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Harley Davidson FLSTF Fat Boy Motorcycle 2002 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLSTF Fat Boy Year: 2002 Product Type: Service Repair Workshop Manual Product Format: Download PDF 👋 Introduction Market Position Model Segment: Cruiser, specifically...
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🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FLSTF Fat Boy
Year:
2002
Product Type:
Service Repair Workshop Manual
Product Format:
Download PDF
👋 Introduction
Market Position
Model Segment:
Cruiser, specifically a 'cruiser' style motorcycle known for its classic styling and relaxed riding position.
Competitive Analysis
Key Competitors:
Other American V-twin cruisers, and potentially some Japanese models with similar styling and displacement, though often distinguished by engine architecture and brand identity.
Key Features
Distinctive Styling:
Iconic wide front tire, chrome accents, teardrop fuel tank, extensive use of chrome and polished metal, classic lines.
Target Audience
Demographic:
Riders who appreciate classic styling, V-twin character, and the Harley-Davidson brand experience.
Manual Purpose
Utility:
Essential for owners and independent mechanics seeking to perform maintenance, repairs, and diagnostics on the 2002 Harley-Davidson FLSTF Fat Boy.
📋 Manual Details
Coverage Areas
Vehicle Make:
Harley-Davidson
Vehicle Model:
FLSTF Fat Boy
Model Years Covered:
2002
Page Count
Estimated Pages:
Estimating from typical Harley-Davidson factory manuals of this era, expect in excess of 500 pages.
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital PDF
📖 Manual Coverage
Systems Covered
Engine:
Twin Cam 88 V-Twin (carbureted variants), engine disassembly, assembly, tuning, lubrication, cooling system.
Transmission:
5-speed Cruise Drive transmission, clutch operation, gearbox inspection, repair, lubrication.
Fuel System:
Carburetor (Keihin CV, likely 40mm), fuel tank, fuel lines, fuel filter replacement, idle speed adjustment, mixture screw settings.
Ignition System:
Electronic ignition system, spark plugs, ignition coils, timing, troubleshooting ignition faults.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting systems (headlight, tail light, signals), starter system, fuses, relays, switches.
Suspension:
Front fork (likely 41mm Showa), rear shock absorbers, fork oil change, fork seal replacement, shock absorber adjustment.
Brakes:
Front and rear disc brakes, brake caliper service, brake fluid flush and replacement, brake line inspection, master cylinder service.
Wheels And Tires:
Spoked wheels, wheel bearing maintenance, tire pressure checks, tire replacement, balancing.
Frame And Bodywork:
Frame inspection, chassis components, fender removal/installation, tank and seat mounting, handlebar installation.
Exhaust System:
Exhaust pipe and muffler inspection, gasket replacement, exhaust hanger inspection.
Procedures Included
Maintenance:
Routine service checks, oil changes, filter replacements, chain lubrication (if applicable, though Fat Boy typically belt-driven), tire pressure, brake system checks.
Diagnostics:
Troubleshooting guides for common performance issues, electrical faults, starting problems, braking concerns, and drivetrain issues.
Repair:
Step-by-step instructions for component disassembly, inspection, repair, and reassembly across all major systems.
Overhaul:
Complete engine and transmission rebuild procedures, including torque specifications and assembly sequence.
Troubleshooting Charts:
Detailed flowcharts and symptom-based diagnostic trees to identify and resolve problems.
Technical Depth
Depth:
Comprehensive. Covers everything from basic rider maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and component-level repairs.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Typically OCR'd or natively searchable text for easy navigation and keyword searching.
Print Quality
Quality:
High-resolution scans of original factory documents, ensuring clarity of text, diagrams, and images.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
Features
Licensing:
No expiry dates, no extra fees (as stated in product description).
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 45-degree V-twin, pushrod actuated, overhead valves.
Engine Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Compression Ratio:
8.8:1 (typical for Twin Cam 88)
Performance
Horsepower:
Approx. 65-70 HP at 5,000 RPM (estimated, as factory figures varied)
Torque:
Approx. 70-75 ft-lbs at 3,000 RPM (estimated)
Fuel System
Carburetor Model:
Keihin CV 40mm (likely)
Fuel Delivery:
Carburetor with manual choke.
Lubrication
Oil Type Recommendation:
Harley-Davidson 20W-50 SYN3 or equivalent motorcycle-specific oil meeting Harley-Davidson specifications.
Oil Capacity
Capacity:
Approx. 3.0 US quarts (2.8 liters) with filter change.
Cooling System
Cooling Method:
Air-cooled, with oil cooler as standard equipment.
🔧 Transmission
Standard
Type:
5-speed constant mesh, sequential manual transmission.
Clutch Type:
Wet, multi-plate, cable-actuated.
Features
Primary Drive:
Duplex chain, rubber isolated.
