Harley Davidson FLSTS Heritage Springer ST 03 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLSTS Heritage Springer ST Model Variant: Heritage Springer Softail Year: 2003 Codes Chassis Code: FLSTS Engine Family Code: Evolution (Big Twin) 👋 Introduction...

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Taper: Motorcycle

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UGS: 441842

Mots clés: 2003 FLSTS Heritage Springer ST Harley Davidson Misc Motorcycle Motorcycles

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

FLSTS Heritage Springer ST

Model Variant:

Heritage Springer Softail

Year:

Codes

Chassis Code:

FLSTS

Engine Family Code:

Evolution (Big Twin)

👋 Introduction

Market Position

Classification:

Premium cruiser, retro-styled motorcycle known for its distinctive Springer front fork.

Competitive Analysis

Competitors:

Other Harley-Davidson Softail models, Indian Chief models, American V-twin cruisers from various manufacturers.

Key Features

Styling:

Classic retro styling with a vintage look and feel.

Front Suspension:

Iconic Harley-Davidson Springer front fork with external coil springs.

Engine:

Harley-Davidson Evolution V-twin engine, known for its torque and distinctive sound.

Rider Experience:

Comfortable, relaxed riding position suited for cruising.

📋 Manual Details

Coverage Areas

Engine:

Complete overhaul, tuning, diagnostics

Transmission:

Disassembly, assembly, maintenance

Drivetrain:

Belt drive, clutch, final drive

Suspension:

Front fork (including Springer fork), rear shocks, adjustments

Brakes:

Hydraulic system, calipers, master cylinders, bleeding

Electrical System:

Wiring diagrams, lighting, ignition, charging system, starting

Fuel System:

Carburetor (CV), fuel tank, fuel lines

Frame And Bodywork:

Chassis components, fenders, fuel tank, seat, saddlebags

Wheels And Tires:

Hubs, spokes, bearings, tire mounting

Controls:

Handlebars, levers, footboards, cables

Diagnostics:

Troubleshooting common issues, fault finding

Specifications:

Torque values, clearances, fluid types and capacities

Page Count

Estimated Pages:

Manual Type

Type:

Service Repair Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF (Digital)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Cylinder head, cylinders, pistons, crankshaft, camshafts, valve train, oil pump

Engine Management:

Ignition system (single fire, dual fire), timing, carburetor operation and adjustment

Transmission Mechanical:

Gearbox internal components, clutch assembly, primary drive chain adjustment

Braking System:

Front and rear brake calipers, master cylinders, hydraulic lines, disc pads, brake fluid specifications

Electrical System Components:

Battery, starter motor, alternator, regulator/rectifier, ignition coil, headlight, taillight, turn signals, horn, instrument cluster

Fuel Delivery:

Mikuni HSR42 carburetor (common upgrade/spec), Keihin CV carburetor (stock), fuel tank venting, petcock operation

Suspension Systems:

Telescopic front fork, coil springs, rear swingarm, adjustable shock absorbers

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, chain adjustment, tire pressure checks, brake inspection

Engine Overhaul:

Top-end rebuild (cylinders, pistons, heads), bottom-end rebuild (crankshaft, bearings), camshaft replacement

Transmission Repair:

Gearbox disassembly and reassembly, bearing replacement, clutch adjustment and replacement

Brake Service:

Brake pad replacement, caliper overhaul, master cylinder rebuild, brake bleeding procedures

Electrical Troubleshooting:

Wiring harness repair, component testing, diagnosing starting and charging issues, lighting circuit repair

Carburetor Tuning:

Idle speed adjustment, jetting, accelerator pump adjustment, idle mixture screw setting

Suspension Adjustment:

Front fork preload and damping adjustments, rear shock preload adjustments

Wheel And Tire Service:

Tire mounting and balancing, wheel bearing replacement, spoke tensioning

Frame And Chassis Maintenance:

Steering head bearing adjustment, swingarm bearing lubrication

Technical Depth

Depth:

Comprehensive from basic maintenance to full engine and transmission rebuilds, including detailed electrical diagnostics and component-level repair.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text content for quick information retrieval.

Print Quality

Quality:

High-resolution scans of original factory documentation, suitable for printing.

