Harley Davidson FLHRCI Road King Classic Complete Workshop Service Repair Manual 2004

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHRCI Road King Classic Year: 2004 Model Code: FLHRCI Generation Generation Identifier: Harley-Davidson Touring Platform (Revised) 👋 Introduction Market Position Positioning: Flagship cruiser...

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标签: 2004 FLHRCI Harley Davidson Misc Motorcycle Motorcycles Road King Classic

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

FLHRCI Road King Classic

Year:

Model Code:

FLHRCI

Generation

Generation Identifier:

Harley-Davidson Touring Platform (Revised)

👋 Introduction

Market Position

Positioning:

Flagship cruiser offering classic styling with modern touring capabilities, targeted at riders seeking comfort, style, and long-distance touring.

Competitive Analysis

Competitors:

Other Harley-Davidson touring models, Indian Chief models, premium cruisers from Japanese manufacturers (e.g., Honda Gold Wing, Kawasaki Vulcan 2000).

Key Features

Features:

Detachable windshield, leather-wrapped saddlebags, large chrome accents, comfortable seating for rider and passenger, classic styling cues, robust V-twin engine.

Target Audience

Audience:

Touring riders, cruisers, enthusiasts of classic American motorcycle design.

Manual Purpose

Purpose:

To provide comprehensive service, repair, and maintenance information for the 2004 Harley-Davidson FLHRCI Road King Classic, enabling owners and technicians to maintain and repair the motorcycle to factory specifications.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Workshop Service and Repair

Page Count

Estimated Pages:

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine assembly, disassembly, internal components, lubrication system, cooling system (if applicable), fuel system, ignition system, exhaust system.

Transmission Systems:

Transmission assembly, disassembly, gears, clutch, shift mechanism, lubrication.

Electrical Systems:

Wiring diagrams, charging system, starting system, ignition system, lighting, instrumentation, battery, fuses, relays, electronic control modules (ECM).

Chassis Systems:

Frame, suspension (front and rear forks, shocks), steering system, wheels, tires, brakes (hydraulic systems, calipers, rotors, master cylinders), final drive (belt drive).

Bodywork And Trim:

Fenders, fuel tank, seat, fairing (if applicable), saddlebags, instrumentation, controls, graphics, chrome components.

Procedures Included

Maintenance Procedures:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, drive belt inspection and adjustment, brake fluid flush, tire pressure checks, battery maintenance.

Repair Procedures:

Engine rebuild, transmission overhaul, brake caliper rebuilding, suspension fork servicing, electrical component diagnosis and replacement, fuel system cleaning and repair.

Troubleshooting:

Diagnostic procedures for common malfunctions, symptom-based troubleshooting charts, fault code interpretation (if applicable).

Assembly Disassembly:

Step-by-step instructions for component removal and installation, torque specifications, special tool requirements.

Technical Depth

Depth:

Comprehensive (from basic maintenance to full engine/transmission rebuilds and advanced electrical diagnostics).

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable

Print Quality

Resolution:

High-resolution (suitable for printing)

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, Twin Cam 103

Displacement:

1600 cc (96 cubic inches)

Bore X Stroke:

3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)

Compression Ratio:

8.8:1

Performance

Horsepower Estimated:

Approximately 65-70 HP (at crank, peak)

Torque Estimated:

Approximately 90-95 ft-lbs (at crank, peak)

Fuel System

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane (premium)

Ignition System

Ignition Type:

Electronic, crank-initiated, coil-on-plug

Lubrication System

Oil Type:

Harley-Davidson Genuine Formula Syn3 Motorcycle Oil or equivalent SAE 20W-50 API CG-4 or higher.

Oil Capacity With Filter:

4.0 U.S. quarts (3.8 liters)

🔧 Transmission

Standard

Type:

5-speed Constant Mesh

Gear Ratios:

1st: 9.59, 2nd: 6.65, 3rd: 4.94, 4th: 3.81, 5th: 3.15

Features

Clutch Type:

Wet, multi-plate, diaphragm spring

Final Drive:

Belt Drive, 32 Tooth Front Pulley / 65 Tooth Rear Pulley (41mm wide belt)

Transmission Fluid Type:

Harley-Davidson Genuine Formula + Transmission Oil or equivalent SAE 80W-90 GL-5.

