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Harley Davidson FLHR Road King 2012 Factory Service Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLHR Road King Year: 2012 Vehicle Type: Cruiser Motorcycle Generation Current Generation: Sixth Generation (2009-2013) Codes Vin Code: 1HD1 👋 Introduction Market Position...
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🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FLHR Road King
Year:
2012
Vehicle Type:
Cruiser Motorcycle
Generation
Current Generation:
Sixth Generation (2009-2013)
Codes
Vin Code:
1HD1
👋 Introduction
Market Position
Segment:
Full-size cruiser motorcycle, often referred to as a 'bagger' due to its touring capabilities.
Target Audience:
Riders seeking comfort, classic styling, and long-distance touring capabilities, as well as DIY mechanics and professional technicians.
Competitive Analysis
Key Competitors:
Indian Chief, Victory Cross Country, Honda Gold Wing (though a different class), some European touring bikes depending on specific touring needs.
Unique Selling Points:
Iconic Harley-Davidson styling, strong V-twin torque, vast customization options, strong dealer network, rider community.
Key Features
Styling:
Classic 'cruiser' aesthetic with large front fairing, comfortable rider and passenger seating, hard saddlebags.
Performance:
Torquey Twin Cam 103 engine providing strong acceleration for cruising and passing.
Comfort:
Ergonomically designed for long-distance riding, including rider floorboards and passenger backrest.
Storage:
Integrated hard saddlebags offer substantial, weather-resistant storage for touring.
📋 Manual Details
Coverage Areas
Primary Coverage:
FLHR Road King
Engine Variants Covered:
103 cubic inch (1690cc) Twin Cam 103 V-Twin
Page Count
Estimated Page Count:
600-800
Manual Type
Manual Type:
Factory Service Manual (FSM)
Content Type:
Repair, Maintenance, Diagnostics, Troubleshooting
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete disassembly, assembly, inspection, and repair of Twin Cam 103 engine, including top end (cylinder heads, valves, camshafts) and bottom end (crankcase, crankshaft, connecting rods).
Fuel System:
EFI (Electronic Fuel Injection) system diagnostics, fuel pump, injectors, throttle body, sensors, and related components.
Ignition System:
Ignition module, spark plugs, coils, and related wiring.
Transmission:
6-speed Cruise Drive transmission: disassembly, assembly, inspection, clutch operation, gear shifting mechanisms, and lubrication.
Drive Train:
Primary drive, belt drive, final drive belt inspection and replacement, chain inspection (if applicable to specific sub-models).
Chassis Frame:
Frame inspection, welding points, steering head bearing replacement, swingarm and pivot bearings.
Suspension:
Front fork (telescopic) overhaul, fork seals replacement, rear shock absorber inspection and replacement.
Braking System:
Front and rear brake systems: hydraulic system, calipers, master cylinders, brake pads, rotors, bleeding procedures, ABS (Anti-lock Braking System) if equipped.
Electrical System:
Complete wiring diagrams, battery, charging system (alternator, stator, regulator/rectifier), lighting, starter motor, and accessory circuits.
Instrumentation Controls:
Speedometer, tachometer, gauges, handlebar controls, and their electrical connections.
Bodywork Fenders:
Fairing removal and installation, fender mounting, fuel tank removal and installation, seat assembly.
Lighting Accessories:
Headlight, tail light, turn signals, auxiliary lighting, and accessory wiring.
Diagnostics:
Troubleshooting charts for common and uncommon issues, diagnostic trouble codes (DTCs), and diagnostic procedures using a service tool (e.g., Digital Technician).
Procedures Included
Preventive Maintenance:
Oil changes, filter replacements, chain adjustment (if applicable), tire pressure checks, brake inspection, battery maintenance.
Repair Procedures:
Step-by-step instructions for all major and minor repairs, including engine rebuilds, transmission overhauls, suspension component replacement, and electrical system repairs.
Troubleshooting Guides:
Systematic approaches to diagnosing and resolving mechanical, electrical, and fuel system problems.
Diagnostic Techniques:
Guidance on using diagnostic tools and interpreting data for accurate fault finding.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Torque Specifications:
Detailed torque values for all critical fasteners to ensure proper assembly and prevent component failure.
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds).
Detail Level:
Factory-level detail with explicit instructions, diagrams, and specifications.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Searchable text within the PDF for quick information retrieval.
Print Quality
Printability:
High-resolution pages suitable for printing a complete physical manual.
Binding Type
Suggested Binding:
Comb binding or professional spiral binding recommended for durability and ease of use during repairs.
Paper Type
Recommended Paper:
Heavyweight, durable paper stock (e.g., 24lb or higher) for workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Harley-Davidson Twin Cam 103
Configuration:
Air-cooled, 45-degree V-twin
Displacement:
103 cubic inches (1690 cc)
Bore X Stroke:
3.875 in. x 4.375 in. (98.4 mm x 111.1 mm)
Compression Ratio:
9.6:1
Valve Train:
Pushrod-activated, overhead valves (OHV), two valves per cylinder.
