🏷️ Basic Information

Make:

Harley-Davidson

Model:

Softail

Model Codes:

FLST, FXST

Year:

2004

Product Name:

Harley Davidson Softail Models FLST FXST 2004 Service Repair Workshop Manual PDF

👋 Introduction

Positioning:

Essential technical documentation for owners and mechanics of 2004 Harley-Davidson Softail models, providing the highest level of repair and maintenance detail.

Value Proposition:

Offers factory-level accuracy and completeness, a crucial resource for maintaining these iconic V-twin motorcycles. Superior to generic repair guides.

Completeness:

The 'Complete Factory Service Repair Workshop Manual' designation indicates comprehensive coverage across all vehicle systems.

Accessibility:

Instant download availability provides immediate access to critical technical information.

📋 Manual Details

Languages:

English

Manual Type:

Service Repair Workshop Manual

Estimated Page Count:

Refer to specific manual edition (typically 500-1000+ pages for comprehensive factory manuals)

File Format:

PDF

Licensing Terms:

No Extra Fees, No Expiry Dates

📖 Manual Coverage

Engine Service:

Detailed diagnostics, repair, overhaul, timing, lubrication, cooling (air-cooled) systems

Fuel System:

Carburetor (Keihin CV), fuel injection (EFI) systems, fuel pumps, lines, tanks

Ignition System:

Ignition modules, coils, spark plugs, wiring diagrams

Transmission Drivetrain:

5-speed constant mesh transmission, primary drive, clutch, final drive belt inspection and replacement

Chassis Frame:

Frame inspection, steering head bearings, swingarm, rear suspension (shock absorbers)

Front Suspension:

Front forks (e.g., 41mm telescopic), fork oil change, seal replacement, adjustments

Brakes:

Front and rear brake systems, caliper service, pad replacement, fluid flush, master cylinders

Electrical System:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, starting system, switches, gauges

Bodywork Fittings:

Fender removal/installation, fuel tank, seat, handlebars, controls, mirrors

Wheels Tires:

Wheel bearing maintenance, tire inspection and replacement, spoke tensioning (if applicable)

Scheduled Maintenance:

Recommended service intervals for oil changes, filter replacements, adjustments, inspections

Engine Troubleshooting:

Diagnostic procedures for common engine performance issues, misfires, starting problems

Transmission Repair:

Clutch adjustment and replacement, internal transmission component service

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, component testing

Brake System Overhaul:

Complete brake system bleeding, component replacement, caliper rebuilding

Fork Rebuild:

Step-by-step instructions for disassembling, cleaning, and reassembling front forks

Wheel Alignment Adjustment:

Procedures for checking and adjusting steering and wheel alignment

Component Disassembly Reassembly:

Detailed instructions for removing and installing major components

Depth:

Comprehensive Factory Level Repair and Diagnostic Information

Target Audience:

Professional Technicians and Experienced DIY Mechanics

📊 Manual Specifications

Scan Quality:

High-resolution PDF, ensuring clarity of diagrams and text

Searchability:

Likely searchable text within the PDF for quick information retrieval

Printability:

Printable for use in a workshop environment

Binding:

N/A (Digital PDF Format)

Paper Type:

N/A (Digital PDF Format)

⚙️ Engine Specifications

Engine Type:

Harley-Davidson Evolution (V-Twin) Big Twin

Displacement:

Commonly 1450cc (88 cubic inches)

Bore X Stroke:

Refer to specific engine variant (e.g., 3.75 in x 4.00 in)

Compression Ratio:

Refer to specific engine variant (e.g., 8.5:1 or 9.0:1)

Horsepower:

Approx. 65-75 HP (Varies by tune and model variant)

Torque:

Approx. 80-90 ft-lbs (Varies by tune and model variant)

Fuel Delivery:

Carbureted (Keihin CV 40mm typically) or Electronic Fuel Injection (EFI) depending on specific sub-model

Fuel Type:

Unleaded gasoline, 91 octane (AKI) or higher recommended

Cooling Method:

Air-cooled

Oil Type:

Harley-Davidson Genuine V-Twin Oil or equivalent motorcycle-specific V-twin lubricant (e.g., SAE 20W-50)

Oil Capacity:

Approx. 3.5 US quarts (3.3 Liters) with filter change

Oil Filter Part Number:

Harley-Davidson P/N 63796-77A (or equivalent aftermarket)

🔧 Transmission

Transmission Type:

5-speed, constant mesh, sequential manual gearbox

Gear Ratios:

Refer to specific manual for detailed gear ratios (e.g., 1st: 9.29, 2nd: 6.07, 3rd: 4.41, 4th: 3.37, 5th: 2.80)

Primary Drive:

Duplex chain, 34/46 tooth sprockets (1.35:1 ratio)

Final Drive:

Belt drive, 32/66 tooth sprockets (2.06:1 ratio)

Fluid Type:

Harley-Davidson Syn 3 (20W-50) or equivalent V-Twin transmission oil

Fluid Capacity:

Approx. 1.0 US quart (0.95 Liters)

Clutch Type:

Wet, multi-plate

📐 Dimensions

Length:

Refer to specific model (e.g., FLSTF 'Fat Boy' ~95.5 in)

Width:

Refer to specific model (e.g., Handlebar width ~35-37 in)

Height:

Refer to specific model (e.g., Seat height ~27 in)

Dry Weight:

Typically 600-670 lbs (272-304 kg) depending on model configuration

Gross Vehicle Weight Rating:

Refer to specific model (usually around 1000-1100 lbs)

Front Tire Size:

Commonly 130/90-16 (e.g., FLSTF) or 80/90-21 (e.g., FXST)

Rear Tire Size:

Commonly 150/80-16

Wheel Type:

Spoked or solid cast aluminum wheels

Wheelbase:

Refer to specific model (e.g., FLSTF ~66.3 in)

🛡️ Safety Features

Crash Safety Ratings:

Motorcycles are not subject to the same standardized crash test ratings as automobiles. Safety depends heavily on rider skill and adherence to maintenance.

Braking System:

Dual-piston calipers with single discs front and rear (11.5-inch rotors typical)

Lighting:

Halogen headlight, LED tail light/brake light, incandescent turn signals

Frame Construction:

Steel tubular frame provides structural integrity

Rider Ergonomics:

Designed for a comfortable riding posture, though customization is common.

💡 Technology Features

Audio System:

Optional factory or aftermarket audio systems were available on some models, often with handlebar-mounted controls.

Gauges:

Analog speedometer, tachometer (optional on some models), fuel gauge, oil pressure indicator, and indicator lamps.

ABS:

Anti-lock Braking System (ABS) was not standard and was a rare option on 2004 Softail models.

Connectivity Features:

No integrated smartphone connectivity or Bluetooth found on standard 2004 models; aftermarket solutions are common.

🔧 Maintenance

First Service:

1,000 miles (1,600 km) - typically includes engine oil and filter change, primary chain tension adjustment, and general inspection.

Subsequent Oil Changes:

Every 5,000 miles (8,000 km) or annually, whichever comes first.

Belt Tension Check:

Every 10,000 miles (16,000 km) or as needed based on riding conditions.

Brake Fluid Flush:

Every 2 years, regardless of mileage.

Engine Oil Viscosity:

SAE 20W-50 motorcycle specific

Transmission Oil Viscosity:

SAE 20W-50 motorcycle specific

Primary Chain Case Oil:

Harley-Davidson Primary Chaincase Lubricant or equivalent, capacity ~1 US quart

Brake Fluid:

DOT 4 Hydraulic Brake Fluid (unless specified otherwise for ABS models, though unlikely for 2004)

Cam Chain Tensioners:

Early Evolution engines (pre-Twin Cam) used plastic cam chain tensioners that could wear. While Twin Cams are more robust, manual inspection is advised.

Regulator Rectifier:

Common failure point on many Harley models, leading to charging issues. Diagnosis and replacement procedures are crucial.

Carburetor Tuning:

Keihin CV carburetors can require periodic adjustment for optimal performance and emissions, especially at altitude or after modifications.

Belt Drive Wear:

Regular inspection for cracks, fraying, and proper tension is vital to prevent catastrophic failure.

📚 Vehicle History

Heritage:

Harley-Davidson, founded in 1903, is an American icon renowned for its V-twin motorcycles, cruiser styling, and distinctive sound.

Softail Lineage:

The Softail platform, introduced in 1984, mimics the look of a hardtail frame while incorporating hidden rear suspension for a smoother ride. The 2004 models represent a mature stage of this design.

2004 Updates:

For 2004, Softail models typically featured the 1450cc Evolution engine, 5-speed transmission, and refinements to braking and electrical systems. Specific model variants like FLSTC (Classic), FLSTF (Fat Boy), FLSTS (Heritage Springer - phased out), and FXST (Standard Softail) offered distinct styling and features.

Manufacturing Location:

United States (primarily York, Pennsylvania and Milwaukee, Wisconsin)

🏆 Awards & Recognition

Brand Acclaim:

Harley-Davidson motorcycles are consistently recognized for their iconic styling, sound, and rider community. Specific model awards for 2004 are less common than overall brand recognition.

Customer Satisfaction:

Generally high customer satisfaction among owners who value the Harley-Davidson experience and heritage.