Transmission Fluid Capacity

Capacity:

1.0 U.S. quart (0.95 liters)

📐 Dimensions

Exterior

Length:

93.9 in. (2385 mm)

Width Handlebars:

37.2 in. (945 mm)

Height Seat:

29.5 in. (750 mm) (Unladen)

Ground Clearance:

5.1 in. (130 mm)

Wheelbase:

63.7 in. (1618 mm)

Weights

Dry Weight:

715 lbs (324 kg)

Wet Weight Estimated:

Approx. 760 lbs (345 kg)

Cargo

Saddlebag Capacity:

Approx. 2,150 cubic inches total (Leather-covered ABS)

Fuel Capacity

Fuel Tank Capacity:

5.0 U.S. gallons (18.9 liters)

Reserve Fuel Capacity:

Approximately 1 gallon

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles are not typically rated by consumer safety organizations like NHTSA or IIHS).

Active Features

Braking System:

Dual-disc front brakes, single-disc rear brake, hydraulic actuation.

Lighting:

Halogen headlight, auxiliary passing lamps, LED taillight/stoplight, front and rear amber turn signals.

Passive Features

Frame Construction:

Steel, cradle frame

Rider Controls:

Ergonomic handlebar and seating position for rider comfort and control.

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM radio with cassette player and/or CD player (optional), speakers integrated into fairing or saddlebags.

Instrumentation:

Analog speedometer, tachometer, fuel gauge, voltage meter, oil pressure gauge, indicator lights for turn signals, high beam, neutral, and engine diagnostics.

Driver Assistance

Cruise Control:

Electronic cruise control (standard on FLHRCI models).

Connectivity

Diagnostic Port:

Access to the Harley-Davidson Electronic Diagnostic Interface (HDI) for system diagnostics and tuning (requires specialized tools).

Engine Management

Engine Control Module (ECM) manages fuel injection, ignition timing, and other engine parameters.

🔧 Maintenance

Service Intervals

First Service:

1,000 miles (1,600 km) or 6 months, whichever comes first.

Subsequent Engine Oil Change:

Every 5,000 miles (8,000 km) or 12 months, whichever comes first.

Drive Belt Inspection Adjustment:

Every 10,000 miles (16,000 km).

Brake Fluid Flush Replace:

Every 24 months, regardless of mileage.

Spark Plug Replacement:

Typically every 10,000 - 20,000 miles depending on plug type and condition.

Fluid Specifications

Engine Oil Specification:

Harley-Davidson Genuine Formula Syn3 or SAE 20W-50 API CG-4 or higher motorcycle oil.

Transmission Oil Specification:

Harley-Davidson Genuine Formula + Transmission Oil or SAE 80W-90 GL-5 gear oil.

Primary Chain Case Fluid:

Harley-Davidson Genuine Formula + Primary Chain Case Lubricant or SAE 80W-90 GL-5 gear oil (check manual for exact specification for this model).

Brake Fluid Specification:

DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Drive belt wear, clutch friction plates, brake pads, fork seals, wheel bearings, battery.

Engine Specifics:

Potential for oil leaks from engine seals, occasional cam bearing wear issues in earlier Twin Cam models (though 2004 is generally considered robust).

Electrical Specifics:

Wiring harness integrity, voltage regulator failure, starter solenoid issues are not uncommon on older Harleys.

📚 Vehicle History

Brand Heritage

Heritage:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer known for its V-twin engines, classic styling, and strong rider community.

Model Evolution

Road King Lineage:

The Road King line, introduced in 1994, is a modern interpretation of classic American touring motorcycles, emphasizing comfort, style, and practicality for long-distance riding.

Flhrci Specifics:

The 'CI' designation typically signifies fuel injection, a significant upgrade for performance and emissions. The Road King Classic differentiates itself with classic styling elements like laced wheels and leather-finished saddlebags.

Production

Manufacturing Location:

United States (Primary manufacturing facilities in Milwaukee, Wisconsin, and York, Pennsylvania).

Production Years

Model Production Run:

The FLHRCI variant was part of the Harley-Davidson touring lineup for many years, with continuous updates to the Twin Cam engine platform.

🏆 Awards & Recognition

Recognitions

Awards:

While specific 'awards' for a model year are rare, the Road King series has consistently been recognized for its comfort, touring capability, and enduring classic styling by motorcycle publications and rider polls.

Ratings

Customer Satisfaction:

Generally high customer satisfaction for comfort and reliability when properly maintained.