🏷️ Basic Information

Make:

Harley-Davidson

Model:

Road King TLE

Model Variant:

TLE

Applicable Model Years:

2000, 2001, 2002, 2003, 2004, 2005, 2006

👋 Introduction

Segment:

Full-size, traditional American touring motorcycle.

Target Audience:

Harley-Davidson owners seeking to perform their own maintenance and repairs, customizers, and professional mechanics.

Competitors:

Other large-displacement V-twin cruisers and touring motorcycles from manufacturers like Indian, and sometimes premium Japanese offerings.

Tle Distinction:

TLE trim often denoted specific features or package options like premium paint, upgraded suspension, or additional accessories not standard on the base Road King.

Touring Comfort:

Designed for long-distance riding, featuring comfortable ergonomics, ample luggage capacity (saddlebags), and wind protection (often via a detachable windshield or batwing fairing).

📋 Manual Details

Primary Coverage:

Complete Workshop Service Repair

Estimated Page Count:

Extensive (Typically 500+ pages for full workshop manuals)

Type:

Workshop Service Repair Manual

Language:

English

Format:

Downloadable (Digital)

📖 Manual Coverage

Engine:

Twin Cam 88, Twin Cam 96 (if applicable in later years of range), engine disassembly, assembly, diagnosis, tuning.

Fuel System:

Carburetion (Keihin CV) and Fuel Injection (EFI - Delphi), fuel pump, fuel filter, fuel tank, lines, diagnosis.

Transmission:

5-speed Cruise Drive (if applicable for later years), clutch, gearbox, primary drive, final drive, diagnosis, overhaul.

Electrical System:

Ignition system, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlight, taillight, turn signals), instruments, wiring diagrams, diagnostic procedures.

Brakes:

Front and rear brake systems, hydraulic lines, master cylinders, calipers, pads, rotors, bleeding procedures, ABS (if equipped on TLE).

Suspension:

Front fork (telescopic), rear shock absorbers, linkages, fork oil specifications, seal replacement, adjustments.

Chassis And Frame:

Frame inspection, steering head bearing, swingarm, wheel bearings, alignment.

Bodywork And Trim:

Fairings, saddlebags, fenders, seat, fuel tank, handlebars, controls, disassembly, reassembly.

Diagnostics:

Troubleshooting charts, fault code interpretation (for EFI models), diagnostic procedures for all major systems.

Routine Maintenance:

Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, lubrication points, chain adjustment (if applicable for earlier models or specific variants).

Engine Repair:

Top-end rebuild (cylinders, pistons, heads), bottom-end rebuild (crankshaft, connecting rods, bearings), valve adjustments, timing procedures.

Transmission Overhaul:

Gearbox disassembly, inspection of gears, synchros, bearings, clutch pack replacement, primary drive maintenance.

Brake Service:

Brake pad replacement, caliper service, master cylinder rebuilding, brake line replacement, bleeding.

Electrical Troubleshooting:

Wiring diagram interpretation, component testing (relays, switches, sensors), battery testing, charging system diagnosis.

Suspension Service:

Fork seal replacement, fork oil change, shock absorber servicing, steering head bearing adjustment/replacement.

Efi System Diagnosis:

Fuel injector cleaning and testing, sensor testing (MAP, TPS, Crankshaft Position), ECM diagnosis, throttle body service.

Depth:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics.

Diagnostics Focus:

In-depth troubleshooting guides, fault code interpretation, component testing procedures.

Special Tools:

Identification and usage instructions for specialized Harley-Davidson tools required for various procedures.

📊 Manual Specifications

Digital Format:

Likely PDF, optimized for digital viewing and printing. Searchable text is a common feature of quality digital manuals.

Print Readability:

Designed for clarity with diagrams and text, suitable for printing individual pages or sections.

Binding For Print:

N/A (Digital Format), but if printed, expect a professional binding like spiral or perfect binding for workshop use.

Paper Quality For Print:

N/A (Digital Format), but OEM manuals typically use durable, coated paper stock.

⚙️ Engine Specifications

Engine Type:

Harley-Davidson Twin Cam 88 V-twin (primarily for the earlier years in this range).

Displacement:

88 cubic inches (approx. 1450cc)

Cooling:

Air-cooled

Valvetrain:

Overhead valves (OHV), 2 valves per cylinder, pushrod actuated.

Horsepower Estimate:

Approximately 65-75 HP (varies slightly by year and configuration).

Torque Estimate:

Approximately 85-95 lb-ft at 3000-3500 RPM.

