Model Years Covered:
2000, 2001, 2002, 2003, 2004, 2005
Product Code Designation:
Service Repair Workshop Manual Download PDF
Target Audience:
Harley-Davidson Softail owners, independent motorcycle repair shops, DIY enthusiasts.
Value Proposition:
Provides factory-level repair and maintenance information essential for preserving the value and performance of the 2000-2005 Harley-Davidson Softail models. Offers significant cost savings over dealership service.
Text Readability:
Easy-to-read text sections
Diagram Emphasis:
Focus on clarity and detail in diagrams and illustrations for step-by-step guidance.
Engine System:
Engine overhaul, diagnosis, tuning, cooling, lubrication, fuel injection (EFI), ignition, exhaust
Transmission System:
Transmission repair, clutch service, primary drive, final drive, troubleshooting
Electrical System:
Wiring diagrams, ignition system, charging system, lighting, starting system, accessories, fault diagnosis
Chassis Suspension:
Front fork service, rear suspension repair, wheel bearing maintenance, steering system
Brake System:
Brake caliper service, master cylinder repair, brake fluid replacement, bleeding procedures
Fuel System:
Fuel tank, fuel pump, fuel injectors, fuel pressure testing
Bodywork Frame:
Frame inspection, body panel removal/installation, seat service
Routine Maintenance:
Oil changes, filter replacements, spark plug service, chain adjustment, lubrication points
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting charts, electrical fault finding
Repair Procedures:
Component disassembly, inspection, repair, and reassembly for all major systems
Diagnostics:
Trouble codes, diagnostic connector access, multimeter usage, specific system checks
Specifications Data:
Torque values, clearances, fluid capacities, electrical resistance readings, diagnostic parameters
Depth Of Coverage:
Comprehensive; suitable for home mechanics, technicians, and advanced enthusiasts. Covers everything from basic maintenance to complete engine and transmission rebuilds.
Engine Family:
Evolution (often referred to as 'Evo' or 'Big Twin Evolution')
Engine Displacement Common:
Typically 88 cubic inches (1442cc) for most Softail models in this era. Some variations might exist, but this is the most prevalent.
Engine Type:
Air-cooled, V-twin, overhead valve (OHV)
Horsepower Approximate:
Typically in the range of 60-70 HP (varies by specific model and tuning)
Torque Approximate:
Typically in the range of 70-80 ft-lbs (varies by specific model and tuning)
Fuel Delivery:
Electronic Fuel Injection (EFI) - Sequential Port Injection (SPI) is standard for this period.
Fuel Type:
Unleaded gasoline, minimum 89 octane recommended (check specific owner's manual for precise requirement)
Oil Type Recommendation:
Harley-Davidson 20W50 V-Twin Motorcycle Oil is typically recommended. Synthetic or semi-synthetic options are available and often preferred for improved performance and protection.
Oil Capacity Approximate:
Approximately 3.5 US quarts (3.3 liters) with filter change. Always verify with dipstick after filling.
Transmission Type:
5-speed manual constant mesh, helical gear
Optional Transmissions:
N/A (5-speed was standard across the Softail line for these years)
Clutch Type:
Wet multi-plate, diaphragm spring
Primary Drive:
Duplex chain drive with automatic chain tensioner
Transmission Fluid Type:
Harley-Davidson Formula + Transmission Lubricant (or equivalent API GL-4, SAE 80W-90 gear oil)
Transmission Fluid Capacity:
Approximately 1 US quart (0.95 liters). Verify with level plug.
Wheelbase Typical:
Approximately 64.5 - 65.5 inches (163.8 - 166.4 cm), varies slightly by specific Softail model (e.g., Fat Boy, Heritage Softail, Night Train).
Seat Height Typical:
Approximately 25 - 27 inches (63.5 - 68.6 cm), unladen
Dry Weight Typical:
Approximately 600 - 650 lbs (272 - 295 kg), varies by model and specific equipment.
Safety Ratings:
Motorcycles are not subject to standard automotive safety rating tests (e.g., NHTSA crash tests). Safety is dependent on rider skill and adherence to maintenance.
Braking System:
Dual-piston calipers front and rear, hydraulic disc brakes. ABS was not standard on most Softail models during this period, though it may have been an option on some higher-trim variants.
Lighting:
Halogen headlight, LED or incandescent taillight, turn signals.
Infotainment Systems:
These models typically do not feature advanced infotainment systems. Audio systems, if equipped, are usually aftermarket or basic factory radio/CD players. Connectivity is minimal, focused on basic bike functions.
Driver Assistance Features:
Driver assistance features common in modern vehicles (e.g., adaptive cruise control, lane departure warning) are not present. Primary focus is on core mechanical and electrical systems.
Connectivity Features:
Limited connectivity. Some models may have a diagnostic port for EFI system access.
Oil Change Interval:
Typically every 5,000 miles (8,000 km) or 6 months, whichever comes first. Check manual for specific break-in oil change interval.
Primary Chain Tensioner Inspection:
Inspect every 5,000 miles. Automatic tensioner should be checked for wear and functionality.
Spark Plug Replacement:
Typically every 10,000 - 15,000 miles (16,000 - 24,000 km), but this can vary greatly depending on plug type and riding conditions.
Drive Belt Inspection And Tension:
Inspect belt for wear and damage at every 5,000 mile service. Check and adjust tension as per specifications.
Brake Fluid Type:
DOT 4 (or DOT 5.1 if specified by manufacturer for specific models within the range, though DOT 4 is common).
Fork Oil Type:
Harley-Davidson Spectro Big Twin Fork Oil (e.g., 10W or 15W, depending on model and rider preference). Manual will specify.
Cam Chain Tensioner Wear:
Hydraulic cam chain tensioners (inner and outer) can wear over time, leading to noise and potential engine damage. Early models had less durable tensioners. Upgrade kits are available.
Primary Chain Tensioner Wear:
The automatic primary chain tensioner can wear, causing noise and premature chain wear. Routine inspection is crucial.
Electrical Connector Corrosion:
Some electrical connectors, particularly those exposed to the elements, can develop corrosion, leading to intermittent issues. Cleaning and dielectric grease application is often recommended.
Fuel Injector Cleaning:
EFI systems may benefit from periodic fuel injector cleaning or servicing to maintain optimal performance.
Brand Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and cruiser-style motorcycles.
Softail Platform Genesis:
The Softail chassis, introduced in 1983, features hidden rear shock absorbers, giving the appearance of a hardtail frame while providing suspension comfort.
Production Era Covered:
This manual covers the second generation of the Softail platform, following the 1984-1999 models. Key updates in this era included fuel injection and improved braking systems.
Manufacturing Location:
Primarily York, Pennsylvania, USA, and Milwaukee, Wisconsin, USA.
