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Harley Davidson FLHR Road King 2004 Service Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHR Road King Year: 2004 Codes Chassis Code: FLHR 👋 Introduction Market Position Target Audience: Professional motorcycle technicians, experienced DIY mechanics, and Harley-Davidson...
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🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FLHR Road King
Year:
2004
Codes
Chassis Code:
FLHR
👋 Introduction
Market Position
Target Audience:
Professional motorcycle technicians, experienced DIY mechanics, and Harley-Davidson enthusiasts.
Vehicle Segment:
Full-size cruiser motorcycle, touring capability.
Competitive Analysis
Market Competitors Era:
Indian Chief, Victory Cruisers, custom motorcycles.
Key Features
Model Appeal:
Classic styling, comfortable touring, V-twin engine character, customization potential.
📋 Manual Details
Coverage Areas
Manual Type:
Service Manual / Workshop Manual / Repair Manual
Language:
English
Format:
PDF Download
Page Count
Estimated Page Count:
Over 500 pages (typical for this era's full service manuals)
📖 Manual Coverage
Systems Covered
Engine Overhaul:
Complete teardown, inspection, repair, and reassembly of Twin Cam 88 engine.
Fuel System:
Carburetor (Keihin CV) tuning, cleaning, and rebuilding; fuel tank, lines, and pump inspection.
Ignition System:
Ignition module, coil, spark plugs, wiring diagnostics, and timing adjustments.
Transmission And Drivetrain:
5-speed gearbox overhaul, clutch adjustment and replacement, primary drive, and belt drive maintenance.
Frame And Suspension:
Fork assembly, rear shock absorber replacement and adjustment, steering head bearing maintenance, wheel bearing service.
Braking System:
Front and rear brake caliper service, brake pad replacement, master cylinder overhaul, hydraulic system bleeding.
Electrical System:
Wiring diagrams, charging system (alternator, regulator), starting system (starter, solenoid), lighting, and accessory circuits.
Bodywork And Fittings:
Fairing removal and installation, fender maintenance, seat, saddlebags, and fuel tank servicing.
Diagnostics And Troubleshooting:
Systematic troubleshooting guides for common performance and operational issues.
Procedures Included
Scheduled Maintenance:
Detailed procedures for routine services like oil changes, filter replacements, and lubrication.
Component Rebuilding:
Step-by-step instructions for rebuilding major components like the carburetor, brake calipers, and transmission.
Wiring Diagrams:
Comprehensive, clearly labeled electrical schematics for all circuits.
Torque Specifications:
Essential torque values for all critical fasteners and bolts.
Special Tools:
Identification and usage of specialized tools required for specific repair tasks.
Technical Depth
Level Of Detail:
Comprehensive; covers everything from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Capabilities:
Advanced diagnostic procedures and troubleshooting flowcharts for identifying root causes of problems.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval.
Print Quality
Resolution:
High-resolution scans for clear text and diagrams.
Readability:
Designed for clear viewing on digital devices and printable for workshop use.
Binding Type
Digital Format:
Downloadable PDF (no physical binding).
⚙️ Engine Specifications
Primary Engine
Engine Family:
Harley-Davidson Twin Cam 88
Configuration:
45-degree V-twin, air-cooled
Displacement:
1450 cc (88 cubic inches)
Bore X Stroke:
3.75 in x 4.00 in (95.25 mm x 101.6 mm)
Compression Ratio:
8.9:1
Performance
Horsepower Est:
Approximately 65-70 HP (at crank, varies by tuning)
Torque Est:
Approximately 75-80 lb-ft @ 3500 RPM (at crank)
Fuel System
Carburetor Model:
Keihin CV (Constant Velocity) 40mm
Fuel Type:
Unleaded gasoline, 91 octane (or higher) recommended
Fuel Capacity:
4.2 gallons (15.9 liters)
Maintenance Notes
Valve Adjustment:
Requires periodic adjustment per service schedule.
Oil Type:
Harley-Davidson 20W50 SYN3 (or equivalent) recommended for engine, primary, and transmission.