Horsepower Estimate:
~70-75 HP (at crank, estimated)
Torque Estimate:
~95-100 lb-ft (at crank, estimated)
Performance
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Exhaust System:
Dual exhaust with catalytic converters (region-dependent).
Fuel System
Fuel Type:
Unleaded gasoline, 91 octane (R+M)/2 (95 RON) recommended.
🔧 Transmission
Standard
Type:
6-speed Cruise Drive
Gear Ratios:
1st: 9.593, 2nd: 6.650, 3rd: 4.935, 4th: 3.818, 5th: 3.407, 6th: 2.790
Primary Drive:
Patented dual-clutch, 34/46 ratio, 1.353
Final Drive:
Belt, 32/66 ratio, 2.063
Features
Clutch:
Hydraulically actuated, 9-plate, wet clutch.
Lubrication:
Integrated transmission and primary chaincase lubrication system.
📐 Dimensions
Exterior
Length:
99.1 in. (2517 mm)
Overall Width:
37.4 in. (950 mm)
Overall Height:
56.9 in. (1445 mm)
Wheelbase:
63.5 in. (1613 mm)
Ground Clearance:
5.1 in. (130 mm)
Seat Height Laden:
27.3 in. (695 mm)
Handlebar Height:
Approximately 55-60 inches depending on fairing and risers.
Weights
Dry Weight:
732 lbs (332 kg)
Gross Vehicle Weight Rating:
1261 lbs (572 kg)
Fuel Capacity:
6.0 gal (22.7 L)
Oil Capacity:
3.5 US qt. (3.3 L) with filter change.
🛡️ Safety Features
Ratings
ABS Availability:
Optional (check specific model configuration)
Braking System Type:
Linked, four-piston calipers with dual front discs and single rear disc.
Active Features
Cruise Control:
Standard electronic cruise control.
Hazard Lights:
Standard hazard warning lights.
Passive Features
Lighting:
Halogen headlight, LED tail light and brake lights, front and rear turn signals.
Ride Stability:
Low center of gravity and substantial weight contribute to stability.
💡 Technology Features
Infotainment
Audio System:
Optional 80-watt AM/FM/WB, CB, weather band, and PA, with CB and passenger intercom functionality; typically features handlebar-mounted controls.
Display:
Integrated instrument cluster with analog speedometer, tachometer, fuel gauge, and indicator lights. May include a small LCD display for odometer, gear indicator, etc.
Driver Assistance
Cruise Control:
Electronic cruise control for highway comfort.
Connectivity
Accessories:
Pre-wiring for accessories, including auxiliary lighting and charging ports, depending on the factory configuration.
🔧 Maintenance
Service Intervals
First Service:
1,000 miles (1600 km) or 6 months, whichever comes first.
Subsequent Services:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first, for routine checks and fluid changes.
Engine Oil Change:
Recommended every 2,500 miles (4,000 km) or 6 months when using non-synthetic oil, or per manual recommendations for synthetic.
Transmission Oil Change:
Recommended at 5,000 mile intervals (refer to manual for specific recommendations and fluid types).
Primary Chain Tensioner Inspection:
Inspect at 10,000 miles (16,000 km) and every 10,000 miles thereafter.
Fluid Specifications
Engine Oil:
Harley-Davidson Genuine V-Twin 20W-50 (or equivalent SAE 20W-50 motorcycle-specific oil, synthetic or conventional).
Transmission Oil:
Harley-Davidson Formula + (or equivalent GL-4 75W-90 synthetic gear oil).
Primary Chain Case Lubricant:
Harley-Davidson Formula + (or equivalent GL-4 75W-90 synthetic gear oil).
Brake Fluid:
DOT 4 (if equipped with ABS); check manual for specific recommendations.
Fork Oil:
Harley-Davidson Type E or 10W (check manual for specific application).
Known Issues
Primary Chain Tensioner:
The hydraulic tensioner can wear over time, leading to noise and potential primary drive damage. Manual provides inspection and replacement procedures.
Cam Chain Tensioner:
Early Twin Cam models had issues; the Twin Cam 103 in 2012 generally uses updated tensioners, but manual covers inspection and replacement if needed.
Electrical Gremlins:
As with many complex motorcycles, occasional electrical issues can arise; the manual's detailed wiring diagrams are crucial for diagnosis.
Fuel Injector Issues:
Rare but possible; manual covers diagnostic procedures and component testing.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines, classic styling, and strong brand identity.
Model Evolution
Road King Introduction:
The Road King lineage began in the early 1990s, offering a blend of classic styling and touring comfort, distinct from the fully-faired tourers like the Electra Glide.
Evolution To 2012:
The 2012 model represents a refinement of the FLHR platform, featuring the larger Twin Cam 103 engine and incorporating contemporary technologies while retaining its retro appeal.
Production
Manufacturing Location:
United States (primarily York, Pennsylvania and Milwaukee, Wisconsin).