Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson FLSTFI Fat Boy 2000 owners, independent repair shops, custom builders.
Manual Value Proposition:
Provides factory-level accuracy and detail for essential maintenance and repair, saving significant costs compared to dealership services.
Completeness:
Official factory content, ensuring accuracy and comprehensive coverage of all vehicle systems.
Searchability:
Digital PDF format allows for quick searching of specific topics and procedures.
Print Flexibility:
Ability to print specific sections or the entire manual for convenient workshop use.
Engine Mechanical:
Engine assembly, disassembly, internal components, cooling system (air-cooled), lubrication system.
Fuel And Emissions:
Fuel delivery system, carburetor (CV type), fuel tank, fuel lines, emissions control systems.
Ignition And Starting:
Ignition system components, spark plugs, ignition timing, starter motor, solenoid, battery.
Transmission And Drivetrain:
Clutch operation and service, transmission assembly and disassembly, gear shifting mechanisms, final drive belt.
Chassis And Suspension:
Frame components, front fork (including hydraulic damper adjustment), rear shock absorbers, swingarm, bearings.
Braking System:
Front and rear brake systems (hydraulic disc), brake caliper service, brake fluid replacement, hydraulic lines.
Electrical System:
Lighting system (headlight, taillight, signals), instrumentation, horn, battery charging system (alternator/regulator), wiring harness, fuses, relays, starter circuit.
Wheels And Tires:
Wheel removal and installation, tire mounting and balancing, spoke tensioning (if applicable to specific wheel type), valve stems.
Body And Trim:
Fenders, fuel tank, seat, handlebars, controls, mirrors, fenders, side covers, trim pieces.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks/replacement, chain/belt adjustment and lubrication, brake fluid checks.
Engine Repair:
Piston removal/installation, cylinder head service, valve adjustments, camshaft service, timing chain/belt inspection.
Transmission Repair:
Gear inspection and replacement, clutch plate service, bearing replacement, shift drum and fork service.
Electrical Diagnostics:
Troubleshooting electrical faults, testing components, using wiring diagrams, component replacement.
Suspension Overhaul:
Fork seal replacement, fork oil change, rear shock absorber service and replacement.
Brake System Service:
Brake pad replacement, caliper overhaul, master cylinder service, brake line flushing and bleeding.
Carburetor Rebuild:
Carburetor disassembly, cleaning, inspection, adjustment, and reassembly.
Wheel Bearing Service:
Wheel bearing inspection, repacking, and replacement.
Depth Level:
Comprehensive Factory Level
Diagnostic Capability:
Advanced diagnostic information and troubleshooting charts for all systems.
Rebuild Procedures:
Detailed step-by-step instructions for complete engine, transmission, and major component rebuilds.
Engine Family:
Evolution (Evo)
Engine Type:
V-Twin, Four-stroke
Displacement:
1449 cc (88 cubic inches)
Bore X Stroke:
3.50 in x 4.47 in (88.9 mm x 113.5 mm)
Cooling System:
Air-Cooled
Valvetrain:
OHV, 2 valves per cylinder
Horsepower Estimate:
Approx. 65-70 HP (at crankshaft, estimated)
Torque Estimate:
Approx. 75-80 lb-ft (at crankshaft, estimated)
Fuel Delivery:
Carburetor
Carburetor Model:
Keihin CV (Constant Velocity) 40mm
Fuel Type:
Unleaded Gasoline, 91 Octane or higher recommended
Initial Service:
1000 miles (1600 km) or 6 months
Subsequent Service:
Every 5000 miles (8000 km) or 12 months thereafter
Engine Oil Change:
Every 5000 miles (8000 km)
Primary Chain Tensioner Inspection:
Every 10000 miles (16000 km)
Engine Oil:
Harley-Davidson Syn3 (SAE 20W-50) or equivalent.
Transmission Oil:
Harley-Davidson Syn3 (SAE 20W-50) or equivalent.
Primary Chain Case Oil:
Harley-Davidson primary fluid or Syn3 (SAE 20W-50).
Primary Chain Tensioner:
Wear on the automatic primary chain tensioner can lead to noise and potential damage. Manual replacement with updated or manual tensioner is a common upgrade.
Cam Chain Tensioners:
Similar to primary tensioners, early Evo models can have wear issues with cam chain tensioners, often addressed with upgraded components.
Carburetor Tuning:
CV carburetors can require periodic adjustment for optimal performance, especially with altitude or aftermarket exhaust/intake changes.
Manufacturer:
Harley-Davidson Motor Company
Fat Boy Introduction:
Introduced in 1990, the Fat Boy quickly became an icon for its distinctive styling, wide front tire, and solid disc wheels.
2000 Model Year Updates:
While major platform changes occurred later, the 2000 model represents a mature iteration of the Evolution engine platform and classic Fat Boy styling.
Manufacturing Location:
York, Pennsylvania, USA and Milwaukee, Wisconsin, USA
