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Harley Davidson Softail models FLST FXST 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Softail Year: 2004 Codes Chassis Codes: FLST, FXST 👋 Introduction Market Position Target Audience: DIY enthusiasts, independent motorcycle mechanics, Harley-Davidson owners seeking to...
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Type: Motorcycle
Vendor:
Sku: 168681
Harley Davidson Softail models FLST FXST 2004 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
Softail
Year:
2004
Codes
Chassis Codes:
FLST, FXST
👋 Introduction
Market Position
Target Audience:
DIY enthusiasts, independent motorcycle mechanics, Harley-Davidson owners seeking to perform their own maintenance and repairs.
Key Features
Manual Advantage:
Provides factory-level detail and procedures identical to those used by professional technicians, enabling comprehensive repairs and maintenance.
Ease Of Use:
Designed for both professional mechanics and DIY enthusiasts with clear, easy-to-follow instructions.
Competitive Analysis
Value Proposition:
Offers significant cost savings by empowering owners to perform repairs themselves, avoiding expensive dealership labor costs.
📋 Manual Details
Coverage Areas
Covered Models:
FLSTC Heritage Softail Classic ST, FLSTCI Heritage Softail Classic ST (EFI), FLSTF Fat Boy ST, FLSTFI Fat Boy ST (EFI), FXST Softail Standard, FXSTB Night Train ST, FXSTD Softail Deuce, FXSTDI Softail Deuce (EFI), FXSTDSE2 Screamin Eagle Deuce, FXSTI Softail Standard (EFI), FXSTS Softail Springer, FXSTSI Softail Springer (EFI)
Page Count
Total Pages:
1068
Manual Type
Type:
Service Repair Manual
Content Type:
Factory/Workshop Manual, Repair Guide, Service Manual
Language
Primary Language:
English
Format
Delivery Format:
Digital Download (PDF, ZIP, RAR, EXE)
Digital Delivery:
Instant download available after payment. Download link provided via email and on checkout page. Three days provided to download.
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, engine components, lubrication, cooling system, fuel system (carburetor and EFI), ignition system, starting system, exhaust system, engine diagnostics, error codes
Drivetrain Systems:
Transmission overhaul, primary reduction gear, clutch, gearshift linkage, drive shaft, final drive, wheel bearings
Chassis Systems:
Frame, suspension (front forks, rear shocks/struts), swingarm, steering, brakes (front and rear, hydraulic systems), wheels, tires
Electrical Systems:
Wiring diagrams, battery, charging system (stator, regulator, rectifier), lighting, ignition, starter motor, fuel injection system (EFI), diagnostic connectors, switches, relays
Body And Frame:
Body panels, fenders, fuel tank, seat, handlebars, controls, frame maintenance, and alignment.
Suspension And Steering:
Detailed procedures for fork disassembly, seal replacement, shock absorber adjustment or replacement, steering head bearing service, and wheel alignment.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes (engine oil, transmission oil, primary oil, brake fluid), filter replacements, tire pressure checks, chain adjustment (if applicable), valve clearance adjustment, spark plug service
Repair Rebuild:
Complete engine tear down and rebuild, transmission rebuild, fork seal replacement, brake caliper service, electrical component replacement, bodywork repair and alignment
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, 'no spark' diagnosis, error code interpretation, starting problems, running issues, electrical faults
Installation:
Instructions for installation of common accessories and replacement parts, such as exhaust systems, handlebars, and lighting.
Diagnostics:
Comprehensive troubleshooting guides for electrical issues, starting problems, engine performance issues, and fuel system faults.
Technical Depth
Diagnostic Capabilities:
Detailed diagnostic procedures, including troubleshooting charts, electrical schematics, and specific tests for components and systems. Covers EFI specific diagnostics and error codes.
Rebuild Instructions:
Comprehensive instructions for complete disassembly and reassembly of major components, including engine, transmission, and suspension.
Special Tools:
Identification and usage of specialized tools required for specific repair and maintenance procedures.
Illustrations:
Richly illustrated with clear step-by-step instructions, including diagrams, part breakdowns, and exploded views.
Part Numbers:
Includes detailed part numbers and diagrams for replacement and assembly, facilitating accurate part ordering.
Torque Specifications:
Extensive torque specifications for critical fasteners throughout the motorcycle, ensuring proper assembly and component integrity.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, printable quality. Text is searchable.