Binding Type

Type:

N/A (Digital PDF)

Paper Type

Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Type:

Air-cooled, 45-degree V-twin, Evolution engine

Displacement:

1450cc (88 cubic inches)

Bore X Stroke:

3.50 in. x 4.47 in. (88.9 mm x 113.5 mm)

Compression Ratio:

8.5:1

Valve Train:

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

Horsepower:

Approx. 60-70 HP (Manufacturer did not widely publish specific HP figures for this era)

Torque:

Approx. 75-85 ft-lbs @ 3200 RPM (Manufacturer did not widely publish specific Torque figures for this era)

Performance

Redline Rpm:

Approx. 5500 RPM (recommended)

Fuel System

Carburetor:

Keihin CV (Constant Velocity) 40mm carburetor (stock)

Fuel Capacity:

4.0 U.S. gallons (15.1 liters)

Oil System

Oil Type:

Harley-Davidson Genuine V-Twin 20W-50 or equivalent API CG-4 certified engine oil

Oil Capacity:

3.0 U.S. quarts (2.8 liters) with filter change

Oil Filter Part Number:

Harley-Davidson 63796-77 (or equivalent aftermarket)

🔧 Transmission

Standard

Type:

5-speed constant mesh, helical gears

Primary Drive:

Duplex chain, 34/46 ratio

Secondary Drive:

Belt drive, 32/65 ratio (30 mm belt)

Features

Clutch:

Wet, multi-plate

Transmission Oil Type:

Harley-Davidson Formula+ Transmission and Primary Chaincase Lubricant or equivalent

Transmission Oil Capacity:

24 U.S. fluid ounces (0.71 liters)

📐 Dimensions

Exterior

Length:

93.1 in. (2365 mm)

Width:

35.6 in. (904 mm)

Height:

54.7 in. (1390 mm)

Wheelbase:

64.4 in. (1636 mm)

Ground Clearance:

4.9 in. (124 mm)

Weights

Dry Weight:

668 lbs (303 kg)

Gross Vehicle Weight Rating:

1050 lbs (476 kg)

Payload Capacity:

382 lbs (173 kg)

Wheels And Tires

Front Tire Size:

MT90B16 72H

Rear Tire Size:

130/90B16 73H

Front Wheel Type:

Wire-spoke

Rear Wheel Type:

Wire-spoke

Wheelbase Bolt Pattern:

N/A (Stud mount)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles are not subject to the same standardized crash testing as automobiles)

Active Features

Braking:

Dual-piston caliper front brake, single-piston caliper rear brake.

Passive Features

Lighting:

Halogen headlight, LED taillight, front and rear turn signals.

Frame Construction:

Steel tubing frame for rigidity and durability.

💡 Technology Features

Infotainment

Audio System:

Optional factory or aftermarket radio/audio systems were available.

Driver Assistance

Features:

N/A (Motorcycle of this era did not feature electronic driver assistance systems like ABS or traction control as standard or widely available options).

🔧 Maintenance

Service Intervals

First Service:

1000 miles (1600 km) or 6 months

Subsequent Oil Changes:

Every 5000 miles (8000 km) or 12 months, whichever comes first.

Primary Chain Adjustment:

Every 5000 miles (8000 km)

Brake Fluid Flush:

Every 2 years

Spark Plug Replacement:

Every 10,000 miles (16,000 km)

Fluid Specifications

Engine Oil:

Harley-Davidson Genuine V-Twin 20W-50 or equivalent API CG-4 certified

Transmission Primary Oil:

Harley-Davidson Formula+ Transmission and Primary Chaincase Lubricant or equivalent

Brake Fluid:

DOT 4 hydraulic brake fluid

Known Issues

Cam Chain Tensioner:

Early Evolution engines had plastic cam chain tensioners that could wear prematurely, leading to potential engine damage. Many owners upgrade to hydraulic tensioners.

Carburetor Tuning:

CV carburetors can require periodic adjustments for optimal performance, especially with altitude or modifications.

Belt Drive Alignment:

Proper alignment of the rear belt drive is crucial to prevent premature wear on the belt and sprockets.

Springer Fork Maintenance:

Regular lubrication and inspection of the Springer fork's pivot points and springs are recommended.

📚 Vehicle History

Brand Heritage

Legacy:

Harley-Davidson, founded in 1903, has a long-standing reputation for American V-twin motorcycles, custom culture, and a powerful brand identity.

Model Evolution

Softail Platform:

The Softail platform, introduced in 1983, features hidden rear shock absorbers to mimic the appearance of a hardtail frame while providing rider comfort.

Heritage Softail Introduction:

The Heritage Softail series was introduced to evoke classic styling reminiscent of the pre-war era.

Springer Variant:

The 'Springer' designation refers to the distinctive Springer front fork, a design dating back to the early days of motorcycling, which was reintroduced by Harley-Davidson.

Production

Production Period:

The FLSTS Heritage Springer was produced from 1997 to 2003. The 2003 model year marked the final production year for this specific variant.

Key Changes 2003:

While specific major changes for the 2003 model are minor, this year represents the culmination of the Softail evolution and a significant model in Harley-Davidson's history.

🏆 Awards & Recognition

Recognitions

Model Recognition:

Recognized for its iconic styling and contribution to the retro cruiser segment. Often praised for its ride quality and comfortable touring capability.