Harley Davidson FXSTS Springer ST 2003 Repair Service Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FXSTS Springer ST Year: 2003 Chassis Code: FXSTS Platform: Softail 👋 Introduction Market Position Category: Cruiser Motorcycle Segment: Custom/Performance Cruiser Target Audience: Enthusiasts...

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UGS: 413519

Mots clés: 2003 FXSTS Springer ST Harley Davidson Misc Motorcycle Motorcycles

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

FXSTS Springer ST

Year:

Chassis Code:

FXSTS

Platform:

Softail

👋 Introduction

Market Position

Category:

Cruiser Motorcycle

Segment:

Custom/Performance Cruiser

Target Audience:

Enthusiasts seeking a classic-styled motorcycle with modern performance and the iconic Harley-Davidson experience

Competitive Analysis

Competitors:

Other Harley-Davidson Softail models, Indian Chief variants, select Japanese cruisers with similar styling and displacement

Key Features

Distinctive Feature 1:

Telescopic Springer front fork providing a unique vintage aesthetic and handling characteristics

Distinctive Feature 2:

Softail chassis with hidden rear shock absorbers, creating a hardtail look

Distinctive Feature 3:

Large displacement V-twin engine delivering characteristic torque and sound

Distinctive Feature 4:

Chrome-laden styling with attention to detail, emphasizing classic cruiser design

📋 Manual Details

Coverage Areas

Engine:

Full coverage (disassembly, assembly, tuning, troubleshooting)

Transmission:

Full coverage (disassembly, assembly, troubleshooting)

Drivetrain:

Full coverage (belt drive, clutch, primary chain)

Suspension:

Full coverage (front Springer fork, rear shock absorbers, linkages)

Brakes:

Full coverage (hydraulic systems, calipers, master cylinders, lines)

Electrical System:

Full coverage (ignition, lighting, charging, starting, wiring diagrams)

Fuel System:

Full coverage (carburetor/fuel injection, fuel pump, lines)

Frame And Bodywork:

Full coverage (frame components, fenders, fuel tank, seat, controls)

Wheels And Tires:

Full coverage (tire inspection, replacement, wheel balancing)

Maintenance:

Comprehensive schedule and procedures

Troubleshooting:

Detailed diagnostic guides for common and complex issues

Wiring Diagrams:

Detailed and color-coded diagrams

Page Count

Estimated Pages:

Approximately 600-800 pages (typical for full service manuals)

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

File Format

Type:

Searchable:

Typically searchable text, allowing quick information retrieval

Printable:

Yes, allows users to print specific sections or the entire manual

Quality:

High resolution scans with clear diagrams and text

Binding Type

Type:

N/A (Digital PDF)

Paper Type

Type:

N/A (Digital PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Cylinder head, pistons, connecting rods, crankshaft, camshafts, oil pump, timing components

Engine Performance:

Carburetor (CV 40mm) tuning, ignition timing, exhaust system considerations

Transmission Components:

Gearbox, clutch assembly, primary drive chain, compensator sprocket

Suspension Components:

Front Springer fork disassembly/assembly, fork oil specifications, rear shock absorber service

Braking System:

Front and rear disc brake calipers, master cylinders, brake fluid types and bleeding procedures

Electrical Components:

Battery, starter motor, alternator, voltage regulator, ignition module, lights, switches, fuses

Fuel Delivery:

Carburetor cleaning, adjustment, fuel filter replacement, fuel line maintenance

Chassis Components:

Frame inspection, steering head bearings, swingarm pivot bearings, wheel bearings

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, brake checks, lubrication points

Engine Rebuild:

Complete top-end and bottom-end overhaul procedures

Transmission Overhaul:

Gearbox disassembly, reassembly, and troubleshooting common issues

Suspension Service:

Fork seal replacement, shock absorber calibration, spring adjustments

Brake System Service:

Brake pad replacement, caliper overhaul, master cylinder rebuild, fluid flush

Electrical Diagnostics:

Troubleshooting starting system, charging system, ignition system faults

Carburetor Adjustment And Rebuild:

Detailed steps for tuning and overhauling the CV carburetor

Wheel And Tire Service:

Tire mounting/dismounting, wheel balancing, spoke adjustment (if applicable)

Bodywork And Trim Removal:

Instructions for removing fenders, fuel tank, seat, and other body panels

Technical Depth

Depth:

Comprehensive, suitable for both DIY enthusiasts and professional mechanics

Diagnostic Codes:

Troubleshooting guides often reference diagnostic trouble codes (DTCs) if applicable to the electronic systems

Torque Specifications:

Precise torque values for all critical fasteners

Clearances And Tolerances:

Specifications for engine internal clearances and wear tolerances

⚙️ Engine Specifications

Primary Engine

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)

Compression Ratio:

8.9:1

Valve Train:

Overhead valves (OHV), 2 valves per cylinder

Cooling System:

Air-cooled

Oil System:

Dry sump with oil tank

Performance

Horsepower Estimate:

Approximately 65-70 hp (at crank)

Torque Estimate:

Approximately 75-80 ft-lbs (at crank, at ~3000 RPM)

