🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLT Series

Model Variant:

Twin Cam 88 / Twin Cam 103

Year:

2002

Engine Family Code:

Twin Cam 88

👋 Introduction

Target Audience:

Harley-Davidson FLT Series owners, independent repair shops, and DIY enthusiasts

Value Proposition:

Empowers owners to perform maintenance and repairs with confidence, reducing reliance on costly dealership services.

Manual Alternatives:

Official Harley-Davidson Service Manuals (often more expensive, print-only), unofficial online forums (less structured, potentially inaccurate).

Accessibility:

Instant download access for immediate use.

Comprehensiveness:

Covers all major mechanical, electrical, and chassis systems.

Detail Level:

Detailed step-by-step instructions with clear diagrams.

📋 Manual Details

Primary Coverage:

All FLT Series Models

Engine Coverage:

Twin Cam 88 & Twin Cam 103 Engine Variants

Estimated Pages:

700+

Type:

Service & Repair Manual

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Engine Mechanical:

Top End (Cylinder Heads, Valves), Bottom End (Crankcase, Crankshaft, Connecting Rods), Camshafts, Pistons, Cylinders, Oil Pump, Oil Cooler

Fuel System:

Carburetor (Keihin CV 40), Fuel Pump, Fuel Lines, Fuel Tank

Ignition System:

Ignition Module, Ignition Coils, Spark Plugs, Crank Position Sensor

Transmission Drivetrain:

5-Speed Cruise Drive Transmission, Clutch, Primary Drive, Belt Drive, Final Drive Belt Inspection & Tensioning

Electrical System:

Wiring Diagrams, Battery, Charging System (Stator, Regulator/Rectifier), Starting System (Starter Motor, Solenoid), Lighting (Headlight, Taillight, Signals), Gauges & Instruments, Horn, Switches

Braking System:

Front & Rear Brakes (Discs, Calipers, Master Cylinders, Lines), Brake Fluid Flush

Suspension Steering:

Front Fork (Springs, Dampers, Seals), Rear Shocks, Swingarm, Wheel Bearings, Steering Head Bearings

Chassis Frame:

Frame Inspection, Swingarm Pivot, Footpeg Mounts

Bodywork Fittings:

Fairing Removal & Installation, Saddlebag Removal & Installation, Seat, Fuel Tank Mounting

Routine Maintenance:

Oil & Filter Changes, Air Filter Replacement, Spark Plug Replacement, Chain/Belt Adjustment & Lubrication (if applicable, though FLT is belt drive), Brake Pad Inspection, Tire Pressure Checks

Engine Repair:

Top End Rebuild, Piston & Cylinder Replacement, Camshaft Installation, Lifter Adjustment, Oil Pump Service

Transmission Repair:

Clutch Adjustment & Replacement, Gearbox Disassembly & Reassembly (5-Speed Cruise Drive)

Electrical Diagnostics:

Troubleshooting Faults using Wiring Diagrams, Component Testing (Stator, Regulator, Starter)

Braking System Service:

Brake Bleeding, Caliper Rebuild, Master Cylinder Replacement

Suspension Steering Service:

Fork Seal Replacement, Shock Absorber Replacement, Steering Head Bearing Adjustment

Troubleshooting:

Diagnostic Guides for Common Issues, Symptom-Based Troubleshooting

Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics)

Diagnostic Focus:

Detailed wiring diagrams and troubleshooting charts for electrical systems

Torque Specifications:

Includes torque values for all critical fasteners

Special Tools:

Lists and describes necessary Harley-Davidson special tools for specific procedures

📊 Manual Specifications

Format Type:

PDF

Searchability:

Searchable text for quick information retrieval

Resolution:

High-resolution scans for clear diagrams and text

Print Quality:

Printable on demand

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Family:

Harley-Davidson Twin Cam 88

Engine Type:

Air-cooled, V-twin, 45-degree

Bore X Stroke 88:

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

Displacement 88:

88 cu. in. (1450cc)

Compression Ratio 88:

8.8:1 (typical, may vary slightly)

Cylinder Heads:

Aluminum alloy, 2 valves per cylinder (pushrod actuated)

Camshafts:

Single camshaft, chain-driven (later models used twin cams)

Engine Variant 103:

Twin Cam 103 (larger displacement, often achieved via big bore kits or factory upgrades)

Bore X Stroke 103:

3.875 in. x 4.375 in. (98.4 mm x 111.1 mm) - Typical for Big Bore

Displacement 103:

103 cu. in. (1690cc) - Typical for Big Bore

Horsepower 88:

Approx. 70-75 HP (at crankshaft, varies)

Torque 88:

Approx. 86-90 lb-ft (at crankshaft, varies)

Fuel Delivery:

