Target Audience:
Harley-Davidson owners and independent motorcycle mechanics seeking in-depth repair and maintenance information.
Purpose:
To provide comprehensive guidance for the repair, maintenance, and troubleshooting of the 2005 Harley-Davidson FLSTF Fat Boy ST Softail.
Comparison To Oem:
Aims to replicate the depth and accuracy of an Official Harley-Davidson Service Manual.
Feature 1:
Detailed step-by-step repair procedures with accompanying illustrations or diagrams (typical for quality manuals).
Feature 2:
Comprehensive troubleshooting sections for diagnosing and resolving common and uncommon issues.
Feature 3:
Inclusion of technical specifications, torque values, and fluid capacities essential for proper servicing.
Engine Mechanical:
Detailed procedures for disassembly, inspection, repair, and reassembly of the Twin Cam 88B engine, including cylinders, pistons, crankshaft, connecting rods, camshafts, and valvetrain.
Fuel System:
Carburetor (CV type) adjustment, cleaning, and overhaul; fuel tank removal/installation; fuel lines and fittings.
Ignition System:
Ignition module troubleshooting, spark plug replacement, ignition coil testing.
Transmission:
5-speed Cruise Drive transmission overhaul, clutch adjustment, primary drive inspection, and service.
Drivetrain:
Belt drive system inspection, adjustment, and replacement; rear sprocket and wheel hub maintenance.
Suspension Front:
Front fork disassembly, seal replacement, fluid changes, and component inspection (e.g., fork tubes, sliders, springs).
Suspension Rear:
Shock absorber replacement, swingarm bearing inspection and service.
Brakes Front:
Brake caliper overhaul, pad replacement, disc inspection, hydraulic system bleeding, and master cylinder service.
Brakes Rear:
Brake caliper overhaul, pad replacement, disc inspection, hydraulic system bleeding, and master cylinder service.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting systems, horn, and instrument cluster troubleshooting.
Wheels And Tires:
Wheel bearing inspection and replacement, tire mounting and balancing, spoke tension adjustment (if applicable).
Frame And Bodywork:
Frame inspection, fender removal/installation, fuel tank removal/installation, seat assembly, handlebars, and controls adjustment.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain/belt adjustments, brake fluid flushes, and lubrication points.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides for common issues.
Overhaul:
Complete rebuild procedures for major components like the engine and transmission.
Component Replacement:
Step-by-step instructions for replacing wear items and failing parts.
Calibration Adjustment:
Procedures for adjusting clutches, cables, carburetors, and suspension settings.
Depth Level:
Comprehensive, covering basic maintenance to full engine and transmission rebuilds.
Diagnostic Capability:
Detailed diagnostic procedures, including electrical system testing and fault code interpretation (if applicable to the era's systems).
Special Tools:
Identification and usage instructions for specialized Harley-Davidson tools required for specific procedures.
Engine Type:
Air-cooled, Twin Cam 88B V-Twin
Displacement:
1449 cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Valve Train:
Overhead valves (OHV), pushrod actuated with hydraulic lifters
Horsepower:
Approx. 65-70 HP (at crank, estimated for 2005 Twin Cam 88B)
Torque:
Approx. 75-80 ft-lbs (at crank, estimated for 2005 Twin Cam 88B)
Carburetor:
Keihin CV (Constant Velocity) 40mm
Fuel Capacity:
4.0 gallons (15.1 liters)
Oil Capacity:
3.5 quarts (3.3 liters) with filter change
Oil Type Specification:
Harley-Davidson Genuine SYN3 (synthetic) or recommended V-twin specific motorcycle oil SAE 20W50 (refer to manual for exact spec).
First Service:
Typically at 1,000 miles (1,600 km) or 6 months, whichever comes first. Includes oil and filter change, primary chain adjustment, and general inspection.
Subsequent Services:
Generally every 5,000 miles (8,000 km) or 12 months. Includes oil/filter change, inspection of various components, and adjustments as needed.
Spark Plug Replacement:
Typically every 10,000 - 15,000 miles (16,000 - 24,000 km).
Brake Fluid Flush:
Recommended every 2 years regardless of mileage.
Engine Oil:
Harley-Davidson Genuine SYN3 (synthetic) or recommended V-twin specific motorcycle oil SAE 20W50.
Transmission Primary Fluid:
Harley-Davidson Syn-3 Transmission/Primary Fluid or equivalent V-twin specific gear oil SAE 75W-90.
Brake Fluid:
DOT 4 (refer to manual for specific Harley-Davidson approved product).
Fork Oil:
Typically a specific weight Harley-Davidson fork oil (e.g., 15W), check manual for exact specification and quantity.
Cam Chain Tensioners:
While the Twin Cam 88B has improved tensioners over earlier Twin Cams, some models can still experience wear. This manual will detail inspection and replacement procedures.
Carburetor Tuning:
CV carburetors can sometimes require fine-tuning for optimal performance, especially at altitude or after modifications.
Oil Leaks:
As with many motorcycles of this era, occasional oil leaks from seals or gaskets can occur and are addressed in the manual.
Heritage Statement:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer known for its distinctive V-twin engines and cruiser-style motorcycles.
Softail Lineage:
The Softail platform, introduced in 1983, features a hidden rear suspension designed to mimic the rigid look of a vintage hardtail frame while providing rider comfort.
Fat Boy Introduction:
The Fat Boy model, introduced in 1990, is characterized by its distinctive wide front fork, "fat" tires, and chrome-plated spoked wheels, evoking a classic, muscular aesthetic.
Manufacturing Location:
United States (Milwaukee, Wisconsin for engines/components, assembly at various facilities).
Model Year Context:
The 2005 model year represents a mature iteration of the Twin Cam 88B engine and Softail platform.
