🏷️ Basic Information

Make:

Harley-Davidson

Model:

FXSTS Springer Softail

Year:

2002

Vin Prefix:

1HD1

👋 Introduction

Positioning:

The FXSTS Springer Softail was positioned as a premium, retro-styled cruiser offering a distinctive aesthetic with its iconic springer front fork and classic Softail design, appealing to riders seeking a nostalgic yet powerful V-twin experience.

Competitors:

Competed with other large-displacement cruiser motorcycles from brands like Indian, and custom-oriented offerings from other manufacturers. Its unique springer front end set it apart from more conventional cruiser designs.

Unique Features:

Distinctive chrome springer front fork, classic Softail rigid-look frame with hidden rear suspension, Harley-Davidson Evolution engine, custom styling cues.

Audience:

Riders who appreciate classic styling, custom looks, and the authentic Harley-Davidson riding experience. Also appeals to those who perform their own maintenance and seek in-depth technical guidance.

📋 Manual Details

Primary Coverage:

Complete service and repair for 2002 Harley-Davidson FXSTS Springer Softail

Engine Coverage:

Evolution Engine (Twin Cam 88 B)

Transmission Coverage:

5-Speed Cruise Drive Transmission

Chassis Coverage:

Springer Front End, Softail Frame, Suspension, Brakes, Wheels, Tires

Electrical Coverage:

Ignition, Lighting, Gauges, Battery, Charging System, Starting System, Accessories

Estimated Pages:

Approximately 600-800 pages (typical for this era's detailed manuals)

Type:

Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Systems:

Engine disassembly, assembly, top-end components (cylinders, pistons, heads, valves), bottom-end components (crankshaft, connecting rods, bearings), lubrication system, cooling system (air-cooled), fuel system (carburetor tuning and overhaul), ignition system (timing, spark plugs), exhaust system

Transmission Systems:

Clutch operation and adjustment, transmission case disassembly and reassembly, gear set inspection and replacement, shifting mechanism, lubrication

Chassis Systems:

Springer front end overhaul, fork leg maintenance, steering head bearing adjustment, swingarm and rear shock absorber servicing, wheel and tire servicing, brake system overhaul (front and rear calipers, master cylinders, brake lines), brake pad replacement, hydraulic system bleeding

Electrical Systems:

Wiring diagrams, battery maintenance and testing, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), ignition system (ignition module, coil), lighting system (headlight, tail light, turn signals), instrument cluster diagnostics and repair, switchgear troubleshooting, accessory installation wiring

Maintenance Procedures:

Routine maintenance checks (oil changes, filter replacements, chain adjustment), lubrication points, spark plug replacement, air filter service, battery charging, brake fluid flush

Diagnostic Procedures:

Troubleshooting common problems (starting issues, running problems, electrical faults), diagnostic charts, symptom-based troubleshooting guides

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair for all major systems, including engine rebuilds, transmission overhauls, brake caliper replacement, suspension servicing

Technical Specifications:

Torque specifications for all fasteners, clearances, adjustments, fluid capacities, electrical resistance values, diagnostic trouble codes (if applicable)

Depth:

Comprehensive from basic scheduled maintenance to complete engine and transmission rebuilds, including detailed electrical system troubleshooting and component-level diagnostics.

📊 Manual Specifications

Format:

PDF

Searchability:

Searchable text content for quick information retrieval.

Printability:

Printable pages for on-the-go reference.

Quality:

High-resolution scans ensuring clarity of diagrams and text.

Binding:

N/A (Digital PDF format)

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution, 45-degree V-twin, pushrod actuated overhead valves

Displacement:

1449 cc (88 cubic inches)

Bore X Stroke:

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

Compression Ratio:

8.8:1

Horsepower:

Approximately 65-70 HP (estimated, exact figures varied by tune)

Torque:

Approximately 78-85 ft-lbs @ 3000-3500 RPM (estimated)

Carburetor:

Keihin CV (Constant Velocity) 40mm

Fuel Type:

Unleaded gasoline, 87 octane minimum recommended

Ignition Type:

Electronic Ignition

Oil Capacity:

3.5 US quarts (3.3 liters) with filter change

Oil Type:

Harley-Davidson Genuine V-Twin 20W-50 or equivalent API SG or higher motorcycle oil

🔧 Transmission

Transmission Type:

5-Speed Cruise Drive

Clutch Type:

Wet, multi-plate

Primary Drive:

Double-row chain

Final Drive:

Belt drive, 32mm wide

Transmission Oil Capacity:

1.0 US quart (0.95 liters)

Transmission Oil Type:

