Harley Davidson FLSTFI Fat Boy 2001 Workshop Service Repair Manual

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This manual covers the FLSTFI Fat Boy, a cruiser motorcycle produced in 2001. Renowned for its iconic design featuring a wide front tire, ample chrome accents, and a distinctive teardrop...

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Taper: Motorcycle

Distributeur:

UGS: 64426

Mots clés: 2001 FLSTFI Fat Boy Harley Davidson Misc Motorcycle Motorcycles

Variantes de produits

Description

This manual covers the FLSTFI Fat Boy, a cruiser motorcycle produced in 2001. Renowned for its iconic design featuring a wide front tire, ample chrome accents, and a distinctive teardrop fuel tank, the FLSTFI is powered by the robust Twin Cam 88B V-twin engine. This model represents a significant part of heritage, celebrated for its substantial presence and classic cruiser aesthetics, making it a desirable choice for riders seeking a blend of style and performance. This comprehensive workshop service repair manual in English provides complete factory service and repair information for the FLSTFI Fat Boy. It details procedures for engine overhaul, transmission service, fuel and ignition systems, chassis, suspension, brakes, and the electrical system. The manual includes routine maintenance tasks, diagnostic troubleshooting, and technical specifications, making it an essential resource for owners and technicians aiming to maintain, repair, and optimize the performance and longevity of their motorcycle.

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

FLSTFI Fat Boy

Year:

Market Segment:

Cruiser Motorcycle

👋 Introduction

Market Position

Positioning:

Iconic cruiser motorcycle, known for its distinctive styling and powerful V-twin engine.

Competitive Analysis

Competitors 2001:

Indian Chief, Yamaha Road Star, Honda Shadow, Kawasaki Vulcan

Key Features

Design Elements:

Wide front tire, chrome accents, teardrop fuel tank, swept-back handlebars.

Engine Type:

Harley-Davidson Twin Cam 88B V-twin engine.

📋 Manual Details

Coverage Areas

General Coverage:

Complete Factory Service & Repair

Page Count

Estimated Pages:

Hundreds (downloadable format implies extensive detail)

Manual Type

Type:

Workshop Service Repair Manual

Language

Primary Language:

English

Format

Download Format:

Digital Download (PDF implied)

📖 Manual Coverage

Systems Covered

Engine:

Twin Cam 88B (including teardown, assembly, diagnosis, tuning)

Fuel System:

Carburetion (Keihin CV type), Fuel Pump, Fuel Tank, Fuel Lines

Ignition System:

Electronic Ignition, Spark Plugs, Ignition Coils

Transmission:

5-Speed Cruise Drive (teardown, assembly, troubleshooting, lubrication)

Drivetrain:

Primary Drive, Belt Drive, Clutch Operation and Service

Chassis Frame:

Frame Inspection, Fork Components, Swingarm, Suspension

Wheel Suspension Steering:

Front Fork (Teardown, Seals, Oil), Rear Shocks, Wheel Bearings, Steering Head Bearings

Brakes:

Front and Rear Hydraulic Brakes, Caliper Service, Master Cylinder, Brake Lines, Bleeding Procedures

Electrical System:

Battery, Charging System (Stator, Regulator/Rectifier), Starting System (Starter Motor, Solenoid), Lighting, Gauges, Horn, Wiring Diagrams

Bodywork Fittings:

Fenders, Fuel Tank, Seat, Handlebars, Control Levers, Mirrors, Footpegs, Exhaust System

Diagnostics Troubleshooting:

System-specific diagnostic flowcharts and common issue resolutions

Procedures Included

Routine Maintenance:

Oil Changes, Filter Replacements, Spark Plug Service, Chain/Belt Adjustment, Brake Pad Replacement, Air Filter Cleaning/Replacement

Engine Overhaul:

Complete engine disassembly, inspection, part replacement, and reassembly

Transmission Service:

Gearbox disassembly, inspection, bearing replacement, clutch adjustment

Suspension Service:

Front fork seal replacement, fork oil changes, rear shock absorber inspection/replacement

Brake System Service:

Brake caliper overhaul, master cylinder service, brake bleeding procedures

Electrical Diagnostics:

Wiring harness troubleshooting, component testing, charging system analysis

Fuel System Cleaning:

Carburetor cleaning and adjustment, fuel line inspection

Wheel Tire Service:

Wheel bearing replacement, tire mounting/balancing, spoke tension adjustment (if applicable)

Steering Head Service:

Steering head bearing adjustment and replacement

Technical Depth

Depth:

Comprehensive (suitable for professional technicians and advanced DIY mechanics)

Detail Level:

Detailed torque specifications, tolerances, diagnostic procedures, and step-by-step instructions with illustrations

📊 Manual Specifications

File Format

Format:

PDF (Downloadable)

Print Quality

Readability:

High-resolution text and diagrams optimized for printing

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Harley-Davidson Twin Cam 88B

Engine Configuration:

