🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLSTF Fat Boy

Year:

2002

Sub Model:

Fat Boy

Vin Model Code:

1HD1

👋 Introduction

Positioning:

The Harley-Davidson FLSTF Fat Boy is a cruiser motorcycle known for its distinctive styling, robust V-twin engine, and comfortable ride, targeting riders who appreciate classic American motorcycle aesthetics and performance.

Competitors:

Rivals include other large-displacement V-twin cruisers from American manufacturers and Japanese brands offering similar styling and displacement.

Design:

Iconic fat tire styling, chrome accents, large displacement V-twin engine.

Manual Utility:

Provides the definitive technical guide for owners and technicians, enabling proper maintenance, repair, and restoration.

Value:

Essential for maintaining the longevity and optimal performance of a 2002 Harley-Davidson FLSTF Fat Boy, covering all aspects from routine checks to complex engine work.

📋 Manual Details

Primary Coverage:

Complete factory service and repair

Secondary Coverage:

Maintenance, troubleshooting, diagnostics, overhaul

Estimated Pages:

Hundreds (exact count not specified but described as 'complete')

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Download PDF

📖 Manual Coverage

Engine:

Engine assembly, disassembly, tuning, internal components, cooling system, lubrication system

Fuel System:

Carburetor (Keihin CV), fuel tank, fuel lines, fuel pump (if applicable), fuel filter

Ignition System:

Ignition module, ignition coils, spark plugs, timing

Transmission:

5-speed gearbox, clutch, primary drive, final drive, lubrication

Electrical System:

Wiring diagrams, battery, charging system, starter, lighting, instrumentation, accessories

Brakes:

Front and rear brake systems, hydraulic lines, calipers, master cylinders, brake fluid specifications

Suspension:

Front fork (Telescopic), rear shock absorbers, adjustments, servicing

Frame And Body:

Frame structure, body panels, fenders, fuel tank mounting, seat, handlebars, controls

Wheels And Tires:

Wheel specifications, bearing maintenance, tire pressure, recommended tire sizes

Maintenance:

Oil changes, filter replacements, spark plug replacement, chain/belt adjustment, lubrication points

Troubleshooting:

Diagnostic procedures for common faults, symptom-based troubleshooting guides

Repair:

Detailed step-by-step repair instructions for all major components

Overhaul:

Complete engine and transmission rebuild procedures

Diagnostics:

Electrical system diagnostics, engine performance diagnostics

Installation:

Component installation and adjustment procedures

Depth:

Comprehensive: Covers basic maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and specifications.

📊 Manual Specifications

Format:

PDF

Searchable:

Likely searchable text within the PDF (typical for factory manuals)

Quality:

High-resolution scans suitable for printing multiple sections or the entire manual.

Binding:

N/A (Digital PDF download)

Paper Type:

N/A (Digital PDF download)

⚙️ Engine Specifications

Engine Family:

Harley-Davidson Evolution (Evo) V-Twin

Engine Type:

Air-cooled, 45-degree V-twin, pushrod actuated overhead valves

Displacement:

1450 cc (88 cubic inches)

Bore X Stroke:

3.437 in. x 3.812 in. (87.3 mm x 96.8 mm)

Compression Ratio:

8.8:1 (Typical for FLSTF)

Horsepower:

Approx. 60-65 HP (estimated at crankshaft)

Torque:

Approx. 70-75 ft-lbs (estimated at crankshaft)

Carburetor:

Keihin CV (Constant Velocity) 40mm

Fuel Type:

Unleaded gasoline, minimum 87 octane

Oil Type:

Harley-Davidson 20W-50 Motorcycle Oil or equivalent API CI-4 rated oil

Oil Capacity:

3.0 US quarts (2.8 liters) with filter change

Cooling Method:

Air-cooled

🔧 Transmission

Gearbox:

5-speed constant mesh

Optional Gearbox:

N/A for this model year

Primary Drive:

Duplex chain, clutch operation via cable

Final Drive:

Belt drive, 132-tooth rear, 32-tooth front pulley

Transmission Oil Type:

Harley-Davidson Synthetic Transmission Fluid or SAE 75W-90 GL-5 gear oil

Transmission Oil Capacity:

24 US fluid ounces (0.71 liters)

📐 Dimensions

Length:

