Market Position:
The Harley-Davidson FLHR Road King is a flagship touring motorcycle known for its classic styling, comfortable ride, and powerful V-twin engine, appealing to riders who prioritize long-distance comfort and traditional cruiser aesthetics.
Competitive Analysis:
Competes with other large displacement touring cruisers from manufacturers like Indian Motorcycle, Victory Motorcycles (discontinued but relevant history), and other premium cruiser brands. Its strong brand heritage and iconic design are key differentiators.
Key Features:
Detachable windshield, spacious saddlebags, comfortable rider and passenger seating, powerful V-twin engine, classic chrome accents, touring-oriented suspension.
Coverage Areas:
Service, Maintenance, Troubleshooting
Page Count:
Estimated 500-700 pages (typical for this model and type of manual)
Manual Type:
Workshop Repair Service Manual
Manual Purpose:
A practical guide for technicians and skilled DIY enthusiasts to perform all maintenance, repairs, and diagnostic procedures correctly and efficiently.
Systems Covered:
Engine, Fuel System, Ignition System, Electrical System, Transmission, Drive Train, Chassis, Suspension, Brakes, Clutch, Wheels and Tires, Bodywork, Lighting, Instruments, Diagnostic Trouble Codes (DTCs), Maintenance Procedures, Troubleshooting Charts, Wiring Diagrams.
Procedures Included:
Routine maintenance (oil changes, filter replacements, lubrication), engine overhaul, fuel injection system diagnosis and repair, ignition system troubleshooting, electrical component testing and replacement, transmission disassembly and assembly, clutch service, brake system bleeding and repair, suspension adjustments, wheel and tire servicing, body panel removal and installation, diagnostic procedures, torque specifications, specialized tool usage.
Technical Depth:
Comprehensive, covering from basic rider maintenance to complete engine and chassis rebuilds, including detailed diagnostic procedures and troubleshooting flowcharts.
DTC Coverage:
Includes detailed information on Diagnostic Trouble Codes (DTCs) for the Electronic Control Module (ECM), enabling precise identification of system faults.
Wiring Diagrams Coverage:
Comprehensive electrical wiring diagrams for all circuits, color-coded and detailed for easy troubleshooting of the electrical system.
Special Tools Coverage:
Lists and describes required specialized Harley-Davidson tools for specific repair and maintenance procedures, essential for performing work to factory specifications.
Bodywork Procedures:
Detailed instructions for the removal, installation, and adjustment of all body panels, including the front fairing, fenders, saddlebags, and console.
Clutch Procedures:
Includes clutch adjustment, inspection of clutch plates, and service of the clutch release mechanism.
Suspension Procedures:
Covers front fork service, rear shock absorber inspection and replacement, and suspension tuning for optimal ride quality.
Primary Engine:
Harley-Davidson Twin Cam 96 (1584cc)
Horsepower:
Approx. 75 HP (rated at crankshaft, actual wheel horsepower will be lower)
Torque:
Approx. 92 ft-lbs @ 3,500 RPM (rated at crankshaft)
Fuel System:
Electronic Sequential Port Fuel Injection (ESPFI)
Engine Type:
Air-cooled, 45-degree V-twin, pushrod-actuated valves
Bore Stroke:
3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)
Oil Capacity:
5.0 US qt (4.7 L)
Oil Type Spec:
Harley-Davidson SYN3 or equivalent SAE 20W-50 Synthetic Motorcycle Oil
Valve Train Type:
Overhead valves (OHV), 2 valves per cylinder, pushrod actuated.
Ignition System Type:
Coil-on-plug, electronic spark control with knock sensor.
Safety Ratings:
Not applicable for motorcycles in the same manner as automobiles, but designed with robust braking and handling characteristics for its class.
Active Safety Features:
Dual front disc brakes with 4-piston calipers, single rear disc brake with 4-piston caliper, often available with optional ABS (Anti-lock Braking System).
Passive Safety Features:
Heavy-duty frame construction, integrated lighting, prominent rider visibility.
Front Brake Spec:
Dual 32 mm, 4-piston, fixed front brake calipers with 11.8 in. (300 mm) front brake rotors.
Rear Brake Spec:
Single 32 mm, 4-piston, floating rear brake caliper with 11.8 in. (300 mm) rear brake rotor.
Infotainment System:
Basic audio system (AM/FM/WB) with fairing-mounted speakers. Often includes cruise control integration. May have provision for aftermarket iPod/MP3 connectivity.
Driver Assistance Features:
Optional ABS (Anti-lock Braking System).
Connectivity Features:
Limited by modern automotive standards. Focus is on rider ergonomics and basic audio control.
Instrument Cluster:
Analog speedometer and tachometer, fuel gauge, voltmeter, oil pressure gauge, and indicator lights integrated into the tank console and fairing.
Initial Service:
First service recommended at 1,000 miles (1,600 km).
Subsequent Service Intervals:
Every 5,000 miles (8,000 km) or annually, whichever comes first, for most routine checks and fluid changes. More in-depth services are scheduled at higher mileage intervals. (Refer to manual for precise schedule).
Tire Pressure Recommendations:
Front: 36 PSI (2.5 bar), Rear: 40 PSI (2.8 bar) - always check manual for exact specs for loaded conditions.
Engine Oil Spec:
SAE 20W-50 Synthetic Motorcycle Oil (Harley-Davidson SYN3 recommended).
Primary Chain Case Fluid Spec:
SAE 50 Transmission Oil (Harley-Davidson Formula+ recommended).
Transmission Fluid Spec:
Harley-Davidson proved gear oil or equivalent SAE 85W-140 gear oil.
Brake Fluid Spec:
DOT 4 recommended.
Coolant Spec:
N/A (Air-cooled engine)
Known Issues:
Potential for primary chain tensioner wear (especially earlier Twin Cam models, though improved in later years), starter clutch issues, and occasional electrical gremlins. The manual will detail inspection and replacement procedures for common wear items.
Oil Filter Part Number:
Likely 63796-77A or similar Harley-Davidson oil filter (verify in manual).
Air Filter Part Number:
Varies by specific configuration, but typically Harley-Davidson part numbers beginning with 29000 series or similar (verify in manual).
Brand Heritage:
Harley-Davidson, founded in 1903, boasts over a century of motorcycle manufacturing, known for its iconic V-twin engines, distinctive styling, and strong association with American culture and freedom.
Model Evolution:
The Road King line, introduced in 1994, evolved from earlier touring models, emphasizing a retro aesthetic with modern performance. It has consistently offered a comfortable, large-displacement touring platform.
Production Location:
United States (various Harley-Davidson assembly plants)
Production Years For Twin Cam 96:
2007-2011 (for the Twin Cam 96 engine platform, adapted across various models including FLHR).