Motorcycle Segment:
Cruiser, Classic Styling
Key Competitors 2002:
Other large-displacement cruiser motorcycles from American and Japanese manufacturers.
Distinctive Features:
Iconic Fat Boy styling, chrome accents, wide front tire, low-slung profile, classic Harley-Davidson V-twin rumble.
User Profile:
Harley-Davidson owners, independent repair shops, technicians specializing in vintage and classic motorcycles.
Diagnostic And Repair Utility:
Empowers users to perform a wide range of maintenance and repair tasks, reducing reliance on dealerships and saving on labor costs.
Engine And Powertrain:
Engine disassembly, assembly, inspection, tuning, fuel system, ignition system, lubrication system, cooling system (if applicable), exhaust system.
Chassis And Suspension:
Frame inspection, front fork overhaul, rear shock absorber service, steering system, wheel and tire service, brake system maintenance and repair (front and rear).
Electrical System:
Battery, charging system (alternator, regulator), starting system (starter, solenoid), lighting system, ignition system diagnostics, instrument cluster, wiring diagrams.
Bodywork And Trim:
Fender removal/installation, fuel tank service, seat assembly, fairings/covers, chrome trim maintenance.
Clutch And Drivetrain:
Clutch operation, primary drive, transmission overhaul, final drive belt inspection and adjustment.
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, spark plug service, brake fluid flush, clutch adjustment, drive belt tensioning.
Diagnostic Procedures:
Troubleshooting guides for common performance issues, electrical faults, and mechanical failures.
Repair Procedures:
Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly.
Diagnostic Level:
Advanced diagnostics, including component testing, circuit analysis, and fault code interpretation (where applicable).
Rebuild Scope:
Complete engine rebuild procedures, transmission overhaul, and major component refurbishment.
Special Tools Requirement:
Identifies and specifies required Harley-Davidson special tools for various procedures.
Engine Type:
Air-cooled, 45-degree V-twin, Twin Cam 88B
Displacement:
1450 cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Horsepower Estimate:
Approx. 65-70 HP (at crankshaft, specific to factory tune)
Torque Estimate:
Approx. 85-90 ft-lbs (at crankshaft, specific to factory tune)
Fuel Delivery:
Fuel Injection (Electronic Sequential Port Fuel Injection - ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane (R+M)/2
Ignition Type:
Electronic CDI (Capacitor Discharge Ignition)
Oil Capacity:
Approx. 4 quarts (3.8 liters) with filter change
Oil Type:
Harley-Davidson Genuine Motor Oil SAE 20W50 or equivalent motorcycle-specific 20W50 API SG or higher.
Transmission Type:
5-speed constant mesh, helical gears
Gear Ratios:
Refer to manual for specific gear ratios (e.g., 1st: 9.006, 2nd: 6.782, 3rd: 5.004, 4th: 3.731, 5th: 3.150)
Clutch Type:
Wet, multi-plate, diaphragm spring
Final Drive:
Carbon fiber reinforced belt, 140-tooth, 1-inch pitch
Transmission Oil Type:
Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant or equivalent SAE 85W-140 API GL-5 gear oil.
Transmission Oil Capacity:
Approx. 24-26 fl oz (710-770 ml)
Length:
Approx. 93.3 in. (2370 mm)
Wheelbase:
Approx. 64.5 in. (1638 mm)
Seat Height Laden:
Approx. 26.7 in. (678 mm)
Ground Clearance:
Approx. 4.7 in. (119 mm)
Dry Weight:
Approx. 675 lbs (306 kg)
Gross Vehicle Weight Rating:
Approx. 1080 lbs (490 kg)
Fuel Tank Capacity:
5.0 US gallons (18.9 liters)
Front Tire Size:
130/90B16 67H
Rear Tire Size:
150/80B16 71H
Wheel Type:
Polished Aluminum Disc Wheels
Safety Certification:
DOT compliant (for road use in the US)
Braking System:
Hydraulic disc brakes, front and rear. Dual front disc setup on some FLSTFI models.
Front Brake Specs:
Dual 11.5 in. (292 mm) discs, 4-piston calipers
Rear Brake Specs:
Single 11.5 in. (292 mm) disc, 2-piston caliper
Lighting:
Halogen headlight, tail light, brake light, front and rear turn signals.
Audio System:
Optional accessory audio systems (radio, CD player) were available, not standard equipment on all 2002 models.
ABS Availability:
Anti-lock Braking System (ABS) was generally not a standard or widely available option for the 2002 Softail models.
Connectivity Features:
Limited to diagnostic connectors for engine management systems; no integrated Bluetooth or smartphone connectivity.
First Service Mileage:
1,000 miles (1,600 km) or 6 months, whichever comes first.
Subsequent Service Mileage:
Every 5,000 miles (8,000 km) or 12 months for oil changes and inspections. More frequent service for heavy use.
Primary Chaincase Oil:
Harley-Davidson Formula+ or equivalent SAE 85W-140 API GL-5 gear oil.
Brake Fluid:
DOT 4 Hydraulic Fluid (Harley-Davidson DOT 4 or equivalent)
Fork Oil Type:
Harley-Davidson Genuine Suspension Fluid (e.g., Type E) or equivalent 10W fork oil.
Common Flstfi Concerns:
Wiring harness chafing (especially in fairing/handlebar areas), rear fender strut cracks (due to vibration/heavy loads), compensator sprocket wear, carburetor (if applicable on earlier models, though this is FI) jetting issues, exhaust system leaks.
Oil Filter Part Number:
Harley-Davidson OEM: 63796-77A (or aftermarket equivalent like 11-0188 K&N, HF170C K&N)
Air Filter Part Number:
Harley-Davidson OEM: 29044-02 (or aftermarket equivalent)
Spark Plug Part Number:
Harley-Davidson OEM: 32302-01 (for Twin Cam 88B) (e.g., NGK DCPR7E)
Harley Davidson Legacy:
Long-standing reputation for V-twin motorcycles, customization, and American industrial design.
Softail Introduction:
The Softail platform, introduced in 1984, mimicked the appearance of a hardtail frame while incorporating rear suspension for comfort.
Fat Boy Introduction:
The Fat Boy model, launched in 1990, quickly became an icon with its distinctive wide front tire, fluted fenders, and extensive chrome.
Production Period For 2002 Model:
Model year 2002
Manufacturing Location:
York, Pennsylvania, USA and Milwaukee, Wisconsin, USA (assembly)
