Category:
Cruiser Motorcycle
Target Audience:
Harley-Davidson Softail FLHR Road King owners and independent motorcycle repair shops.
Competitors 2006:
Indian Chief, Victory Kingpin, Honda VTX1800, Yamaha Roadliner, Kawasaki Vulcan 2000.
Distinctive Features:
Classic cruiser styling, large displacement engine, comfortable touring ergonomics, iconic Harley-Davidson heritage.
Comprehensiveness:
Offers the most complete information available for maintaining, diagnosing, and repairing the 2006 FLHR Road King, empowering owners to perform their own work or understand professional service.
Primary Coverage:
Comprehensive Service, Maintenance, and Repair
Specific Systems:
Engine, Transmission, Drivetrain, Chassis, Electrical, Brakes, Suspension, Fuel System, Exhaust System, Cooling System, Bodywork, Controls, Instruments, and Accessories
Estimated Pages:
Over 600 pages
Type:
Official Factory Service Manual (likely a reproduction or authorized reprint)
Engine Mechanical:
Detailed disassembly, inspection, assembly, and adjustment procedures for the Twin Cam 96 engine (1584cc).
Fuel System:
EFI (Electronic Fuel Injection) system diagnosis, adjustment, and component replacement (throttle body, injectors, fuel pump, regulator).
Ignition System:
Ignition module, spark plugs, ignition coils, and related wiring diagnostics and service.
Transmission Drivetrain:
5-speed Cruise Drive transmission service, clutch operation, final drive belt inspection and tensioning.
Electrical System:
Complete wiring diagrams, component testing, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), battery maintenance, lighting, and accessory circuits.
Brakes:
Hydraulic brake system service, caliper overhaul, pad replacement, master cylinder service, brake fluid specifications and bleeding procedures.
Suspension Steering:
Front fork (Greaseless fork design common in FLHR) and rear shock absorber service, steering head bearing adjustment.
Chassis Frame:
Frame inspection, swingarm and pivot bearing service, wheel bearing replacement.
Bodywork Fittings:
Fairing removal and installation, saddlebag service, fuel tank mounting, seat adjustment.
Routine Maintenance:
Oil changes, filter replacement, air filter service, spark plug replacement, lubrication points, tire pressure checks, brake adjustments.
Troubleshooting:
Diagnostic flowcharts and procedures for common starting, running, and electrical issues.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, electrical system repairs.
Component Replacement:
Step-by-step instructions for replacing specific parts like the clutch, starter, alternator, fuel pump, etc.
Depth:
Comprehensive from basic owner maintenance to complete engine and transmission rebuilds, including detailed torque specifications and clearances.
Quality:
High-quality paper, clear diagrams and text (assumed for a professional reproduction).
Binding:
Professionally bound (e.g., perfect bound, spiral bound for lay-flat usability).
Paper:
Durable, semi-gloss paper suitable for workshop environments.
Engine Type:
Harley-Davidson Twin Cam 96 V-Twin
Displacement:
1584 cc (96 cubic inches)
Bore X Stroke:
3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)
Cooling System:
Air-cooled
Valve Train:
Overhead Valve (OHV), 2 valves per cylinder
Horsepower:
Approx. 65-70 HP (estimate based on typical Twin Cam 96 tuning)
Torque:
Approx. 90-95 ft-lbs @ 3000 RPM (estimate based on typical Twin Cam 96 tuning)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, 91 octane (R+M)/2 or higher recommended
Transmission Type:
Harley-Davidson Cruise Drive 5-speed constant mesh
Clutch Type:
Wet, multi-plate, diaphragm spring
Final Drive:
Belt drive, 32/66 tooth pulleys (ratio 2.06)
Gear Ratios:
1st: 2.93, 2nd: 2.07, 3rd: 1.54, 4th: 1.19, 5th: 0.93
Transmission Fluid:
Harley-Davidson recommended Syn3 or equivalent SAE 20W-50 transmission/primary lubricant.
Overall Length:
93.1 in. (2365 mm)
Overall Width:
36.0 in. (914 mm)
Overall Height:
54.9 in. (1394 mm)
Wheelbase:
63.5 in. (1613 mm)
Dry Weight:
Approx. 653 lbs. (296 kg)
Gross Vehicle Weight Rating:
Approx. 1050 lbs. (476 kg)
Fuel Capacity:
5.0 US gallons (18.9 L)
Front Tire Size:
130/70-18
Rear Tire Size:
140/75-17
Front Wheel:
18 x 3.50 inches (Cast Aluminum or Chrome Spoke options)
Rear Wheel:
17 x 4.50 inches (Cast Aluminum or Chrome Spoke options)
Safety Certifications:
Meets all applicable Federal Motor Vehicle Safety Standards (FMVSS) for motorcycles.
Braking System:
Dual 292mm front discs with 4-piston calipers, Single 292mm rear disc with 2-piston caliper.
Lighting:
Halogen headlamp, auxiliary passing lamps, integrated tail/stop/turn signals.
Ergonomics:
Comfortable riding position for long-distance touring.
Fairing:
Batwing fairing with windshield provides rider protection from elements.
Audio System:
Optional AM/FM/WB radio with CD player, often integrated into the fairing.
Cruise Control:
Typically standard on the Road King model for enhanced touring comfort.
ABS:
Anti-lock Braking System (ABS) was often an optional feature for this model year; the manual would cover its operation and diagnostics.
Diagnostics:
On-board diagnostics system (OBD-II related for EFI systems) with specific Harley-Davidson diagnostic codes.
First Service:
1,000 miles (1,600 km) or 6 months, whichever comes first (check oil, primary fluid, transmission fluid, belt tension, clutch, brakes, tire pressure).
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months for oil changes, filter replacement, and inspections.
Spark Plug Replacement:
Typically every 10,000-15,000 miles, but consult manual for specific Twin Cam 96 recommendations.
Engine Oil:
Harley-Davidson Genuine Motor Oil SAE 20W-50 or equivalent.
Engine Oil Capacity:
3.0 US quarts (2.8 L) with filter change.
Primary Chain Case Fluid:
Harley-Davidson Genuine Formula+ Transmission and Primary Chaincase Lubricant or equivalent SAE 90 hypoid gear oil.
Primary Chain Case Capacity:
2.7 US quarts (2.6 L).
Transmission Fluid:
Harley-Davidson Genuine Formula+ Transmission and Primary Chaincase Lubricant or equivalent SAE 90 hypoid gear oil.
Transmission Fluid Capacity:
3.0 US quarts (2.8 L).
Brake Fluid:
DOT 4 hydraulic fluid.
Common Wear Items:
Clutch plates, belt drive, front fork seals, brake pads.
Twin Cam Considerations:
Early Twin Cam engines (though less prevalent by 2006) sometimes had issues with cam chain tensioners. This manual would detail inspection and replacement procedures.
Efi Diagnostics:
The manual is crucial for diagnosing any EFI-related fault codes or performance issues.
Founding:
Founded in 1903 in Milwaukee, Wisconsin.
Legacy:
Iconic American motorcycle manufacturer known for its V-twin engines and distinctive styling.
Softail Introduction:
The Softail frame concept, mimicking a hardtail look with hidden suspension, was introduced by custom builder Bill Davis in the early 1970s and later acquired by Harley-Davidson.
Road King Introduction:
The Road King model was introduced in 1994, blending classic styling with modern touring capabilities.
Twin Cam Era:
The 2006 model year is part of the Twin Cam engine era, which began in 1999, replacing the Evolution Big Twin.
Manufacturing Location:
Milwaukee, Wisconsin, USA (and other Harley-Davidson facilities).