93.5 inches (2375 mm)

Width Handlebars:

37.0 inches (940 mm)

Height:

49.0 inches (1245 mm)

Wheelbase:

63.5 inches (1613 mm)

Ground Clearance:

5.0 inches (127 mm)

Dry Weight:

635 lbs (288 kg)

Wet Weight:

Approx. 670 lbs (304 kg)

Gvwr:

N/A (Motorcycle)

Payload Capacity:

N/A (Motorcycle)

Front Tire Size:

130/90-16 67H

Rear Tire Size:

150/80B16 71H

Front Wheel Type:

16-inch, 5-spoke cast aluminum disc wheel

Rear Wheel Type:

16-inch, 5-spoke cast aluminum disc wheel

Front Wheel Bolt Pattern:

N/A (Cast wheel with integrated hub)

Rear Wheel Bolt Pattern:

N/A (Cast wheel with integrated hub)

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycle safety is evaluated differently than automobiles)

Braking System:

Dual hydraulic disc brakes (front and rear)

Lighting:

Halogen headlamp, LED taillight, turn signals

Frame Construction:

Steel cradle frame designed for stability and rider control

Rider Ergonomics:

Forward-mounted foot controls, low seat height for rider confidence.

💡 Technology Features

Infotainment System:

Basic; typically includes analogue speedometer, tachometer, odometer, trip meter, and indicator lights. No advanced infotainment systems are standard.

Driver Assistance Features:

None (Motorcycle)

Connectivity Features:

None (Motorcycle)

🔧 Maintenance

First Service:

1000 miles (1600 km) or 6 months (whichever comes first)

Subsequent Service:

Every 5000 miles (8000 km) or 12 months (whichever comes first), with specific checks at intermediate intervals.

Engine Oil And Filter:

Every 5000 miles (8000 km) or 12 months

Transmission Oil:

Every 10000 miles (16000 km) or 24 months

Primary Chain Case Oil:

Inspect every 2500 miles (4000 km), change as needed (typically with clutch/primary maintenance)

Spark Plugs:

Inspect every 5000 miles (8000 km), replace as needed (refer to manual for specific part numbers)

Brake Fluid:

DOT 4 (or specified equivalent, check manual for exact spec)

Primary Chain Case Oil Type:

Harley-Davidson primary fluid or SAE 20W-50 motorcycle oil (check manual for definitive spec)

Cam Chain Tensioner:

Early Evolution engines (pre-2007) can have issues with the cam chain tensioners wearing out, potentially leading to engine damage if not replaced proactively. The manual will detail inspection and replacement procedures.

Carburetor Tuning:

The Keihin CV carburetor may require occasional adjustment or cleaning for optimal performance, especially with modifications or varying fuel quality. The manual provides tuning guidelines.

Primary Clutch Adjustment:

The primary chain and clutch may require periodic adjustment. The manual details the correct procedure and specifications.

Electrical Connections:

As with any older motorcycle, corrosion or loose connections in the electrical system can lead to intermittent issues. The manual's wiring diagrams are crucial for troubleshooting.

📚 Vehicle History

Heritage:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer with a rich history of building V-twin engines and cruiser-style motorcycles.

Fat Boy Introduction:

The Fat Boy model was introduced in 1990, quickly becoming a flagship model known for its distinctive styling inspired by post-WWII custom motorcycles and its large tires.

2002 Model Year Significance:

The 2002 model year continues the legacy of the Fat Boy, featuring the larger 1450cc Evolution engine and refined styling elements. It represents a mature iteration of the popular cruiser.

Production Location:

York, Pennsylvania, USA and Milwaukee, Wisconsin, USA (assembly plants)

Notable Appearances:

Famously featured in the movie 'Terminator 2: Judgment Day' (though an earlier model year, the design language is similar).

🏆 Awards & Recognition

Model Recognition:

The Harley-Davidson Fat Boy is widely recognized as a cultural icon and a benchmark in the cruiser motorcycle segment, often cited for its distinctive styling and enduring appeal.

Owner Satisfaction:

Generally high owner satisfaction, particularly for riders who value the Harley-Davidson experience, styling, and V-twin sound.

Manufacturing Standards:

Manufactured to Harley-Davidson's proprietary quality and performance standards.