Systems Covered:
Engine, Fuel System, Ignition System, Transmission, Clutch, Primary Drive, Final Drive, Chassis, Suspension, Brakes, Electrical System, Lighting, Instruments, Controls, Bodywork, Frame, Maintenance, Troubleshooting, Diagnostics, Repair Procedures.
Page Count:
Estimated 600+ pages (typical for this era's detailed Harley-Davidson service manuals)
Manual Type:
Service Repair Workshop Manual
Engine Mechanical:
Disassembly, inspection, assembly, and troubleshooting of Twin Cam 88 engine components (cylinders, pistons, connecting rods, crankshaft, camshafts, valvetrain).
Fuel System:
Carburetor (Keihin CV 40), fuel tank, fuel lines, fuel filter, fuel pump (if applicable for specific configurations, though 2003 FLSTS is typically carbureted), troubleshooting and adjustment.
Ignition System:
Ignition module, ignition coil, spark plugs, wiring, timing adjustment, troubleshooting ignition faults.
Transmission Drivetrain:
5-speed gearbox, clutch assembly, primary drive (chain, compensator sprocket, clutch hub), final drive (belt drive system), servicing, adjustments, and troubleshooting.
Chassis Frame:
Frame structure, steering head bearings, front fork (Springer front end), rear swingarm, pivot bearings, wheel bearings.
Suspension:
Front Springer fork maintenance, rear shock absorber service, troubleshooting suspension issues.
Brakes:
Front and rear brake caliper service, master cylinder overhaul, brake fluid replacement, bleeding procedures, rotor and pad inspection/replacement.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting circuits (headlight, taillight, turn signals), horn, electrical diagnostics, wiring diagrams.
Instruments Controls:
Speedometer, tachometer, indicator lights, handlebar controls, throttle and clutch cables, brake levers, switchgear maintenance and repair.
Bodywork Trim:
Fenders, fuel tank, seat, saddlebags, windshield, chrome components, trim pieces, removal and installation procedures.
Routine Maintenance:
Oil changes, filter replacement, spark plug replacement, air filter service, drive belt inspection and adjustment, brake fluid flush, tire pressure checks, battery maintenance.
Troubleshooting:
Systematic diagnosis of common problems using diagnostic charts and symptom analysis for engine, electrical, and drivetrain issues.
Repair Overhaul:
Detailed step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly of all major motorcycle systems.
Technical Specifications:
Torque values, clearances, fluid capacities, electrical specifications, engine timing, and other critical data for accurate servicing.
Depth Of Coverage:
Comprehensive. Covers everything from basic rider maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and troubleshooting guides.
Engine Type:
Air-cooled, Twin Cam 88 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)
Horsepower:
Approx. 60-65 HP (estimated, flywheel horsepower)
Torque:
Approx. 72-78 ft-lbs @ 3500 RPM (estimated, flywheel torque)
Fuel Delivery:
Carbureted (Keihin CV 40mm)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Length:
Approx. 99.9 inches (2537 mm)
Width:
Approx. 36.0 inches (914 mm)
Height:
Approx. 53.2 inches (1351 mm)
Dry Weight:
Approx. 658 lbs (298.5 kg)
Gross Vehicle Weight Rating:
Approx. 1030 lbs (467.2 kg)
Payload Capacity:
Approx. 372 lbs (168.7 kg)
Fuel Capacity:
5.0 US gallons (19 liters)
Wheelbase:
Approx. 66.0 inches (1676 mm)
Ground Clearance:
Approx. 4.5 inches (114 mm)
Initial Service:
1,000 miles (1,600 km)
Subsequent Service:
Every 5,000 miles (8,000 km) or annually, whichever comes first.
Engine Oil:
Harley-Davidson Genuine V-Twin 20W-50 (or equivalent API CG-4 or better)
Engine Oil Capacity:
3.5 US quarts (3.3 liters) with filter change.
Primary Chain Case Oil:
Harley-Davidson Genuine Primary Chain Lubricant or Syn3 Synthetic (if recommended for the year/application).
Primary Chain Case Oil Capacity:
2.7 US quarts (2.5 liters)
Transmission Oil:
Harley-Davidson Genuine Transmission Lubricant or Syn3 Synthetic (if recommended for the year/application).
Transmission Oil Capacity:
2.5 US quarts (2.4 liters)
Brake Fluid:
DOT 4 (refer to manual for specific Harley-Davidson recommendation).
Drive Belt Tension:
1/4 inch to 3/8 inch (6 mm to 10 mm) free play at midpoint of lower span.
Common Wear Items:
Clutch plates, brake pads, tires, wheel bearings, drive belt, and fork seals.
Twin Cam 88 Notes:
Early Twin Cam 88 engines experienced issues with cam chain tensioners wearing out prematurely. Later models (and this manual should cover updates/fixes) may have revised components or recommended upgrades.
Springer Fork Maintenance:
Requires periodic lubrication and adjustment of the pivot and spring mechanisms.
Ignition Module Failures:
While less common, ignition modules can be a point of failure, affecting starting and running.
Founding:
Harley-Davidson Motor Company founded in 1903.
Heritage Series:
The Heritage Springer line pays homage to classic Harley-Davidson styling from the 1940s and 1950s, particularly the iconic Hydra-Glide era.
Flsts Introduction:
Introduced in 1997, the FLSTS was a significant departure, featuring the distinctive Springer front end and retro styling, powered initially by the Evolution engine before transitioning to the Twin Cam 88.
Production Years:
1997-2003 (as FLSTS Heritage Springer)
Engine Transition:
For the 2000 model year, the FLSTS transitioned from the Evolution (Blockhead) engine to the new Twin Cam 88 engine.
