Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson owners and independent repair shops specializing in motorcycles.
Competitors:
This manual is specific to Harley-Davidson, but comparable models from other manufacturers in the cruiser segment during this era include Indian Chief, Honda Shadow, Yamaha V-Star, and Kawasaki Vulcan.
Unique Selling Proposition:
Detailed coverage of the iconic Springer front fork system, specific to the FXSTS model.
Value Proposition:
Empowers owners and technicians with the precise information needed to maintain, diagnose, and repair their FXSTS Springer Softail.
Years Covered:
2000, 2001, 2002, 2003, 2004, 2005
Regions Covered:
Global (US, European, Asian specifications may have minor variations not explicitly detailed)
Estimated Page Count:
Approximately 500-700 pages (typical for this model year range and depth)
Type:
Factory Service Manual / Repair Manual
Digital Format:
PDF (Portable Document Format)
Engine Mechanical:
Complete overhaul, disassembly, assembly, troubleshooting, and specifications for the Evolution V-Twin engine.
Fuel System:
Carburetor (Keihin CV) and fuel injection (EFI - if equipped on specific models) systems, fuel pump, lines, and tank.
Ignition System:
Ignition module, coils, spark plugs, wiring, and troubleshooting.
Transmission Drivetrain:
5-speed constant mesh transmission, clutch assembly, primary drive, secondary drive (belt drive), and related components.
Suspension:
Front Springer forks (detailed disassembly and service), rear shock absorbers, swingarm, and linkage.
Braking System:
Front and rear disc brakes, calipers, master cylinders, hydraulic lines, fluid specifications, and bleeding procedures.
Electrical System:
Battery, charging system (stator, regulator/rectifier), lighting, starter system, wiring diagrams, fuse box, and electrical troubleshooting.
Frame Bodywork:
Frame inspection, fork mounting, fenders, fuel tank, seat, handlebars, controls, and body panel removal/installation.
Wheels Tires:
Wheel bearing service, tire selection and mounting, spoke tensioning (if applicable).
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, drive belt adjustment and inspection, brake fluid flush, lubrication points.
Troubleshooting:
Systematic diagnosis of common and uncommon problems with step-by-step guides.
Disassembly Assembly:
Detailed instructions for disassembling and reassembling all major components and sub-assemblies.
Rebuilds:
Complete rebuild procedures for the engine, transmission, and brake system components.
Wiring Diagrams:
Comprehensive, color-coded wiring schematics for electrical system diagnostics and repair.
Special Tool Usage:
Identification and usage instructions for Harley-Davidson proprietary tools required for specific repairs.
Depth:
Comprehensive coverage from basic user maintenance to full engine and transmission rebuilds, including advanced electrical diagnostics.
Type:
Air-cooled, Evolution V-Twin
Displacement:
1339 cc (81.8 cubic inches)
Bore X Stroke:
3.437 in (87.3 mm) x 4.375 in (111.1 mm)
Compression Ratio:
8.9:1 (typical)
Valvetrain:
Overhead valves (OHV), pushrod actuated, 2 valves per cylinder
Cooling System:
Air-cooled
Horsepower:
Approximately 60-65 HP (at crankshaft, varies slightly by year/tuning)
Torque:
Approximately 70-75 ft-lbs (at crankshaft, varies slightly by year/tuning)
Carburetor Model:
Keihin CV 40 (Constant Velocity)
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2
Fuel Tank Capacity:
4.0 US gallons (15.1 L) typical
Type:
5-speed, constant mesh, sequential manual transmission
Primary Drive:
Duplex chain, wet clutch, 34/46 ratio
Secondary Drive:
Belt drive, 32/65 ratio (3" wide belt typical)
Clutch Type:
Multi-plate, wet
Transmission Fluid Type:
Harley-Davidson Formula+ (or equivalent SAE 50 transmission oil)
Transmission Fluid Capacity:
28 US fluid ounces (0.83 L)
Length:
Approx. 92.6 inches (2352 mm)
Width Handlebars:
Approx. 35 inches (889 mm)
Height:
Approx. 47.6 inches (1209 mm)
Wheelbase:
Approx. 64.2 inches (1630 mm)
Dry Weight:
Approx. 640 lbs (290 kg)
Gross Vehicle Weight Rating:
Approx. 1010 lbs (458 kg)
Payload Capacity:
Approx. 370 lbs (168 kg)
N A:
N/A (Motorcycle, typically accessories like saddlebags)
N A:
Motorcycles are not rated by NHTSA or IIHS in the same way as cars.
