Harley Davidson FLSTF Fat Boy Motorcycle 2002 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLSTF Fat Boy Year: 2002 Product Type: Service Repair Workshop Manual Product Format: Download PDF 👋 Introduction Market Position Model Segment: Cruiser, specifically...

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类型: Motorcycle

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标签: 2002 FLSTF Fat Boy Harley Davidson Misc Motorcycle Motorcycles

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

FLSTF Fat Boy

Year:

Product Type:

Service Repair Workshop Manual

Product Format:

Download PDF

👋 Introduction

Market Position

Model Segment:

Cruiser, specifically a 'cruiser' style motorcycle known for its classic styling and relaxed riding position.

Competitive Analysis

Key Competitors:

Other American V-twin cruisers, and potentially some Japanese models with similar styling and displacement, though often distinguished by engine architecture and brand identity.

Key Features

Distinctive Styling:

Iconic wide front tire, chrome accents, teardrop fuel tank, extensive use of chrome and polished metal, classic lines.

Target Audience

Demographic:

Riders who appreciate classic styling, V-twin character, and the Harley-Davidson brand experience.

Manual Purpose

Utility:

Essential for owners and independent mechanics seeking to perform maintenance, repairs, and diagnostics on the 2002 Harley-Davidson FLSTF Fat Boy.

📋 Manual Details

Coverage Areas

Vehicle Make:

Harley-Davidson

Vehicle Model:

FLSTF Fat Boy

Model Years Covered:

Page Count

Estimated Pages:

Estimating from typical Harley-Davidson factory manuals of this era, expect in excess of 500 pages.

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital PDF

📖 Manual Coverage

Systems Covered

Engine:

Twin Cam 88 V-Twin (carbureted variants), engine disassembly, assembly, tuning, lubrication, cooling system.

Transmission:

5-speed Cruise Drive transmission, clutch operation, gearbox inspection, repair, lubrication.

Fuel System:

Carburetor (Keihin CV, likely 40mm), fuel tank, fuel lines, fuel filter replacement, idle speed adjustment, mixture screw settings.

Ignition System:

Electronic ignition system, spark plugs, ignition coils, timing, troubleshooting ignition faults.

Electrical System:

Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting systems (headlight, tail light, signals), starter system, fuses, relays, switches.

Suspension:

Front fork (likely 41mm Showa), rear shock absorbers, fork oil change, fork seal replacement, shock absorber adjustment.

Brakes:

Front and rear disc brakes, brake caliper service, brake fluid flush and replacement, brake line inspection, master cylinder service.

Wheels And Tires:

Spoked wheels, wheel bearing maintenance, tire pressure checks, tire replacement, balancing.

Frame And Bodywork:

Frame inspection, chassis components, fender removal/installation, tank and seat mounting, handlebar installation.

Exhaust System:

Exhaust pipe and muffler inspection, gasket replacement, exhaust hanger inspection.

Procedures Included

Maintenance:

Routine service checks, oil changes, filter replacements, chain lubrication (if applicable, though Fat Boy typically belt-driven), tire pressure, brake system checks.

Diagnostics:

Troubleshooting guides for common performance issues, electrical faults, starting problems, braking concerns, and drivetrain issues.

Repair:

Step-by-step instructions for component disassembly, inspection, repair, and reassembly across all major systems.

Overhaul:

Complete engine and transmission rebuild procedures, including torque specifications and assembly sequence.

Troubleshooting Charts:

Detailed flowcharts and symptom-based diagnostic trees to identify and resolve problems.

Technical Depth

Depth:

Comprehensive. Covers everything from basic rider maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and component-level repairs.

📊 Manual Specifications

File Format

Format:

Searchability:

Typically OCR'd or natively searchable text for easy navigation and keyword searching.

Print Quality

Quality:

High-resolution scans of original factory documents, ensuring clarity of text, diagrams, and images.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

Features

Licensing:

No expiry dates, no extra fees (as stated in product description).

⚙️ Engine Specifications

Primary Engine

Engine Type:

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

Engine Displacement:

1450cc (88 cubic inches)

Bore X Stroke:

3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)

Compression Ratio:

8.8:1 (typical for Twin Cam 88)

Performance

Horsepower:

Approx. 65-70 HP at 5,000 RPM (estimated, as factory figures varied)

Torque:

Approx. 70-75 ft-lbs at 3,000 RPM (estimated)

Fuel System

Carburetor Model:

Keihin CV 40mm (likely)

Fuel Delivery:

Carburetor with manual choke.

