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Harley Davidson FXSTS Springer ST 2003 Repair Service Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: FXSTS Springer ST Year: 2003 Chassis Code: FXSTS Platform: Softail 👋 Introduction Market Position Category: Cruiser Motorcycle Segment: Custom/Performance Cruiser Target Audience: Enthusiasts...
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🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FXSTS Springer ST
Year:
2003
Chassis Code:
FXSTS
Platform:
Softail
👋 Introduction
Market Position
Category:
Cruiser Motorcycle
Segment:
Custom/Performance Cruiser
Target Audience:
Enthusiasts seeking a classic-styled motorcycle with modern performance and the iconic Harley-Davidson experience
Competitive Analysis
Competitors:
Other Harley-Davidson Softail models, Indian Chief variants, select Japanese cruisers with similar styling and displacement
Key Features
Distinctive Feature 1:
Telescopic Springer front fork providing a unique vintage aesthetic and handling characteristics
Distinctive Feature 2:
Softail chassis with hidden rear shock absorbers, creating a hardtail look
Distinctive Feature 3:
Large displacement V-twin engine delivering characteristic torque and sound
Distinctive Feature 4:
Chrome-laden styling with attention to detail, emphasizing classic cruiser design
📋 Manual Details
Coverage Areas
Engine:
Full coverage (disassembly, assembly, tuning, troubleshooting)
Transmission:
Full coverage (disassembly, assembly, troubleshooting)
Drivetrain:
Full coverage (belt drive, clutch, primary chain)
Suspension:
Full coverage (front Springer fork, rear shock absorbers, linkages)
Brakes:
Full coverage (hydraulic systems, calipers, master cylinders, lines)
Electrical System:
Full coverage (ignition, lighting, charging, starting, wiring diagrams)
Fuel System:
Full coverage (carburetor/fuel injection, fuel pump, lines)
Frame And Bodywork:
Full coverage (frame components, fenders, fuel tank, seat, controls)
Wheels And Tires:
Full coverage (tire inspection, replacement, wheel balancing)
Maintenance:
Comprehensive schedule and procedures
Troubleshooting:
Detailed diagnostic guides for common and complex issues
Wiring Diagrams:
Detailed and color-coded diagrams
Page Count
Estimated Pages:
Approximately 600-800 pages (typical for full service manuals)
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
File Format
Type:
PDF
Searchable:
Typically searchable text, allowing quick information retrieval
Printable:
Yes, allows users to print specific sections or the entire manual
Quality:
High resolution scans with clear diagrams and text
Binding Type
Type:
N/A (Digital PDF)
Paper Type
Type:
N/A (Digital PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Cylinder head, pistons, connecting rods, crankshaft, camshafts, oil pump, timing components
Engine Performance:
Carburetor (CV 40mm) tuning, ignition timing, exhaust system considerations
Transmission Components:
Gearbox, clutch assembly, primary drive chain, compensator sprocket
Suspension Components:
Front Springer fork disassembly/assembly, fork oil specifications, rear shock absorber service
Braking System:
Front and rear disc brake calipers, master cylinders, brake fluid types and bleeding procedures
Electrical Components:
Battery, starter motor, alternator, voltage regulator, ignition module, lights, switches, fuses
Fuel Delivery:
Carburetor cleaning, adjustment, fuel filter replacement, fuel line maintenance
Chassis Components:
Frame inspection, steering head bearings, swingarm pivot bearings, wheel bearings
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, brake checks, lubrication points
Engine Rebuild:
Complete top-end and bottom-end overhaul procedures
Transmission Overhaul:
Gearbox disassembly, reassembly, and troubleshooting common issues
Suspension Service:
Fork seal replacement, shock absorber calibration, spring adjustments
Brake System Service:
Brake pad replacement, caliper overhaul, master cylinder rebuild, fluid flush
Electrical Diagnostics:
Troubleshooting starting system, charging system, ignition system faults
Carburetor Adjustment And Rebuild:
Detailed steps for tuning and overhauling the CV carburetor
Wheel And Tire Service:
Tire mounting/dismounting, wheel balancing, spoke adjustment (if applicable)
Bodywork And Trim Removal:
Instructions for removing fenders, fuel tank, seat, and other body panels
Technical Depth
Depth:
Comprehensive, suitable for both DIY enthusiasts and professional mechanics
Diagnostic Codes:
Troubleshooting guides often reference diagnostic trouble codes (DTCs) if applicable to the electronic systems
Torque Specifications:
Precise torque values for all critical fasteners
Clearances And Tolerances:
Specifications for engine internal clearances and wear tolerances
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, Twin Cam 88B V-twin
Displacement:
1449 cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Compression Ratio:
8.9:1
Valve Train:
Overhead valves (OHV), 2 valves per cylinder