Braking:
Dual-piston calipers with floating brake discs front and rear.
Lighting:
Halogen headlight, LED taillight and brake light, front and rear turn signals.
Frame Construction:
Steel, single-downtube frame with cradle.
Ergonomics:
Forward-mounted foot controls, swept-back handlebars for a classic riding posture.
First Service:
500-1000 miles (800-1600 km) - includes engine oil and filter change, primary chain adjustment, and general inspection.
Subsequent Oil Changes:
Every 2,500 - 5,000 miles (4,000 - 8,000 km) or annually, whichever comes first, depending on oil type and usage.
Primary Chain Adjustment:
Every 5,000 miles (8,000 km) or as needed.
Belt Drive Inspection:
Check tension and condition every 5,000 miles (8,000 km).
Brake Fluid Flush:
Every 2 years or as recommended by fluid condition.
Spark Plug Replacement:
Every 10,000 miles (16,000 km) or as needed.
Engine Oil:
Harley-Davidson 20W-50 SYN3 Synthetic or equivalent API SG or higher quality oil (e.g., V-Twin specific). Capacity: 3 US quarts (2.8 L) with filter.
Primary Chain Case Oil:
Harley-Davidson Formula+ or equivalent SAE 50 transmission oil. Capacity: 28 US fl oz (0.83 L).
Transmission Oil:
Harley-Davidson Formula+ or equivalent SAE 50 transmission oil. Capacity: 28 US fl oz (0.83 L).
Brake Fluid:
DOT 4 (or DOT 5.1, check manual for specific recommendation if available). Do NOT use DOT 5 silicone fluid unless specified for a specific system.
Fork Oil:
Harley-Davidson Type 'E' or 'B' (or equivalent 5W or 10W fork oil, check manual for specific application)
Harley Springer Forks:
Wear in pivot points, potential for shimmy at certain speeds, requires specialized maintenance and lubrication of the springer mechanism.
Crankcase Breather:
Early models may experience oil blow-by; later models have improved breather systems. Manual will detail inspection and potential upgrades.
Cam Chain Tensioners:
Evolution engines use plastic cam chain tensioners which can wear over time, potentially leading to noise or damage. Manual covers inspection and replacement procedures.
Belt Drive Wear:
Belt can wear prematurely if misaligned, under/over-tensioned, or contaminated. Regular inspection is crucial.
Electrical Connectors:
Corrosion on electrical connectors can lead to intermittent faults. Manual provides guidance on cleaning and protecting them.
Manufacturer Founding:
Founded in 1903 in Milwaukee, Wisconsin, USA.
Brand Philosophy:
Known for its iconic V-twin engines, custom styling, and a strong community culture.
Softail Introduction:
The Softail line, featuring hidden rear shock absorbers for a hardtail appearance, was introduced in 1983.
Springer Introduction:
The Springer front end, a revival of the classic girder fork design from the early 20th century, was reintroduced by Harley-Davidson in the late 1980s.
Fxsts Positioning:
The FXSTS Springer Softail was a flagship model combining modern Softail engineering with vintage styling cues, particularly the distinctive Springer front fork.
Manufacturing Location:
Milwaukee, Wisconsin, USA (and Kansas City, Missouri, USA for some components/assembly)
Production Period:
The FXSTS model was produced from 1988 to 2007, with the specific years 2000-2005 covered by this manual.
N A:
While specific awards for this exact model year may not be readily documented, Harley-Davidson motorcycles of this era consistently received accolades for their styling, performance, and iconic status within the cruiser market. The FXSTS was celebrated for its blend of retro aesthetics and modern Softail platform.
N A:
Customer satisfaction and rider reviews often highlight the distinctive ride feel and visual appeal of the Springer models.
N A:
N/A (Motorcycle homologation varies by country)
