Model Variants:
FLSTC Heritage Softail Classic, FLSTCI Heritage Softail Classic, FLSTF Fat Boy, FLSTFI Fat Boy, FLSTS Heritage Springer, FXST Softail Standard, FXSTI Softail Standard, FXSTB Night Train, FXSTBI Night Train, FXSTD Softail Deuce, FXSTDI Softail Deuce, FXSTS Springer Softail
Chassis Codes:
FLST, FXST
Target Audience:
Harley-Davidson Softail owners, independent repair shops, DIY enthusiasts.
Value Proposition:
Provides a comprehensive, digital resource for maintaining and repairing a wide range of 2002 Harley-Davidson Softail models, including detailed electrical diagnostics, often surpassing factory manual scope for DIY accessibility.
Features:
Extensive page count, inclusion of electrical diagnostics manual, detailed part diagrams, torque specifications, and a searchable PDF format.
Support:
Free replacement of the manual if lost.
Powertrain:
Engine (complete teardown and rebuild), Transmission, Drive Train (primary, secondary), Clutch
Chassis And Suspension:
Frame, Forks, Swingarm, Suspension (front and rear), Wheels, Tires, Brakes (front and rear), Steering
Electrical And Ignition:
Ignition System, Starting System, Charging System, Lighting (front, rear), Electrical Diagnostics, Schematics, Fuses, Relays, Battery
Body And Controls:
Bodywork, Fenders, Seat, Handlebars, Controls, Cables, Plastics
Fuel And Exhaust:
Fuel System (including EFI and Carburetor details), Carburetor Adjustments (pilot jet, slow jet, main jet, mixture screw), Fuel Tank, Exhaust System
Maintenance:
Scheduled Maintenance, Fluid Changes (engine oil, transmission oil, primary oil, brake fluid, coolant), Filter Replacement, Lubrication
Diagnostics And Troubleshooting:
Troubleshooting Guides, Error Codes, No Spark Issues, Performance Problems, System Diagnostics
Repair And Rebuild:
Complete Teardown and Rebuild Procedures, Component Overhaul, Installation Procedures
Adjustments:
Carburetor adjustments, Valve Clearance adjustments, Throttle Cable adjustments, Clutch adjustments
Depth:
Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including detailed electrical diagnostics and schematics.
Visual Aids:
Includes Pictures and Part Diagrams
Navigability:
Searchable and Clickable Chapters
Engine Type:
V-Twin, Air-Cooled OHV (Evolution Engine)
Displacement:
Typically 1450cc (88 cubic inches) for 2002 Softail models.
Horsepower:
Approx. 60-70 HP (varies slightly by model and tuning).
Torque:
Approx. 75-85 ft-lbs (varies slightly by model and tuning).
Fuel Delivery:
Carburetor (Keihin CV) or Electronic Fuel Injection (EFI).
Ignition System:
Electronic Ignition (CDI or similar).
Oil Type:
Refer to manual for specific viscosity and API rating (e.g., SAE 20W-50 motorcycle-specific oil recommended by many owners/shops).
Camshaft Type:
Pushrod actuated overhead valves.
Cooling System:
Air-Cooled.
Compression Ratio:
Typically around 8.8:1 to 9.1:1, depending on specific model and tuning.
Type:
5-speed Manual Constant Mesh
Drive Type:
Belt Drive (primary), Belt Drive (secondary).
Clutch Type:
Wet, multi-plate
Transmission Oil:
Refer to manual for specific viscosity (e.g., SAE 80W-90 gear oil or Harley-Davidson transmission fluid).
Transmission Oil Capacity:
Approx. 1.0-1.2 Quarts (refer to manual for exact capacity).
Wheelbase:
Varies by model, generally around 64-66 inches.
Dry Weight:
Varies by model, typically 590-640 lbs.
Wet Weight:
Varies by model, typically 610-660 lbs.
Lighting:
Headlight, Taillight, Turn Signals, Brake Light.
Brakes:
Disc Brakes (Front and Rear) with hydraulic actuation.
Tire Safety:
Tubeless Tires (typically) with specifications for pressure as outlined in the manual.
Audio System:
Factory base models typically do not include an integrated infotainment system. Aftermarket accessories are common.
ABS:
Anti-lock Braking System (ABS) was an optional feature on some 2002 Softail models. Manual will cover its diagnostics if equipped.
Diagnostics:
Advanced electrical diagnostic capabilities are included, with a dedicated section for troubleshooting electrical systems and components.
Engine Oil Change:
Typically every 2,500 to 5,000 miles or annually, whichever comes first (refer to manual for exact mileage and time intervals).
Transmission Oil Change:
Typically every 5,000 to 10,000 miles or annually.
Primary Chain Case Oil Change:
Typically every 5,000 to 10,000 miles or annually.
Spark Plug Replacement:
Refer to manual, often around 10,000-15,000 miles.
Air Filter Cleaning/Replacement:
Depends on riding conditions, typically inspected every 5,000 miles, cleaned or replaced as needed.
Engine Oil Viscosity:
SAE 20W-50 is commonly recommended for air-cooled V-twins, but verify specific needs in the manual.
Brake Fluid Type:
DOT 4 (refer to manual for confirmation and specific brands).
Common Wear Items:
Clutch plates, primary chain tensioner, wheel bearings, voltage regulator, ignition coil.
Efi Troubleshooting:
Potential for fuel injector clogging or fuel pump issues on EFI models; electrical diagnostic tools and schematics are crucial.
Carburetor Tuning:
CV carburetor may require adjustment of pilot jets, main jets, and mixture screws for optimal performance, especially at different altitudes or after modifications.
Heritage:
Harley-Davidson, a legendary American motorcycle manufacturer with a rich history dating back to 1903, known for its iconic V-twin engines and distinctive styling.
Softail Line:
The Softail platform, introduced in 1984, is characterized by its hidden rear suspension, creating a hardtail appearance. The 2002 models represent a refined iteration of this design, incorporating fuel injection on some variants.
Manufacturing Location:
United States (typically Milwaukee, Wisconsin or Kansas City, Missouri for this era).