45-degree V-twin

Displacement:

1450 cc (88 cubic inches)

Bore X Stroke:

3.75 in x 4.00 in (95.25 mm x 101.6 mm)

Compression Ratio:

8.9:1

Valve Train:

Overhead Valves (OHV), 2 valves per cylinder

Performance

Horsepower Estimate:

Approximately 60-65 HP (at crank, manufacturer figures vary)

Torque Estimate:

Approximately 75-80 lb-ft (at crank, manufacturer figures vary)

Fuel System

Carburetor Type:

Keihin CV (Constant Velocity) 40mm

Fuel Type:

Unleaded Gasoline, Minimum 87 Octane

Fluid Specifications

Engine Oil Type:

Harley-Davidson 20W-50 or equivalent (meeting Harley-Davidson specification)

Engine Oil Capacity:

3.0 US quarts (2.8 liters) with filter change

Primary Chain Case Oil Type:

Harley-Davidson Primary Chain Lubricant or equivalent

Primary Chain Case Oil Capacity:

1 US quart (0.95 liters)

🔧 Transmission

Standard

Transmission Type:

5-Speed Constant Mesh

Optional

Optional Transmissions:

N/A for this model year

Features

Drive Type:

Belt Drive (Rear)

Clutch Type:

Wet, Multi-plate

Fluid Specifications

Transmission Oil Type:

Harley-Davidson Transmission and Primary Chain Case Lubricant or equivalent

Transmission Oil Capacity:

24 US fluid ounces (710 ml)

📐 Dimensions

Exterior

Overall Length:

Approximately 93.9 in (2385 mm)

Wheelbase:

63.5 in (1613 mm)

Seat Height:

26.2 in (665 mm)

Ground Clearance:

4.7 in (119 mm)

Weights

Dry Weight:

Approximately 657 lbs (298 kg)

Gross Vehicle Weight Rating Gvwr:

Not specified, but typically around 1000 lbs for cruiser motorcycles

Fuel Capacity

Fuel Tank Capacity:

4.0 US gallons (15.1 liters)

Wheel Tire

Front Tire Size:

130/90B16 67H

Rear Tire Size:

150/80B16 77H

Front Wheel Type:

Cast Aluminum Disc

Rear Wheel Type:

Cast Aluminum Disc

Wheelbase Measurement Unit:

Inches

🛡️ Safety Features

Ratings

Safety Ratings:

Motorcycle safety is generally based on design, braking, and handling rather than standardized crash test ratings like cars.

Active Features

Braking System:

Dual disc front brakes, single disc rear brake with hydraulic actuation.

Passive Features

Lighting:

Headlight, Taillight, Turn Signals, Brake Lights.

💡 Technology Features

Infotainment

Infotainment System:

Basic analogue instrumentation (speedometer, tachometer, fuel gauge, oil pressure light). No integrated infotainment system in the modern sense.

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Options:

Lighting Technology

Headlight Type:

Halogen

🔧 Maintenance

Service Intervals

First Service:

Typically 1,000 miles (1,600 km) or 6 months

Subsequent Services:

Every 5,000 miles (8,000 km) or 12 months for regular maintenance (oil, filter, inspection).

Major Service Intervals:

Refer to manual for specific intervals for transmission fluid, brake fluid, and internal engine component checks.

Fluid Specifications

Brake Fluid Type:

DOT 5 Silicone Fluid (check manual for exact specification and replacement interval)

Fork Oil Type:

Harley-Davidson Spectro HD fork oil or equivalent (viscosity typically 10W, check manual for precise specification)

Known Issues

Common Wear Items:

Clutch friction plates, brake pads, tires, fork seals, primary drive belt, wheel bearings.

Potential Problems 2001:

While generally robust, common areas for inspection and potential maintenance include the charging system (stator/regulator), fuel line integrity, and carburetor tuning for optimal performance.

📚 Vehicle History

Brand Heritage

Brand Legacy:

Harley-Davidson boasts a long and storied history in motorcycle manufacturing, dating back to 1903, with a focus on creating iconic V-twin engines and distinctive cruiser styling.

Model Evolution

Fat Boy Introduction:

The Fat Boy model was introduced in 1990 and quickly became a flagship model, known for its retro-futuristic styling and substantial presence.

Twin Cam Introduction:

The Twin Cam 88 engine, which powers this 2001 model, was introduced in 1999, replacing the Evolution (Evo) engine and offering increased displacement and power.

Production

Manufacturing Location:

United States (primarily York, Pennsylvania)

Flstfi Specifics:

The 'FI' in FLSTFI denotes Fuel Injection, however, the 2001 model year FLSTFI Fat Boy typically utilized a carburetor. This manual likely covers the carbureted version common for this year.

🏆 Awards & Recognition

Recognitions

Model Recognition:

The Fat Boy has consistently been recognized as a popular and stylish cruiser, often associated with pop culture (e.g., 'Terminator 2') which boosted its desirability.