Final Drive:
Belt drive, 151-tooth, 1.125-inch wide, 25mm pitch.
Fluid Type
Transmission Oil:
Harley-Davidson Formula Plus or equivalent primary chaincase lubricant.
Fluid Capacity
Primary Chaincase Capacity:
Approx. 2.8 US quarts (2.6 Liters).
📐 Dimensions
Exterior
Length:
Approx. 93.5 inches (2375 mm)
Width:
Approx. 37.6 inches (955 mm)
Height:
Approx. 48.0 inches (1220 mm)
Wheelbase:
Approx. 63.5 inches (1613 mm)
Weights
Dry Weight:
Approx. 630 lbs (286 kg)
Gross Vehicle Weight Rating:
Approx. 1000 lbs (454 kg)
Gvwr:
Approx. 1000 lbs (454 kg)
Cargo
Fuel Capacity:
4.5 US gallons (17.0 Liters)
Wheels And Tires
Front Tire Size:
130/90-16 67H (Note: Wider than standard, characteristic of the Fat Boy)
Rear Tire Size:
150/80B16 71H
Front Wheel Type:
Chrome steel laced, 16 x 3.00
Rear Wheel Type:
Chrome steel laced, 16 x 3.00
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycles typically do not undergo standardized crash testing like passenger cars).
Active Features
Braking System:
Dual-piston caliper front and rear disc brakes.
Lighting:
Halogen headlight, taillight, stoplight, front and rear turn signals.
Passive Features
Frame Construction:
Steel, cradle-type frame designed for stability and rider comfort.
Handlebars:
Wide, pullback handlebars to provide leverage and a relaxed riding posture.
💡 Technology Features
Infotainment
Audio System:
Not typically equipped with a factory-integrated audio system on this model. Aftermarket options are common.
Driver Assistance
Features:
No electronic driver assistance systems like ABS or traction control are standard on this model.
Connectivity
Features:
N/A (No modern connectivity features like Bluetooth or smartphone integration).
Lighting
Headlight Type:
Halogen, sealed-beam unit.
🔧 Maintenance
Service Intervals
Initial Service:
First service typically around 1,000 miles (1600 km) for oil change, filter check, belt tension check, and general inspection.
Regular Oil Changes:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first, for engine oil and filter.
Primary Chaincase Fluid Change:
Typically every 10,000-20,000 miles (16,000-32,000 km), refer to manual for exact interval.
Transmission Fluid Change:
Same interval as primary chaincase fluid, refer to manual.
Belt Tension Check:
Every 1,000 miles, adjust as needed.
Fluid Specifications
Engine Oil Specification:
Harley-Davidson H-D 360 SAE 20W-50 Motor Oil or H-D SYN3 Synthetic Motorcycle Oil.
Primary Chaincase Lubricant Specification:
Harley-Davidson Formula Plus or SAE 50 weight motorcycle oil meeting HD specification HD-8762.
Brake Fluid Specification:
DOT 4 brake fluid.
Fork Oil Type:
Harley-Davidson Silicone Fork Oil (weight varies by preference, typically 10W or 15W for a balanced ride).
Known Issues
Common Concerns:
Potential for cam bearing wear (though improved with Twin Cam 88B), exhaust leaks, occasional charging system issues (regulator/rectifier), and carburetor tuning sensitivity.
Maintenance Focus Areas:
Regular checks of belt tension, brake system, and electrical connections are crucial for longevity and performance.
Part Numbers
Oil Filter Part Number:
Harley-Davidson Part Number 63806-00 (or compatible aftermarket).
Air Filter Part Number:
Harley-Davidson Part Number 29461-99 (or compatible aftermarket).
📚 Vehicle History
Brand Heritage
Brand Identity:
Harley-Davidson, established in 1903, is an iconic American motorcycle manufacturer known for its V-twin engines, distinctive styling, and strong brand loyalty.
Model Evolution
Fat Boy Origin:
The Fat Boy model, introduced in 1990, was a tribute to the post-WWII 'Liberator' bomber aircraft and gained significant popularity, including a prominent role in the movie Terminator 2: Judgment Day.
Twin Cam Introduction:
The Twin Cam 88 engine was introduced in 1999, representing a significant upgrade over the Evolution engine with increased displacement and improved performance and durability.
Production
Manufacturing Location:
United States (primarily Milwaukee, Wisconsin and Kansas City, Missouri for this era).
🏆 Awards & Recognition
Recognitions
Cultural Impact:
Recognized as an icon of American motorcycling, heavily influencing the cruiser market segment. Gained significant cultural relevance through media appearances.
Ratings
Customer Satisfaction:
Generally high customer satisfaction for its styling and riding experience, though performance metrics may be secondary to brand appeal for many owners.
Certifications
Emissions Compliance:
Compliant with US EPA and California ARB emissions standards for its model year.