Covered Years:
2000, 2001, 2002, 2003, 2004, 2005
Chassis Codes:
FLST Series (e.g., FLSTF, FLSTC, FLSTS), FXST Series (e.g., FXST, FXSTB, FXSTS)
Engine Codes:
Twin Cam 88B, Twin Cam 95B, Twin Cam 103B
Segment:
Cruiser Motorcycle Segment
Competitors:
Custom motorcycles, other cruiser manufacturers (e.g., Indian Motorcycle, Victory Motorcycles), and performance-oriented custom builders.
Vehicle Highlights:
Iconic Harley-Davidson styling, powerful Twin Cam V-twin engines, comfortable riding position, and extensive customization potential.
Systems Covered:
General Information, Troubleshooting, Lubrication, Maintenance and Tune Up, Engine, Clutch & Primary Drive, Transmission, Fuel System, Ignition System, Exhaust System, Frame and Suspension, Wheels and Tires, Brakes, Electrical System, Body and Fenders, Controls, Battery, Starting System, Charging System, Lighting System, Instruments and Gauges
Estimated Pages:
Approximately 600-800 (typical for comprehensive service manuals of this era)
Type:
Factory Authorized Repair/Service Manual
Format:
Printed Manual (likely bound)
Engine:
Detailed disassembly, assembly, inspection, and repair of Twin Cam 88B, 95B, and 103B engines, including top-end (cylinder heads, valves, camshafts), bottom-end (crankshaft, connecting rods, bearings), oiling system, and cooling (air-cooled specifics).
Drivetrain:
Comprehensive coverage of the primary drive system (clutch components, compensator sprocket, primary chain) and the transmission (gearbox internals, shift mechanism, bearings, seals, lubrication).
Electrical:
Wiring diagrams for all circuits, troubleshooting electrical faults, component testing (ignition module, coils, stator, regulator, battery, starter, lights), and accessory integration.
Brakes:
Front and rear brake system diagnostics, fluid replacement, caliper service, master cylinder rebuild, and ABS component (if applicable for specific models/years) inspection.
Suspension Steering:
Front fork service (disassembly, fluid change, seal replacement), rear shock absorber removal and installation, swingarm and pivot bearing inspection, and steering head bearing adjustment/replacement.
Maintenance:
Scheduled maintenance intervals, oil and filter changes (engine, primary, transmission), spark plug replacement, air filter servicing, brake fluid flush, tire pressure checks, and lubrication points.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting trees, and diagnostic trouble codes (DTCs) if applicable to the era's EFI systems.
Repair Rebuild:
Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly for all major vehicle systems, including complete engine and transmission overhauls.
Depth:
Comprehensive. Covers everything from basic fluid checks and adjustments to complete engine and transmission rebuilds, electrical system diagnostics, and frame component repairs. Suitable for professional mechanics and skilled DIY enthusiasts.
Format:
Printed, bound manual
Quality:
High-quality paper, durable binding, clear schematics and photographic illustrations.
Binding:
Likely spiral-bound or perfect-bound for lay-flat usability in a workshop environment.
Paper:
Durable, possibly coated paper to resist shop grime.
Engine Family:
Harley-Davidson Twin Cam
Engine Configurations:
Air-cooled, 45-degree V-twin
Displacement Variants:
88 cubic inches (approx. 1450cc), 95 cubic inches (approx. 1550cc), 103 cubic inches (approx. 1690cc) - often achieved through Big Bore kits/factory options.