Harley-Davidson Genuine Formula + Transmission/Primary Chaincase Lubricant or equivalent

📐 Dimensions

Length:

93.5 inches (2375 mm)

Width:

36.2 inches (919 mm)

Height:

47.0 inches (1194 mm)

Wheelbase:

64.0 inches (1626 mm)

Ground Clearance:

5.0 inches (127 mm)

Seat Height:

27.0 inches (686 mm) (unladen)

Dry Weight:

Approximately 655 lbs (297 kg)

Gross Vehicle Weight Rating:

Approximately 1085 lbs (492 kg)

Fuel Tank Capacity:

4.0 US gallons (15.1 liters)

Front Tire:

MT90B16

Rear Tire:

MU85B16

Front Wheel:

16-inch laced or cast aluminum

Rear Wheel:

16-inch laced or cast aluminum

Wheel Bolt Pattern:

N/A (Hub mounted)

🛡️ Safety Features

Safety Ratings:

Not typically rated by governmental bodies like NHTSA for motorcycles; relies on manufacturer design and rider responsibility.

Braking System:

Dual-piston caliper front and rear brakes with hydraulic actuation. Single 11.5-inch disc front and rear.

Lighting:

Halogen headlamp, tail lamp, brake lamp, front and rear turn signals.

Frame Construction:

Steel tube frame with traditional Softail swingarm design.

Suspension Design:

Harmonic-driven springer front fork and horizontally concealed rear shock absorbers contribute to ride comfort and stability.

💡 Technology Features

Infotainment System:

N/A (Basic analog instrumentation)

Instrumentation:

Analog speedometer, tachometer, odometer, trip meter, oil pressure light, neutral indicator, high beam indicator, turn signal indicators.

Driver Assistance Features:

N/A (Motorcycle)

Connectivity Features:

N/A (Motorcycle)

Engine Management System:

Electronic Ignition and Fuel Delivery (carburetor-based).

🔧 Maintenance

Initial Service:

First service typically at 1,000 miles (1600 km) for engine oil and filter change, primary chaincase oil check, and general inspection.

Regular Oil Change:

Every 5,000 miles (8000 km) or annually, whichever comes first, for engine oil and filter.

Transmission Primary Oil Change:

Every 10,000 miles (16000 km) or annually.

Spark Plug Replacement:

Inspect at 5,000 miles (8000 km), replace as needed (often around 10,000-15,000 miles).

Belt Drive Tension:

Check and adjust as needed every 5,000 miles (8000 km).

Engine Oil Grade:

20W-50 Harley-Davidson Genuine V-Twin Motorcycle Oil (API SG or higher)

Transmission Primary Oil Grade:

Harley-Davidson Genuine Formula + Transmission/Primary Chaincase Lubricant

Brake Fluid Type:

DOT 4

Cam Chain Tensioners:

Early Twin Cam models (pre-2007) had plastic cam chain tensioners that could wear and fail. While the 2002 model has the Twin Cam 88B, which uses a different cam drive system, it's still a point of inspection for wear in manuals of this era.

Primary Drive Belt:

Regular inspection for wear and proper tension is crucial for the belt drive system.

Carburetor Tuning:

Keihin CV carburetors may require periodic tuning or adjustment for optimal performance and idle.

Wiper Motor Issues:

N/A (Motorcycle)

📚 Vehicle History

Heritage:

Harley-Davidson, founded in 1903, has a long-standing reputation for producing iconic American motorcycles known for their V-twin engines, robust construction, and distinctive styling.

Softail Lineage:

The Softail platform, introduced in the early 1980s, emulates the rigid frame look of vintage hardtail motorcycles while incorporating hidden rear suspension for improved ride quality. The Springer Softail variant adds the distinctive heritage springer front end.

Production Period Fxsts:

The FXSTS Springer Softail was produced in various forms from the late 1980s through the early 2000s, with the 2002 model representing a mature iteration of the platform featuring the Twin Cam 88B engine.

Manufacturing Location:

Harley-Davidson motorcycles, including the FXSTS, were primarily manufactured in the United States.

🏆 Awards & Recognition

Brand Awards:

Harley-Davidson as a brand has received numerous awards and accolades over its history for iconic design, V-twin performance, and contribution to motorcycle culture. Specific awards for the 2002 FXSTS model are less common in formal automotive awards, but it was highly regarded within the cruiser and custom segments.

Customer Satisfaction:

Consistently high customer satisfaction and brand loyalty among Harley-Davidson owners, particularly for models with classic styling.

Manufacturing Standards:

Manufactured to Harley-Davidson's rigorous internal quality and safety standards.