Cooling System:
Air-cooled
Oil System:
Dry sump with oil tank
Performance
Horsepower Estimate:
Approximately 65-70 hp (at crank)
Torque Estimate:
Approximately 75-80 ft-lbs (at crank, at ~3000 RPM)
Fuel System
Fuel Delivery:
Carburetor: Keihin CV 40mm
Fuel Type:
Unleaded gasoline, minimum 91 octane (R+M)/2
Fuel Tank Capacity:
4.0 gallons (15.1 L)
🔧 Transmission
Standard
Type:
5-speed constant mesh
Gear Ratios:
1st: 2.875, 2nd: 1.732, 3rd: 1.216, 4th: 1.000, 5th: 0.818
Primary Drive:
Duplex chain, 34/46 tooth (1.35:1 ratio)
Clutch:
Wet, multi-plate, compensator sprocket
Final Drive:
Belt drive, 32/66 tooth (2.06:1 ratio)
Features
Transmission Fluid:
Harley-Davidson recommended transmission lubricant (e.g., Formula+ or Syn3)
📐 Dimensions
Exterior
Length:
Approximately 92.3 inches (2345 mm)
Seat Height Laden:
Approximately 26.2 inches (665 mm)
Ground Clearance:
Approximately 4.3 inches (109 mm)
Weights
Dry Weight:
Approximately 629 lbs (285 kg)
Gross Vehicle Weight Rating:
Approximately 1035 lbs (469 kg)
Wheels And Tires
Front Tire:
MT90B16 72H
Rear Tire:
MU85B16 77H
Wheelbase:
64.5 inches (1638 mm)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycles are not typically subject to the same crash testing standards as automobiles)
Active Features
Braking System:
Hydraulic disc brakes front and rear
Passive Features
Lighting:
Headlight, taillight, brake lights, turn signals
Frame Construction:
Steel frame and swingarm designed for stability
💡 Technology Features
Infotainment
Audio System:
Optional accessory audio systems might have been available, but not standard on this model. Manual covers accessory installation wiring.
Driver Assistance
Features:
None standard (e.g., no ABS, traction control on this model year)
Connectivity
Features:
No integrated connectivity features like Bluetooth or smartphone integration on the base model.
🔧 Maintenance
Service Intervals
First Service:
Approximately 1,000 miles (1,600 km) or 6 months, whichever comes first (includes oil change, filter change, primary chain adjustment, inspection)
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months for general maintenance (oil, filter, inspections); transmission and primary chaincase fluid changes at specific intervals as per manual
Spark Plugs:
Inspect at 5,000 miles, replace as needed or at manufacturer recommended intervals (typically 10,000-20,000 miles)
Belt Drive Tension:
Check and adjust belt tension every 5,000 miles
Fluid Specifications
Engine Oil:
Harley-Davidson 20W-50 V-Twin Motorcycle Oil or equivalent API CI-4 rated oil (Capacity: approx. 4 quarts/3.8 liters with filter)
Transmission Fluid:
Harley-Davidson Formula+ Transmission/Primary Chaincase Lubricant or HD Syn3 Synthetic Motorcycle Oil (Capacity: approx. 1 quart/0.95 liters)
Primary Chaincase Fluid:
Same as transmission fluid
Brake Fluid:
DOT 4 Hydraulic Fluid (ensure it meets specifications for Harley-Davidson)
Fork Oil:
Harley-Davidson Type 'E' (10W) or Type 'H-D 10W' Fork Oil (or equivalent viscosity index fork oil) - specific quantity per leg
Known Issues
Cam Chain Tensioners:
Early Twin Cam engines (pre-2007) had plastic cam chain tensioners that could wear out, leading to potential engine damage. Later models used hydraulic tensioners. This manual will cover inspection and replacement procedures.
Crankshaft Runout:
Some Twin Cam engines can be susceptible to crankshaft runout issues. The manual will provide specifications and inspection methods.
Primary Clutch Adjustment:
Proper primary chain and clutch adjustment is critical for smooth operation and longevity. The manual details the correct procedures.
Harley Davidson Oil Leaks:
Commonly found around base gaskets, primary cover, and transmission seals. Manual provides gasket replacement and sealing procedures.
📚 Vehicle History
Brand Heritage
Brand:
Harley-Davidson, established 1903, iconic American motorcycle manufacturer
Model Evolution
Softail Lineage:
The Softail platform, introduced in the late 1970s, is known for its hidden rear suspension mimicking a hardtail look, providing a classic profile with modern ride comfort.
Springer Fork History:
The Springer front fork is a revival of an early motorcycle suspension design, offering a distinctive visual and tactile riding experience. Harley-Davidson has offered Springer models periodically since the 1980s.
Production
Model Production Period:
The FXSTS Springer Softail was produced from 1988 to 2006.
2003 Model Year Significance:
Represents a mature iteration of the Twin Cam 88B engine and Softail platform.
🏆 Awards & Recognition
Recognitions
Brand Awards:
Harley-Davidson consistently recognized for its brand heritage, build quality (relative to its style), and iconic V-twin engines.
Ratings
Customer Satisfaction:
Highly variable, but generally strong among loyal owners. The manual is key to maintaining optimal performance and satisfaction.
Certifications
Certification Standards:
Meets all applicable federal motor vehicle safety standards for its model year.