Carbureted (Keihin CV 40 as standard)

Fuel Type:

Unleaded Gasoline, 91 Octane (or higher)

Oil Type:

Harley-Davidson 20W-50 Motorcycle Oil (or equivalent API SG/SH/SJ)

Oil Capacity:

Approx. 4 quarts (3.8 L) with filter change

Cooling:

Air-cooled

🔧 Transmission

Type:

5-Speed Cruise Drive

Gear Ratios Approx:

1st: 9.31, 2nd: 6.70, 3rd: 4.92, 4th: 3.87, 5th: 3.25

Transmission Fluid:

Harley-Davidson Formula+ or SYN3 (or equivalent HD transmission lubricant)

Transmission Fluid Capacity:

Approx. 24 US fl oz (710 ml)

Clutch Type:

Wet, multi-plate, cable-actuated

Primary Drive:

Duplex chain

Final Drive:

Belt drive (32mm wide)

📐 Dimensions

Wheelbase:

Approx. 63.5 inches (1613 mm)

Length:

Approx. 93.4 inches (2372 mm)

Width Handlebar:

Approx. 36.0 inches (914 mm)

Height Seat:

Approx. 29.0 inches (737 mm) (unladen)

Dry Weight:

Approx. 700 lbs (318 kg)

Gross Vehicle Weight Rating:

Approx. 1160 lbs (526 kg)

Fuel Capacity:

Approx. 5.0 US gallons (18.9 L)

🛡️ Safety Features

Crash Test Ratings:

Not Applicable (Motorcycle)

Braking System Type:

Dual disc front, single disc rear

Headlight:

Halogen reflector

Frame Construction:

Steel, welded

💡 Technology Features

Audio System:

Factory optional CB radio, intercom, and AM/FM/WB radio systems were common on FLHT/FLHTC models.

Gauges:

Analog speedometer, tachometer, fuel gauge, voltage meter, oil pressure gauge.

Cruise Control:

Available as an option or standard on some FLHT models.

Diagnostic Ports:

OBD-II style diagnostic connector for engine management system access (limited compared to modern bikes).

🔧 Maintenance

Oil Filter Change:

Every 5,000 miles (8,000 km) or annually

Engine Oil Change:

Every 5,000 miles (8,000 km) or annually

Air Filter Inspection:

Every 5,000 miles (8,000 km)

Spark Plug Replacement:

Every 10,000 miles (16,000 km)

Brake Fluid Flush:

Every 2 years or as needed

Drive Belt Tension Check:

Every 5,000 miles (8,000 km)

Engine Oil:

Harley-Davidson 20W-50 Motorcycle Oil (or equivalent API SG/SH/SJ)

Transmission Fluid:

Harley-Davidson Formula+ or SYN3 (or equivalent HD transmission lubricant)

Primary Chain Case Oil:

Harley-Davidson Formula+ or SYN3 (or equivalent HD primary lubricant)

Brake Fluid:

DOT 4

Cam Chain Tensioners:

Early Twin Cam 88 models (pre-2007) used plastic cam chain tensioners that could wear out, leading to potential damage. Manual covers inspection and replacement.

Primary Chain Tensioner:

Automatic primary chain tensioner wear can occur. Manual details inspection and adjustment/replacement.

Oil Leaks:

Potential for oil leaks from rocker boxes, pushrod tubes, or crankcase seals. Manual provides guidance for diagnosis and repair.

Carburetor Tuning:

Keihin CV 40 carburetor may require periodic adjustment or cleaning. Manual covers tuning procedures.

📚 Vehicle History

Brand Legacy:

Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer renowned for its V-twin engines and distinctive styling.

Flt Introduction:

The FLT series, often referred to as the 'Touring' models, introduced the FLHT (Electra Glide Standard) and FLHTC (Electra Glide Classic) with significant frame and suspension improvements over earlier models, emphasizing comfort and stability.

Twin Cam Introduction:

The Twin Cam 88 engine, launched in 1999, replaced the Evolution engine, offering increased displacement and a more rigid engine design for improved performance and longevity.

Year 2002 Updates:

The 2002 model year saw the continuation of the Twin Cam 88 and the introduction/availability of the larger Twin Cam 103 option, often through SE (Screamin' Eagle) performance upgrades or specific factory packages.

Production Era:

Twin Cam 88 production ran from 1999 to 2006, with the 2002 model representing a key year in its development.

🏆 Awards & Recognition

Model Recognition:

The FLT series models with the Twin Cam 88 engine are widely recognized for establishing a new benchmark in Harley-Davidson touring comfort and performance.

Reliability Perception:

Generally considered reliable with proper maintenance, though specific early Twin Cam issues require attention.

Manual Certification:

N/A (This is a third-party service manual, not an official certification).