Harley Davidson FXSTSI Springer ST 2003 Repair Servce Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FXSTSI Springer Softail Standard Year: 2003 Model Code: FXSTSI 👋 Introduction Market Position Target Audience: Harley-Davidson owners, independent motorcycle mechanics, and enthusiasts seeking...

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Taper: Motorcycle

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UGS: 413520

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

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

FXSTSI Springer Softail Standard

Year:

Model Code:

FXSTSI

👋 Introduction

Market Position

Target Audience:

Harley-Davidson owners, independent motorcycle mechanics, and enthusiasts seeking in-depth repair knowledge.

Value Proposition:

Provides the necessary technical expertise to perform all maintenance and repairs, saving time and money on dealership service.

Competitive Analysis

Comparison To Oem Manuals:

Often rivals or exceeds the detail of official Harley-Davidson service manuals in terms of clarity and accessibility for a broader audience.

Key Features

Historical Significance:

The FXSTSI represents a specific styling era for Harley-Davidson, blending classic aesthetics with modern performance for its time.

Unique Selling Points:

The iconic Springer front end requires specific maintenance and diagnostic procedures, which are thoroughly covered.

📋 Manual Details

Coverage Areas

Coverage Summary:

Comprehensive service, maintenance, and troubleshooting for the 2003 Harley-Davidson FXSTSI Springer Softail Standard.

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine System:

Detailed diagnostics, repair procedures, component overhaul, timing, and tuning for the Evolution engine.

Transmission System:

Service and repair of the 5-speed Cruise Drive transmission, clutch, and primary drive.

Fuel System:

Carburetor (Keihin CV) service, fuel injection (if applicable), fuel pump, fuel lines, and tank maintenance.

Electrical System:

Wiring diagrams, ignition system, lighting, starting and charging systems, battery, and accessory circuits.

Brakes System:

Hydraulic brake system service, caliper repair, master cylinder maintenance, brake fluid replacement, and bleeding procedures.

Suspension System:

Front Springer fork service, rear shock absorber replacement, and suspension adjustments.

Frame And Bodywork:

Frame inspection, body panel removal/installation, fenders, fuel tank, seat, and console.

Wheel And Tire System:

Wheel bearing service, tire replacement, spoke tensioning, and wheel balancing.

Controls And Instruments:

Handlebar controls, throttle cables, brake levers, instrument cluster, and lighting controls.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, spark plug service, chain adjustment (if applicable), belt tensioning, and lubrication points.

Troubleshooting Guides:

Diagnostic flowcharts and symptom-based troubleshooting for common and uncommon issues.

Component Disassembly And Assembly:

Step-by-step instructions for dismantling and reassembling major motorcycle components.

Torque Specifications:

Precise torque values for all fasteners and critical assembly points.

Special Tool Requirements:

Identification and usage instructions for specialized tools required for certain procedures.

Wiring Diagrams:

Complete and detailed electrical schematics for easy fault finding.

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to complete engine rebuilds and electrical diagnostics).

📊 Manual Specifications

File Format

File Format:

Searchability:

Searchable text content for quick information retrieval.

Printability:

Printable pages for workshop use.

Print Quality

Image Resolution:

High-resolution images and diagrams.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Harley-Davidson Twin Cam 88B

Displacement:

1450 cc (88 cubic inches)

Configuration:

V-Twin, Air-Cooled

Bore X Stroke:

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

Compression Ratio:

8.8:1

Performance

Horsepower Estimated:

Approx. 65-70 HP (at crank, depending on tuning)

Torque Estimated:

Approx. 80-85 ft-lbs (at crank, depending on tuning)

Fuel System

Fuel Delivery:

Carburetor (Keihin CV 40mm) or Electronic Sequential Port Fuel Injection (ESPFI) for California models.

Fuel Type Recommendation:

Unleaded gasoline, 91 octane (AKI) or higher recommended.

Oil System

Oil Type Recommendation:

Harley-Davidson SYN3 (20W-50) Synthetic Motorcycle Oil or equivalent API CI-4 rated diesel engine oil.

Oil Capacity:

3.5 US quarts (3.3 liters) with filter change.

Ignition System

Ignition Type:

Electronic Ignition with dual spark plugs per cylinder.

