Target Audience:
Harley-Davidson FLSTF Fat Boy owners seeking to perform their own maintenance and repairs, or independent motorcycle shops.
Value Proposition:
Provides in-depth technical information essential for maintaining and repairing the iconic FLSTF Fat Boy, saving on dealership service costs.
Uniqueness:
Focuses specifically on the 1997-1998 FLSTF Fat Boy models, ensuring relevance and accuracy for those specific years.
Engine Overhaul:
Complete teardown, inspection, and reassembly procedures for the Evolution engine.
Fuel System:
Carburetor (Keihin CV) tuning, jetting, float bowl service, and fuel line maintenance.
Ignition System:
Spark plug diagnosis, coil testing, ignition module troubleshooting, and timing adjustments.
Transmission And Drivetrain:
Primary drive chain adjustment, clutch service, 5-speed gearbox disassembly/assembly, and final belt drive maintenance.
Electrical System:
Wiring diagrams, battery maintenance, starter system, charging system (alternator/regulator), lighting, and accessory circuits.
Braking System:
Front and rear brake caliper service, hydraulic system bleeding, pad replacement, and rotor inspection.
Suspension:
Front fork oil changes, seal replacement, and rear shock absorber adjustment/replacement.
Frame And Bodywork:
Handlebar removal/installation, fender mounting, fuel tank removal, seat service, and chassis inspection.
Routine Maintenance:
Oil and filter changes, spark plug replacement, air filter cleaning/replacement, and brake fluid checks.
Troubleshooting Guides:
Diagnostic trees for common starting, running, and electrical issues.
Component Rebuilds:
Detailed steps for rebuilding carburetors, master cylinders, and wheel bearings.
Electrical Diagnostics:
Troubleshooting faulty circuits, testing sensors, and diagnosing charging system problems.
Torque Specifications:
Essential torque values for engine, transmission, and chassis fasteners.
Diagnostic Capabilities:
Advanced diagnostic procedures for identifying root causes of mechanical and electrical failures.
Repair Scope:
Covers everything from basic adjustments to complete engine and transmission overhauls.
Wiring Diagrams Detail:
Comprehensive, high-resolution wiring diagrams with component identification.
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
1337 cc (81.5 cubic inches)
Bore X Stroke:
3.4375 in x 4.25 in (87.31 mm x 107.95 mm)
Horsepower Est:
Approximately 60-65 HP (at crankshaft)
Torque Est:
Approximately 70-75 ft-lbs (at crankshaft)
Carburetor:
Keihin CV (Constant Velocity) 40mm
Fuel Type:
Unleaded Gasoline, 91 octane (Octane Rating can vary by region and specific tuning)
Ignition Type:
Electronic Ignition (CDI based)
Oil Type:
Harley-Davidson 20W50 motorcycle oil or equivalent (e.g., SYN3 if compatible and specified)
Oil Capacity W Filter:
3.0 US quarts (2.84 liters)
Crash Test Data:
N/A for motorcycles of this era; focus on structural integrity and component reliability.
Braking System:
Dual-action, front and rear hydraulic disc brakes.
Frame Construction:
Steel, tubular, cradle frame.
Audio System:
OEM optional audio systems were available but not standard. This manual will cover basic electrical routing if installed.
ABS:
Anti-lock Braking System (ABS) was not a standard or common option for the FLSTF Fat Boy in these model years.
Cruise Control:
Not a standard feature on this model, but aftermarket kits exist. Manual provides basic electrical system understanding.
First Service:
1,000 miles (1,600 km)
Subsequent Oil Change:
Every 5,000 miles (8,000 km) or annually, whichever comes first.
Primary Chain Tensioner:
Inspect at 2,500 miles (4,000 km) and 7,500 miles (12,000 km), adjust as needed.
Engine Oil Grade:
20W50 Motorcycle Oil (e.g., Harley-Davidson genuine oil, Mobil 1 V-Twin 20W50, Spectro Plus 20W50)
Transmission Fluid Type:
Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant (or equivalent syn/mineral oil meeting HD specs)
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Carburetor Performance:
Keihin CV carburetors can sometimes develop issues with diaphragm tears or pilot jet clogging, affecting idle and low-speed running. Manual covers tuning and cleaning.
Primary Chain Tensioner:
The automatic spring-loaded tensioner can wear out, leading to chain slap noise. Manual covers inspection and replacement.
Rear Belt Drive:
Requires regular inspection for wear and proper tensioning. Manual provides procedures for inspection and adjustment.
Electrical Connectors:
Corrosion or loose connections can occur in older wiring harnesses, impacting lights or starting. Manual aids in tracing and rectifying these.
Brand Legacy:
Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903, known for its V-twin engines and distinctive styling.
Fat Boy Introduction:
The Fat Boy was first introduced in 1990, quickly becoming a modern classic with its distinctive wide-set front fork, solid aluminum wheels, and fat tires.
1997-1998 Updates:
These years represent a refinement of the original Fat Boy design, incorporating the robust Evolution engine and improvements in chassis and braking systems that were characteristic of Harley-Davidson's development in the late 90s.
Manufacturing Location:
Milwaukee, Wisconsin, USA
