big Twin Fork Oil) as per manual, quantity per leg.

Cam Chain Tensioner Wear:

Early Twin Cam 88 models are known for hydraulic cam chain tensioners wearing out, potentially leading to noise or failure. Upgrade kits are available.

Oil Leaks:

Potential for leaks from primary or transmission seals, especially with age and mileage.

Carburetor Tuning:

CV carburetors can require periodic adjustment for optimal performance and idle.

Oil Filter:

e.g., Harley-Davidson 63796-77A or aftermarket equivalent (e.g., K&N HD-1701).

Air Filter:

Specific to model, e.g., Harley-Davidson 29043-94B for original OE.

Spark Plugs:

e.g., Harley-Davidson 31600-99 or equivalent (e.g., NGK DCPR7E).

📚 Vehicle History

Founding:

Harley-Davidson Motor Company founded in 1903.

Legacy:

Renowned for its V-twin engines, distinctive styling, and strong rider community.

Electra Glide Origin:

The Electra Glide line dates back to 1965, evolving through various engine families (Panhead, Shovelhead, Evolution) and configurations.

Road King Introduction:

The Road King model was introduced in 1994 as a more retro-styled touring machine, often featuring a detachable windshield rather than a fixed fairing found on the Electra Glide Standard or Classic.

Engine Transition To Twin Cam:

The 2002 model year signifies the widespread adoption of the Twin Cam 88 engine, which replaced the Evolution Big Twin, offering improved performance and reliability.

Manufacturing Location:

United States (e.g., York, Pennsylvania; Milwaukee, Wisconsin)

🏆 Awards & Recognition

Industry Acclaim:

Harley-Davidson touring models, including the Electra Glide line, are consistently recognized for their iconic status, comfort, and capability as American cruising motorcycles.