🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLHR Road King

Year:

2004

Product Type:

Service Repair Workshop Manual

👋 Introduction

Positioning:

The Harley-Davidson FLHR Road King is a flagship touring motorcycle known for its classic styling, comfortable ride, and long-distance capabilities. It appeals to riders who appreciate traditional cruiser aesthetics combined with practical touring features.

Competitors 2004:

Primary competitors include other large-displacement V-twin touring motorcycles from brands like Indian, and potentially some high-end cruisers from Japanese manufacturers adapted for touring.

Features 2004 Flhr:

Detachable windscreen, hard-shell saddlebags, comfortable rider and passenger seating, powerful V-twin engine, classic styling with chrome accents, cruise control (optional), robust touring platform.

Value Proposition:

This service manual provides owners and technicians with the definitive guide to maintaining, troubleshooting, and repairing the 2004 Harley-Davidson FLHR Road King, ensuring optimal performance and longevity.

📋 Manual Details

Manual Scope:

Complete Factory Service Repair Workshop Manual

Estimated Page Count:

Likely 600-800 pages (typical for factory service manuals of this era)

Type:

Service Manual / Workshop Manual / Repair Manual

Language:

English

Format:

PDF (Downloadable)

📖 Manual Coverage

Engine:

Twin Cam 88, Twin Cam 88B Engine Mechanicals, Lubrication, Fuel System, Ignition System, Starting System, Charging System

Transmission:

5-Speed Cruise Drive Transmission: Disassembly, Assembly, Troubleshooting, Lubrication

Drivetrain:

Primary Drive, Clutch, Belt Drive, Final Drive Maintenance and Repair

Chassis:

Frame, Swingarm, Suspension (Front and Rear), Steering Head, Wheels, Tires, Brakes (Front and Rear), Brake System Components

Electrical:

Wiring Diagrams, Lighting, Gauges, Ignition, Starting, Charging, Accessories, Troubleshooting Electrical Faults

Bodywork And Fittings:

Fairing, Windshield, Fuel Tank, Seat, Fenders, Saddlebags, Controls, Handlebars

Diagnostic Procedures:

Troubleshooting guides for all major systems, diagnostic trouble codes (DTCs) where applicable, performance testing

Routine Maintenance:

Oil and filter changes, spark plug replacement, air filter servicing, brake fluid checks, chain/belt adjustment, lubrication points

Major Repairs:

Engine overhaul, transmission rebuild, suspension component replacement, brake caliper service, electrical component replacement

Disassembly And Assembly:

Detailed step-by-step instructions for all major components and systems

Troubleshooting:

Systematic approaches to diagnosing and resolving common and uncommon problems

Depth:

Comprehensive factory-level diagnostic and repair procedures, suitable for professional technicians and experienced DIY mechanics

📊 Manual Specifications

Format Details:

PDF (Portable Document Format)

Quality:

High-resolution scans of original factory documentation, ensuring clarity of text and diagrams

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Format)

Searchable Text:

Likely contains searchable text for easy navigation and keyword searches (depending on PDF OCR quality)

Licensing:

Provided for reference; usage terms may vary by vendor.

⚙️ Engine Specifications

Engine Type:

Harley-Davidson Twin Cam 88 / Twin Cam 88B (depending on specific FLHR sub-model configuration, B denotes balanced)

Displacement:

1450cc (88 cubic inches)

Configuration:

Air-cooled, 45-degree V-twin

Bore X Stroke:

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

Compression Ratio:

Typically 8.8:1 or 9.1:1 (check specific model documentation)

Valvetrain:

Pushrod-actuated overhead valves, 2 valves per cylinder

Horsepower:

Approx. 65-70 HP (at crankshaft, estimated)

Torque:

Approx. 85-90 lb-ft (at crankshaft, estimated at 3500 RPM)

Fuel Delivery:

Carburetor (Keihin CV 40mm) for most models, Electronic Fuel Injection (EFI) available on some specific models or as an upgrade path.

Fuel Type:

Unleaded gasoline, minimum 87 octane (91 AKI)

Oil Type:

Harley-Davidson SYN3 (synthetic blend) or equivalent V-twin specific motorcycle oil, SAE 20W50 recommended

Oil Capacity:

Approx. 4 quarts (3.8 liters) with filter change

🔧 Transmission

Type:

5-Speed Cruise Drive

Gear Ratios:

1st: 9.315, 2nd: 6.436, 3rd: 4.784, 4th: 3.838, 5th: 3.150 (check manual for exact ratios)

Clutch Type:

Wet, multi-plate

Features:

Helical-cut gears for quieter operation, robust design for touring duty.