🔧 Transmission

Standard

Transmission Type:

5-speed Constant Mesh, Manual

Primary Drive:

Duplex chain, 34/46 ratio

Final Drive:

Belt drive, 32/66 ratio

Features

Clutch Type:

Wet, multi-plate, diaphragm spring

Transmission Oil Type Recommendation:

Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant or equivalent.

Transmission Oil Capacity:

24 US fluid ounces (0.71 liters)

📐 Dimensions

Exterior

Overall Length:

Approx. 93.2 inches (2367 mm)

Wheelbase:

Approx. 65.9 inches (1674 mm)

Ground Clearance:

Approx. 4.4 inches (112 mm)

Seat Height Laden:

Approx. 25.5 inches (648 mm)

Weights

Dry Weight:

Approx. 617 lbs (280 kg)

Gross Vehicle Weight Rating:

Not explicitly stated but typically around 1000 lbs (454 kg)

Fuel Capacity

Fuel Tank Capacity:

4.0 US gallons (15.1 liters)

Wheels And Tires

Front Tire Size:

MT90B16 72H

Rear Tire Size:

130/90B16 67H

Front Wheel Type:

Spoked, 16-inch

Rear Wheel Type:

Spoked, 16-inch

Bolt Pattern:

5 x 4.5 inch (114.3 mm) for rear wheel, hub-specific for front.

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle safety is assessed differently than automobiles; this manual will detail relevant safety system maintenance).

Active Features

Braking System:

Dual-piston caliper front and rear, hydraulic actuation.

Lighting System:

Halogen headlight, LED tail light, turn signals.

Passive Features

Frame Construction:

Steel frame and swingarm designed for stability and handling.

Chassis Design:

Softail frame with hidden rear shock absorbers for a rigid tail look, Springer front end for distinct steering feel.

💡 Technology Features

Infotainment

Infotainment System:

Basic, typically no integrated infotainment system beyond radio and CB (optional).

Driver Assistance

Driver Assistance Features:

N/A (No electronic rider aids like ABS or traction control standard on this model).

Connectivity

Connectivity Options:

N/A (No Bluetooth or smartphone integration).

🔧 Maintenance

Service Intervals

First Service:

1,000 miles (1,600 km) or 6 months, whichever comes first.

Subsequent Maintenance:

Every 5,000 miles (8,000 km) or 12 months, whichever comes first, for oil changes and general checks.

Major Service Intervals:

Refer to manual for specific intervals for belt inspection/tensioning, fork oil, and engine tune-ups.

Fluid Specifications

Engine Oil:

Harley-Davidson SYN3 (20W-50) or equivalent API CI-4 diesel engine oil.

Transmission Primary Oil:

Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant or equivalent.

Brake Fluid:

DOT 4 Heavy Duty Brake Fluid (for hydraulic systems).

Chassis Lubrication:

Harley-Davidson all-purpose grease or equivalent for various pivot points and bearings.

Known Issues

Common Wear Items:

Clutch plates, brake pads, tires, battery, drive belt, fork seals.

Springer Specific Wear:

Pivot points and bushings in the Springer front end may require periodic lubrication and inspection for play.

Twin Cam 88B Considerations:

Some early Twin Cam engines had oiling system considerations; the manual will detail relevant checks and upgrades.

📚 Vehicle History

Brand Heritage

Brand Legacy:

Harley-Davidson, founded in 1903, is renowned for its iconic cruiser motorcycles and a rich racing and cultural history.

Model Evolution

Softail Lineage:

The Softail platform, introduced in the early 1980s, aimed to replicate the look of a hardtail frame while incorporating rear suspension.

Springer Heritage:

The Springer front end is a nod to the earliest motorcycle designs, providing a unique aesthetic and riding experience.

Production

Production Era:

The FXSTSI Springer Softail Standard was produced for a specific period within the early 2000s, representing a distinct styling direction.

Manufacturing Location:

Primarily assembled in York, Pennsylvania, and Milwaukee, Wisconsin, USA.

🏆 Awards & Recognition

Recognitions

Model Specific Awards:

While specific awards for the FXSTSI are not readily documented, Harley-Davidson motorcycles consistently receive acclaim for their design, heritage, and V-twin character.

Ratings

Owner Satisfaction:

Generally high owner satisfaction due to the iconic styling and riding experience, though maintenance can be more involved.