🔧 Transmission
Standard
Type:
5-speed constant mesh, helical gears
Primary Drive:
Chain drive (wet clutch, 36T primary sprocket, 31T clutch sprocket)
Final Drive:
Belt drive (29T motor pulley, 66T rear sprocket)
Features
Clutch Type:
Wet, multi-plate, diaphragm spring
Gear Ratios Est:
1st: 9.34, 2nd: 6.70, 3rd: 5.02, 4th: 3.93, 5th: 3.15
Maintenance Notes
Transmission Fluid Type:
Harley-Davidson Formula + (or equivalent heavy-duty gear oil)
Primary Chain Tension:
Requires periodic adjustment.
📐 Dimensions
Exterior
Length:
94.0 inches (2388 mm)
Width:
38.0 inches (965 mm)
Height:
55.3 inches (1405 mm)
Wheelbase:
63.5 inches (1613 mm)
Weights
Dry Weight:
665 lbs (301.6 kg)
Gross Vehicle Weight Rating Gvwr:
1100 lbs (500 kg)
Load Capacity:
435 lbs (197 kg)
Cargo
Saddlebag Capacity:
Approx. 2 cubic feet total
Specifications
Ground Clearance:
5.2 inches (132 mm)
Seat Height:
28.2 inches (716 mm)
🛡️ Safety Features
Ratings
Crash Testing:
Motorcycles typically not subjected to standardized crash testing like automobiles. Focus is on rider protection through design and component integrity.
Active Features
Braking System:
Dual disc front brakes, single disc rear brake.
Suspension:
Conventional telescopic front forks (41mm), rear air-adjustable shock absorbers.
Passive Features
Frame Construction:
Steel, under-seat tube frame.
Lighting:
Halogen headlight, LED tail light, turn signals.
Maintenance Impact
Brake Fluid Type:
DOT 4 hydraulic fluid
💡 Technology Features
Infotainment
Audio System:
Optional accessory radio/audio system available; base models may not include it.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an optional feature, not standard on all 2004 FLHR models.
Connectivity
Cruise Control:
Available as an optional accessory, not standard.
🔧 Maintenance
Service Intervals
Initial Service:
1000 miles (1600 km)
Subsequent Services:
Every 5000 miles (8000 km) thereafter, or annually, whichever comes first.
Oil Change Interval:
Every 5000 miles (8000 km) or annually.
Fluid Specifications
Engine Oil Capacity:
3.0 US quarts (2.8 liters) with filter change.
Primary Chain Case Oil Capacity:
1.0 US quart (0.95 liters).
Transmission Oil Capacity:
2.4 US pints (1.1 liters).
Brake Fluid:
DOT 4
Fork Oil:
Specify weight based on manual, typically SAE 15W or 20W.
Known Issues
Cam Chain Tensioners:
Early Twin Cam models (pre-2007) are known for wear on cam chain tensioners, requiring inspection and potential replacement with upgraded hydraulic units.
Carburetor Performance:
Keihin CV carburetor can require periodic adjustment for optimal performance, especially with altitude or temperature changes.
Electrical Connectors:
Corrosion or loose connections in the electrical system can lead to intermittent issues.
Maintenance Part Numbers Example
Oil Filter Harley Davidson:
63796-77A (or equivalent)
Air Filter Harley Davidson:
29400045 (or specific model year equivalent)
📚 Vehicle History
Brand Heritage
Harley Davidson Legacy:
Founded in 1903, a long history of V-twin motorcycles and American motorcycling culture.
Model Evolution
Road King Introduction:
Introduced in 1994, positioned as a classic cruiser with touring capabilities.
Flhr Twin Cam Era:
The 2004 model features the then-new Twin Cam 88 engine, replacing the Evolution engine.
Production
Manufacturing Location:
York, Pennsylvania, USA and Milwaukee, Wisconsin, USA
🏆 Awards & Recognition
Recognitions
Model Reputation:
The FLHR Road King is consistently recognized for its blend of classic styling, comfortable ride, and touring capability, making it a popular choice among Harley-Davidson riders.
Ratings
Rider Satisfaction:
High rider satisfaction ratings due to its iconic design and the Harley-Davidson ownership experience.