Transmission Oil Type:

Harley-Davidson Transmission Lubricant or equivalent heavy-duty gear oil, SAE 75W-90 or 75W-140 (check manual for specific recommendation)

Transmission Oil Capacity:

Approx. 24 oz. (0.7 L)

📐 Dimensions

Length:

Approx. 93.7 in. (2380 mm)

Width:

Approx. 37.4 in. (950 mm)

Height:

Approx. 53.1 in. (1350 mm)

Wheelbase:

Approx. 63.7 in. (1618 mm)

Ground Clearance:

Approx. 5.1 in. (130 mm)

Dry Weight:

Approx. 680 lbs. (308 kg)

Gross Vehicle Weight Rating Gvwr:

Typically around 1150 lbs. (522 kg) - consult manual for exact rating

Fuel Tank Capacity:

5.0 gallons (19 L)

Front Wheel:

16 x 3.0 inch cast aluminum or laced spoke

Rear Wheel:

16 x 3.0 inch cast aluminum or laced spoke

Front Tire:

MT90B16 72H (Dunlop Harley-Davidson bias-ply or radial)

Rear Tire:

130/90B16 73H (Dunlop Harley-Davidson bias-ply or radial)

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycles typically do not receive NHTSA safety ratings like cars; focus is on rider protection through design and features).

Braking System:

Dual 292mm discs, 4-piston calipers front; Single 292mm disc, 4-piston caliper rear. Often equipped with linked braking or ABS on later models, but standard for 2004 is likely non-ABS.

Suspension:

Front: Telescopic forks, 41mm stanchions; Rear: Coil-over shock absorbers with adjustable preload.

Lighting:

Halogen headlight, front and rear turn signals, tail/brake lights, license plate light.

Rider Controls:

Handlebar-mounted controls, floorboards for rider comfort and control.

💡 Technology Features

Audio System:

Optional AM/FM radio with CB and intercom, often integrated into the handlebar fairing or dashboard. CD player or cassette options may have been available.

Display:

Analog gauges for speedometer, tachometer, fuel level, oil pressure, and voltage. Warning lights for indicators.

Cruise Control:

Available as an optional feature on many 2004 FLHR models.

Connectivity Features:

Basic connectivity for audio accessories. No integrated smartphone connectivity or Bluetooth in this era.

🔧 Maintenance

Initial Service:

First service typically around 1,000 miles (1600 km): oil change, filter change, primary chain adjustment, clutch adjustment, inspection of all critical components.

Routine Intervals:

Subsequent services every 5,000 miles (8,000 km) or annually: oil changes, lubrication, inspection of brakes, tires, lights, and all fasteners.

Major Service Intervals:

Refer to manual for specific intervals for spark plug replacement (e.g., 10,000 miles), brake fluid flush (e.g., every 2 years), transmission fluid change (e.g., every 10,000-20,000 miles).

Engine Oil Type And Capacity:

As listed in engine specs: Harley-Davidson SYN3 or equivalent V-twin specific 20W-50; 4 quarts (3.8 L) with filter.

Transmission Oil Type And Capacity:

As listed in transmission specs: Harley-Davidson Transmission Lubricant or equivalent SAE 75W-90/140 gear oil; 24 oz. (0.7 L).

Primary Chain Case Oil Type And Capacity:

Harley-Davidson Primary Chain Case Oil or equivalent; typically 1 quart (0.95 L) - check manual.

Brake Fluid Type:

DOT 4 recommended

Common Wear Items:

Clutch plates, brake pads, tires, wheel bearings, fork seals, drive belt, battery.

Potential Problems 2004 Tc88:

Some earlier Twin Cam models experienced issues with cam chain tensioners (often upgraded to hydraulic tensioners), potential oil leaks from primary/transmission seals, and carburetor performance quirks.

Specific Flhr Points:

Fork seal leaks, saddlebag latch wear, occasional electrical connector issues due to vibration and exposure.

📚 Vehicle History

Brand History:

Harley-Davidson boasts a rich heritage dating back to 1903, synonymous with American motorcycle culture, freedom, and robust V-twin engineering.

Road King Lineage:

The Road King model line was introduced in 1994, reviving classic styling cues from the Hydra-Glide era. It has consistently been a popular touring model, known for its versatility and classic appeal. The 2004 model year falls within the early era of the Twin Cam engine.

Manufacturing Location:

York, Pennsylvania, USA and Milwaukee, Wisconsin, USA

Key Updates 2004:

The 2004 models continued the evolution of the Twin Cam 88 engine. Minor updates often include refinements to ergonomics, styling, and component integration. Cruise control became a more common option.

🏆 Awards & Recognition

Brand Awards:

Harley-Davidson consistently ranks high in customer satisfaction and brand loyalty surveys. Specific model awards are less common for individual years, but the Road King platform is frequently praised for its touring comfort and classic appeal.

Ownership Satisfaction:

High owner satisfaction ratings for comfort, style, and long-term ownership experience, especially for those who appreciate the traditional Harley-Davidson feel.