Fuel Delivery:

Carburetor (Keihin CV) for earlier models, Electronic Fuel Injection (EFI - Delphi) for later models within the range.

Fuel Type:

Unleaded gasoline, minimum 87 octane recommended.

🔧 Transmission

Transmission Type:

5-speed constant mesh manual transmission.

Primary Drive:

Patented HD Ball & Ramp Clutch and 34T/46T (48P) primary drive sprocket.

Final Drive:

Belt drive (132-tooth, 1" width).

Clutch Type:

Wet multi-plate, diaphragm spring clutch.

📐 Dimensions

Length:

Approx. 94.5 inches (2400 mm)

Width:

Approx. 38 inches (965 mm)

Height:

Approx. 57.5 inches (1460 mm) (seat height varies)

Dry Weight:

Approx. 700 lbs (318 kg)

Wet Weight:

Approx. 750-770 lbs (340-350 kg)

Gross Vehicle Weight Rating:

Not typically specified, but rider and cargo weight limits are important.

Saddlebag Capacity:

Substantial, designed for touring luggage. Specific volume typically listed in owner's manual.

🛡️ Safety Features

Crash Test Results:

Motorcycles are not typically subjected to standardized crash testing in the same manner as automobiles. Safety relies on rider skill and vehicle design.

Braking System:

Dual 300mm disc brakes front, single 300mm disc brake rear. ABS optional on certain TLE models.

Lighting:

Halogen headlight, LED taillight/brake light, incandescent turn signals.

Chassis Stability:

Robust steel frame and balanced geometry contribute to stability.

Engine Braking:

V-twin engine design provides significant engine braking.

💡 Technology Features

Audio System:

Many Road King models of this era featured an AM/FM/Cassette/CD stereo system integrated into the fairing or handlebars, often with CB and intercom capabilities on touring versions.

Display:

Analog gauges for speedometer, tachometer, fuel, voltage, and oil pressure.

ABS:

Anti-lock Braking System (ABS) was an option on some TLE models, offering enhanced braking control.

Cruise Control:

Often equipped with electronic cruise control for highway comfort.

🔧 Maintenance

First Service:

Typically 1,000 miles (1600 km) or 6 months, whichever comes first. Includes oil change, filter, primary check, etc.

Subsequent Services:

Generally every 5,000 miles (8000 km) or 12 months for regular service, with more detailed inspections at higher mileages. Always refer to specific manual.

Engine Oil:

Harley-Davidson SYN3 (fully synthetic) or equivalent SAE 20W-50 motorcycle oil meeting Harley-Davidson P/N 99824-02 (or manufacturer's current spec). Capacity: 4 US quarts (3.8 L) with filter.

Primary Chain Case Oil:

Harley-Davidson primary fluid (Formula+ Transmission and Primary Chain Lubricant) or Syn3. Capacity: 2.8 US quarts (2.6 L).

Transmission Oil:

Harley-Davidson SYN3 or Formula+. Capacity: 0.95 US quarts (0.9 L).

Brake Fluid:

DOT 4 hydraulic fluid (refer to manual for specific Harley-Davidson P/N if used).

Fork Oil:

Harley-Davidson Type E (5W) or Type B (10W) fork oil, depending on desired damping characteristics. Specific quantity per fork leg.

Twin Cam 88 Early Issues:

Potential for oil leaks around primary cover and rocker boxes, cam chain tensioner wear (especially earlier versions), some cases of crank runout.

Efi System Considerations:

Need for occasional idle air control (IAC) cleaning, fuel injector maintenance, and ensuring proper battery voltage for sensor operation.

Electrical Connections:

Importance of ensuring all electrical connectors are clean and tight, especially on high-vibration vehicles.

📚 Vehicle History

Manufacturer:

Harley-Davidson Motor Company, Milwaukee, Wisconsin, USA.

Iconic Status:

Harley-Davidson is a highly iconic American brand with a long history in motorcycle manufacturing.

Road King Lineage:

The Road King line has been a staple of Harley-Davidson's cruiser/touring segment, evolving from earlier FL models. The TLE typically represented a higher-spec version.

Twin Cam Introduction:

The Twin Cam engine platform was introduced for the 1999 model year, replacing the Evolution (Evo) engine, and formed the basis for this era of Road Kings.

Production Period:

2000-2006 for this specific manual's coverage.

Manufacturing Location:

Primarily York, Pennsylvania, USA, and Milwaukee, Wisconsin, USA.

🏆 Awards & Recognition

Market Reputation:

Harley-Davidson motorcycles, including the Road King, are consistently recognized for their iconic styling, V-twin character, and strong owner loyalty.