Positioning:
The Harley-Davidson Fat Boy has long been an iconic cruiser, known for its distinctive styling and V-twin performance. The 15th Anniversary Edition celebrates this legacy. This manual serves owners and independent repair shops needing detailed technical guidance.
Competition:
Competes with other large-displacement cruisers of its era, emphasizing style, comfort, and the Harley-Davidson riding experience. This manual provides the essential technical backbone for maintaining and repairing these sought-after machines.
Anniversary Features:
The 15th Anniversary Edition is characterized by specific badging, color schemes, and often cosmetic enhancements. This manual covers the standard Fat Boy platform applicable to these special editions.
Value Proposition:
Crucial for ensuring the longevity and optimal performance of the Fat Boy, offering substantial cost savings over dealership-specific repairs and empowering enthusiasts with the knowledge for DIY maintenance.
Engine:
Disassembly, assembly, tuning, diagnostics, common issues, specifications (Twin Cam 88B, carbureted and fuel-injected variants)
Transmission:
5-speed Cruise Drive: Removal, installation, internal component service, fluid specifications, troubleshooting
Clutch:
Operation, adjustment, replacement of friction plates and components
Electrical System:
Wiring diagrams, component testing, charging system, ignition system, lighting, diagnostics for EFI and carbureted models
Fuel System:
Carburetor (CV 40) service, fuel injection (EFI) system diagnostics, fuel pump, fuel lines
Suspension:
Front fork (Show Chrome) overhaul, rear shock absorber service, adjustments
Brakes:
Front and rear brake system service, hydraulic lines, calipers, master cylinders, bleeding procedures, specifications
Frame And Bodywork:
Component removal and installation, fairings, fenders, fuel tank, seat, controls
Wheels And Tires:
Wheel bearing service, tire installation and balancing, specifications
Diagnostics:
Troubleshooting charts, fault code interpretation (for EFI models)
Maintenance:
Regular scheduled maintenance, fluid changes, filter replacements, lubrication points, inspections
Repair:
Step-by-step instructions for component repair and replacement across all major systems
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and complex issues
Rebuilds:
Detailed instructions for complete engine and transmission rebuilds
Adjustments:
Carburetor tuning, clutch and brake lever adjustments, suspension settings
Depth:
Comprehensive, covering everything from basic fluid changes to complete engine and electrical system overhauls. Includes detailed torque specifications and diagnostic procedures.
Diagnostic Coverage:
Detailed diagnostic flowcharts and fault code interpretation for EFI models, crucial for accurate troubleshooting without relying solely on specialized electronics.
File Type:
PDF (Portable Document Format)
Searchability:
Typically searchable text for quick information retrieval
Print Quality:
High resolution, suitable for printing individual pages or the entire manual
Binding:
N/A (Digital PDF Download)
Paper Type:
N/A (Digital PDF Download)
Scope:
Comprehensive workshop manual, covering all aspects of repair, maintenance, and diagnostics. Not a condensed version.
Engine Type:
V-Twin, Air-Cooled
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.0 in. (95.25 mm x 101.6 mm)
Valve Train:
Overhead Valves (OHV), 2 valves per cylinder
Carburetion:
Keihin CV 40 (Constant Velocity) for carbureted models
Fuel Injection:
Electronic Sequential Port Fuel Injection (ESPFI) for EFI models
Horsepower:
Approx. 65-70 HP (at crankshaft, estimated)
Torque:
Approx. 86-90 lb-ft @ 3200 RPM (at crankshaft, estimated)
Peak Rpm:
Recommended maximum operating RPM typically around 5500 RPM (refer to manual for exact limit)
Fuel Capacity:
4.0 US gallons (15.1 L)
Crash Test Ratings:
N/A (Motorcycles are not subject to the same crash test ratings as passenger cars)
Braking System:
Dual-action, four-piston front brake caliper with 292mm disc; Dual-action, two-piston rear brake caliper with 292mm disc.
Lighting:
Halogen headlight, LED tail lamp, amber lens front and rear turn signals.
Frame:
Mild steel, tubular frame with integral steering head; rectangular downtubes.
Passenger Footpegs:
Standard
Audio System:
Factory-installed audio systems were optional and varied. Many models featured basic AM/FM radio with cassette or CD players, and speaker integration.
ABS:
Anti-lock Braking System (ABS) was an optional feature on certain models within this range, not standard.
Diagnostic Tools:
For EFI models, dealer-level diagnostic tools (e.g., Harley-Davidson Digital Technician) are required for advanced diagnostics and module programming. This manual provides the theoretical knowledge and troubleshooting steps for these systems.
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months
Engine Oil:
Harley-Davidson 20W50 SYN3 or equivalent API CI-4 rated motorcycle oil (refer to manual for exact capacity: approx. 4 US quarts / 3.8 L with filter change)
Primary Chain Case Oil:
Harley-Davidson primary fluid or equivalent SAE 75W-90 (API GL-4/GL-5) gear oil (refer to manual for capacity: approx. 2.5 US quarts / 2.4 L)
Transmission Oil:
Harley-Davidson Syn3 or equivalent API GL-5 rated gear oil (refer to manual for capacity: approx. 1 US quart / 0.95 L)
Brake Fluid:
DOT 4 hydraulic fluid
Coolant Type:
N/A (Air-Cooled Engine)
Drive Belt Tension:
1/4" - 3/8" (6 mm - 10 mm) deflection at midpoint
Spark Plugs:
Harley-Davidson specified spark plugs (e.g., NGK DPR6EA-9 or equivalent, verify via manual/parts catalog)
Engine Breather:
Potential for oil blow-by through the breather, especially with aggressive riding. Manual addresses system inspection and potential upgrades.
Clutch Adjustment:
Clutch lever play requires periodic adjustment. Manual details the procedure precisely.
Carburetor Tuning:
CV carburetor may require fine-tuning for optimal performance, especially at different altitudes. Manual provides detailed tuning steps.
Fuel Line Wear:
Older fuel lines can degrade. Manual provides part numbers and replacement instructions.
Heritage:
Harley-Davidson boasts a rich legacy dating back to 1903, renowned for its V-twin engines, custom culture influence, and unwavering brand loyalty.
Fat Boy Origin:
The original Fat Boy, introduced in 1990, was a radical departure with its fat tires, disc wheels, and streamlined styling, inspired by post-war 'kicker' models and the Harley-Davidson Hydra-Glide.
Twin Cam Introduction:
The 2000 model year marked the transition to the new Twin Cam 88B engine, offering increased displacement, power, and refinement over the Evolution engine.
15Th Anniversary Context:
The 15th Anniversary Edition commemorates a decade and a half of the Fat Boy's iconic presence in the Harley-Davidson lineup. Specific production numbers for this anniversary model are typically limited.
Model Awards:
While specific awards for the 2000-2005 Fat Boy 15th Anniversary Edition might not be widely cataloged, the Fat Boy model line has consistently received accolades for its design and cultural impact within the motorcycle industry.
Owner Satisfaction:
Generally high owner satisfaction, attributed to the iconic styling, comfortable ride, and the emotional connection associated with the Harley-Davidson brand. This manual directly supports maintaining that satisfaction.