Fuel System

Fuel Delivery:

Carburetor: Keihin CV 40mm

Fuel Type:

Unleaded gasoline, minimum 91 octane (R+M)/2

Fuel Tank Capacity:

4.0 gallons (15.1 L)

🔧 Transmission

Standard

Type:

5-speed constant mesh

Gear Ratios:

1st: 2.875, 2nd: 1.732, 3rd: 1.216, 4th: 1.000, 5th: 0.818

Primary Drive:

Duplex chain, 34/46 tooth (1.35:1 ratio)

Clutch:

Wet, multi-plate, compensator sprocket

Final Drive:

Belt drive, 32/66 tooth (2.06:1 ratio)

Features

Transmission Fluid:

Harley-Davidson recommended transmission lubricant (e.g., Formula+ or Syn3)

📐 Dimensions

Exterior

Length:

Approximately 92.3 inches (2345 mm)

Seat Height Laden:

Approximately 26.2 inches (665 mm)

Ground Clearance:

Approximately 4.3 inches (109 mm)

Weights

Dry Weight:

Approximately 629 lbs (285 kg)

Gross Vehicle Weight Rating:

Approximately 1035 lbs (469 kg)

Wheels And Tires

Front Tire:

MT90B16 72H

Rear Tire:

MU85B16 77H

Wheelbase:

64.5 inches (1638 mm)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles are not typically subject to the same crash testing standards as automobiles)

Active Features

Braking System:

Hydraulic disc brakes front and rear

Passive Features

Lighting:

Headlight, taillight, brake lights, turn signals

Frame Construction:

Steel frame and swingarm designed for stability

💡 Technology Features

Infotainment

Audio System:

Optional accessory audio systems might have been available, but not standard on this model. Manual covers accessory installation wiring.

Driver Assistance

Features:

None standard (e.g., no ABS, traction control on this model year)

Connectivity

Features:

No integrated connectivity features like Bluetooth or smartphone integration on the base model.

🔧 Maintenance

Service Intervals

First Service:

Approximately 1,000 miles (1,600 km) or 6 months, whichever comes first (includes oil change, filter change, primary chain adjustment, inspection)

Subsequent Service:

Every 5,000 miles (8,000 km) or 12 months for general maintenance (oil, filter, inspections); transmission and primary chaincase fluid changes at specific intervals as per manual

Spark Plugs:

Inspect at 5,000 miles, replace as needed or at manufacturer recommended intervals (typically 10,000-20,000 miles)

Belt Drive Tension:

Check and adjust belt tension every 5,000 miles

Fluid Specifications

Engine Oil:

Harley-Davidson 20W-50 V-Twin Motorcycle Oil or equivalent API CI-4 rated oil (Capacity: approx. 4 quarts/3.8 liters with filter)

Transmission Fluid:

Harley-Davidson Formula+ Transmission/Primary Chaincase Lubricant or HD Syn3 Synthetic Motorcycle Oil (Capacity: approx. 1 quart/0.95 liters)

Primary Chaincase Fluid:

Same as transmission fluid

Brake Fluid:

DOT 4 Hydraulic Fluid (ensure it meets specifications for Harley-Davidson)

Fork Oil:

Harley-Davidson Type 'E' (10W) or Type 'H-D 10W' Fork Oil (or equivalent viscosity index fork oil) - specific quantity per leg

Known Issues

Cam Chain Tensioners:

Early Twin Cam engines (pre-2007) had plastic cam chain tensioners that could wear out, leading to potential engine damage. Later models used hydraulic tensioners. This manual will cover inspection and replacement procedures.

Crankshaft Runout:

Some Twin Cam engines can be susceptible to crankshaft runout issues. The manual will provide specifications and inspection methods.

Primary Clutch Adjustment:

Proper primary chain and clutch adjustment is critical for smooth operation and longevity. The manual details the correct procedures.

Harley Davidson Oil Leaks:

Commonly found around base gaskets, primary cover, and transmission seals. Manual provides gasket replacement and sealing procedures.

📚 Vehicle History

Brand Heritage

Brand:

Harley-Davidson, established 1903, iconic American motorcycle manufacturer

Model Evolution

Softail Lineage:

The Softail platform, introduced in the late 1970s, is known for its hidden rear suspension mimicking a hardtail look, providing a classic profile with modern ride comfort.

Springer Fork History:

The Springer front fork is a revival of an early motorcycle suspension design, offering a distinctive visual and tactile riding experience. Harley-Davidson has offered Springer models periodically since the 1980s.

Production

Model Production Period:

The FXSTS Springer Softail was produced from 1988 to 2006.

2003 Model Year Significance:

Represents a mature iteration of the Twin Cam 88B engine and Softail platform.

🏆 Awards & Recognition

Recognitions

Brand Awards:

Harley-Davidson consistently recognized for its brand heritage, build quality (relative to its style), and iconic V-twin engines.

Ratings

Customer Satisfaction:

Highly variable, but generally strong among loyal owners. The manual is key to maintaining optimal performance and satisfaction.

Certifications

Certification Standards:

Meets all applicable federal motor vehicle safety standards for its model year.