Bore Stroke Tc88B:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Bore Stroke Tc95B:
3.875 in. x 4.25 in. (98.4 mm x 108 mm) (typical big bore kit specification for 95ci)
Bore Stroke Tc103B:
3.875 in. x 4.38 in. (98.4 mm x 111.3 mm) (typical big bore kit specification for 103ci)
Compression Ratio Tc88B:
8.8:1 (typical)
Compression Ratio Tc95B:
9.2:1 (typical)
Compression Ratio Tc103B:
9.7:1 (typical)
Horsepower Tc88B:
Approx. 65-70 HP (at crankshaft)
Torque Tc88B:
Approx. 75-80 lb-ft (at crankshaft)
Horsepower Tc95B:
Approx. 70-75 HP (at crankshaft)
Torque Tc95B:
Approx. 85-90 lb-ft (at crankshaft)
Horsepower Tc103B:
Approx. 75-80 HP (at crankshaft)
Torque Tc103B:
Approx. 90-95 lb-ft (at crankshaft)
Fuel Delivery:
Carbureted (Keihin CV) or Fuel Injection (EFI - Sequential Port)
Carburetor Model:
Keihin 40mm Constant Velocity (CV) Carburetor (on carbureted models)
Efi System:
Electronic Fuel Injection with throttle body and fuel injectors
Engine Oil Capacity:
3.0 US quarts (2.8 L) - check specific model/year for exact amount
Engine Oil Type:
Harley-Davidson Genuine V-Twin 20W-50 or equivalent API CI-4 or higher (check manual for exact specifications).
Transmission Type:
5-speed constant mesh manual transmission
Optional Gear Ratios:
Not typically offered as an option, but aftermarket gear sets exist.
Primary Drive:
Enclosed primary drive system with wet multi-plate clutch and primary chain.
Transmission Fluid Capacity:
Approximately 24 US fluid ounces (0.71 L) - check manual for exact amount.
Transmission Fluid Type:
Harley-Davidson Genuine Formula + Transmission and Primary Chaincase Lubricant or equivalent.
Wheelbase Flst:
Approx. 64.5 inches (1638 mm)
Wheelbase Fxst:
Approx. 64.5 inches (1638 mm)
Dry Weight Typical:
Approx. 640-680 lbs (290-308 kg) depending on model
Gross Vehicle Weight Rating Gvwr:
Typically around 950-1000 lbs (431-454 kg) - check specific model
Crash Test Ratings:
Motorcycles are not subjected to standardized crash test ratings like automobiles.
Braking System:
Dual-piston front caliper with 292mm disc, single-piston rear caliper with 292mm disc. Some models may have optional ABS beginning around 2008, but less common in this 2000-2005 range.
Lighting:
Halogen headlight, LED taillight, turn signals.
Audio System:
Not standard on most Softail models of this era. Optional radio and speaker systems were available, often integrated into fairings or saddlebags for touring variants.
ABS:
Optional on select models and years within this range, but not universally equipped.
Data Port:
Diagnostic data port (e.g., for SEST/Super Tuner) for engine management adjustments.
First Service:
1,000 miles (1,600 km) or 6 months (whichever comes first)
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months (whichever comes first), with more detailed inspections at higher mileage intervals (e.g., 10,000 miles, 20,000 miles).
Brake Fluid Type:
DOT 4 (for models equipped with ABS, otherwise DOT 3 or DOT 4 depending on original fill - check manual)
Primary Chain Case Fluid Type:
Harley-Davidson Genuine Formula + Transmission and Primary Chaincase Lubricant or equivalent.
Transmission Fluid Type:
Harley-Davidson Genuine Formula + Transmission and Primary Chaincase Lubricant or equivalent.
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, brake pads, tires, battery.
Twin Cam Specifics:
Potential for cam chain tensioner wear (especially earlier models), oil leaks at gasket points, rear cylinder cooling issues in prolonged stop-and-go traffic.
Electrical Common Faults:
Regulator/stator failure, battery charging issues, starter solenoid problems, faulty switches.
Legacy:
Harley-Davidson, founded in 1903, is one of the oldest motorcycle manufacturers in the world, synonymous with American motorcycle culture and the cruiser segment.
Softail Lineage:
The Softail platform, introduced in 1983, is characterized by its concealed rear suspension, mimicking the look of a hardtail frame while providing rider comfort. The Twin Cam engine replaced the Evolution engine starting in 1999.
Manufacturing Location:
United States (Milwaukee, Wisconsin; York, Pennsylvania; Kansas City, Missouri)