Compression:
May be compressed in ZIP or RAR format, requiring unzipping software (e.g., WinZip, WinRAR).
Operating Systems Compatibility:
Compatible with Windows (97, 2000, Me, XP, Vista, 7, 10) and Mac operating systems.
File Size Consideration:
Manuals can be very large (up to 4000MB). Ensure adequate storage space and a stable internet connection for download.
Print Quality
Print Permissions:
Printable on any computer and printer.
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled V-Twin (specific displacement varies by model variant but typically 88 cubic inches or 1450cc for this generation of Softail)
Performance
Torque Figures:
Refer to specific model sections within the manual for precise torque specifications for various components and fasteners.
Horsepower:
Typical horsepower figures for the 88 cubic inch engine are in the range of 60-70 HP, though this can vary based on specific tuning and model.
Fuel System
Fuel Delivery:
Carbureted (Keihin CV) or Electronic Fuel Injection (EFI) depending on the specific model variant (e.g., FLSTF vs. FLSTFI).
Engine Type
Displacement:
Typically 88 cubic inches (1450cc) for standard models. The FXSTDSE2 Screamin Eagle Deuce may feature a larger displacement engine (e.g., 95 cubic inches / 1550cc).
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh, manual transmission
Features
Clutch Type:
Wet, multi-plate
📐 Dimensions
Weights
Dry Weight:
Varies by model, generally between 650-700 lbs (approx. 295-318 kg). Refer to specific model data within the manual for exact figures.
Gross Vehicle Weight Rating:
Refer to specific model sections within the manual for GVWR.
🛡️ Safety Features
Active Features
Braking System:
Hydraulic disc brakes, front and rear. Dual piston calipers typically.
Passive Features
Frame Construction:
Steel tubular frame with a cradle design.
💡 Technology Features
Infotainment
Audio System:
Base models typically did not feature integrated audio systems. Some touring-oriented Softail variants or aftermarket installations might include audio.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was not standard on most 2004 Softail models and was often an optional feature, especially on touring-oriented variants. Manual coverage will depend on specific model and options.
Connectivity
Diagnostic Ports:
Features diagnostic connectors for use with Harley-Davidson specific diagnostic tools (e.g., Digital Technician) for EFI models.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 2,500 to 5,000 miles (4,000 to 8,000 km) or annually, depending on usage and oil type. Refer to manual for exact intervals.
Primary Oil Change:
Recommended at similar intervals to engine oil changes. Primary oil lubricates the clutch and transmission gears.
Fluid Specifications
Engine Oil Viscosity:
Commonly 20W-50 or 10W-40 for air-cooled V-twins. Specific API classification and Harley-Davidson approval recommended. Refer to manual for precise specifications.
Brake Fluid Type:
DOT 4 recommended for hydraulic brake systems.
Transmission Oil:
Harley-Davidson transmission oil or equivalent with appropriate viscosity rating (e.g., SAE 90 gear oil). Refer to manual for exact specifications and capacity.
Primary Oil Type:
Harley-Davidson primary chaincase lubricant or equivalent. Refer to manual for specific type and capacity.
Known Issues
Common Wear Items:
Clutch wear, wheel bearings, front fork seals, brake pads, and potential starter drive issues are common wear items on motorcycles of this era.
Efi Troubleshooting:
Specific EFI models may encounter issues related to fuel pump, injectors, sensors (e.g., O2 sensor, throttle position sensor), or ECU diagnostics. The manual provides detailed troubleshooting for these.
Carburetor Tuning:
Carbureted models may require periodic tuning, adjustment of idle speed, and main/pilot jet cleaning or replacement for optimal performance and emissions.
📚 Vehicle History
Brand Heritage
Foundation:
Harley-Davidson Motor Company, founded in 1903, is an iconic American motorcycle manufacturer with a rich history of performance and customization.
Model Evolution
Softail Lineage:
The Softail platform, introduced in 1984, is known for its classic styling, mimicking the look of a hardtail frame while incorporating hidden rear suspension for improved ride comfort.
Softail Characteristics:
The Softail's signature feature is its hidden rear shock absorbers, contributing to its rigid, classic look while providing a comfortable ride.
Production
Manufacturing Location:
Assembly typically took place in Milwaukee, Wisconsin, USA.
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