Lubrication

Oil Type Recommendation:

Harley-Davidson 20W-50 SYN3 or equivalent motorcycle-specific oil meeting Harley-Davidson specifications.

Oil Capacity

Capacity:

Approx. 3.0 US quarts (2.8 liters) with filter change.

Cooling System

Cooling Method:

Air-cooled, with oil cooler as standard equipment.

🔧 Transmission

Standard

Type:

5-speed constant mesh, sequential manual transmission.

Clutch Type:

Wet, multi-plate, cable-actuated.

Features

Primary Drive:

Duplex chain, rubber isolated.

Final Drive:

Belt drive, 151-tooth, 1.125-inch wide, 25mm pitch.

Fluid Type

Transmission Oil:

Harley-Davidson Formula Plus or equivalent primary chaincase lubricant.

Fluid Capacity

Primary Chaincase Capacity:

Approx. 2.8 US quarts (2.6 Liters).

📐 Dimensions

Exterior

Length:

Approx. 93.5 inches (2375 mm)

Width:

Approx. 37.6 inches (955 mm)

Height:

Approx. 48.0 inches (1220 mm)

Wheelbase:

Approx. 63.5 inches (1613 mm)

Weights

Dry Weight:

Approx. 630 lbs (286 kg)

Gross Vehicle Weight Rating:

Approx. 1000 lbs (454 kg)

Gvwr:

Approx. 1000 lbs (454 kg)

Cargo

Fuel Capacity:

4.5 US gallons (17.0 Liters)

Wheels And Tires

Front Tire Size:

130/90-16 67H (Note: Wider than standard, characteristic of the Fat Boy)

Rear Tire Size:

150/80B16 71H

Front Wheel Type:

Chrome steel laced, 16 x 3.00

Rear Wheel Type:

Chrome steel laced, 16 x 3.00

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles typically do not undergo standardized crash testing like passenger cars).

Active Features

Braking System:

Dual-piston caliper front and rear disc brakes.

Lighting:

Halogen headlight, taillight, stoplight, front and rear turn signals.

Passive Features

Frame Construction:

Steel, cradle-type frame designed for stability and rider comfort.

Handlebars:

Wide, pullback handlebars to provide leverage and a relaxed riding posture.

💡 Technology Features

Infotainment

Audio System:

Not typically equipped with a factory-integrated audio system on this model. Aftermarket options are common.

Driver Assistance

Features:

No electronic driver assistance systems like ABS or traction control are standard on this model.

Connectivity

Features:

N/A (No modern connectivity features like Bluetooth or smartphone integration).

Lighting

Headlight Type:

Halogen, sealed-beam unit.

🔧 Maintenance

Service Intervals

Initial Service:

First service typically around 1,000 miles (1600 km) for oil change, filter check, belt tension check, and general inspection.

Regular Oil Changes:

Every 5,000 miles (8,000 km) or 12 months, whichever comes first, for engine oil and filter.

Primary Chaincase Fluid Change:

Typically every 10,000-20,000 miles (16,000-32,000 km), refer to manual for exact interval.

Transmission Fluid Change:

Same interval as primary chaincase fluid, refer to manual.

Belt Tension Check:

Every 1,000 miles, adjust as needed.

Fluid Specifications

Engine Oil Specification:

Harley-Davidson H-D 360 SAE 20W-50 Motor Oil or H-D SYN3 Synthetic Motorcycle Oil.

Primary Chaincase Lubricant Specification:

Harley-Davidson Formula Plus or SAE 50 weight motorcycle oil meeting HD specification HD-8762.

Brake Fluid Specification:

DOT 4 brake fluid.

Fork Oil Type:

Harley-Davidson Silicone Fork Oil (weight varies by preference, typically 10W or 15W for a balanced ride).

Known Issues

Common Concerns:

Potential for cam bearing wear (though improved with Twin Cam 88B), exhaust leaks, occasional charging system issues (regulator/rectifier), and carburetor tuning sensitivity.

Maintenance Focus Areas:

Regular checks of belt tension, brake system, and electrical connections are crucial for longevity and performance.

Part Numbers

Oil Filter Part Number:

Harley-Davidson Part Number 63806-00 (or compatible aftermarket).

Air Filter Part Number:

Harley-Davidson Part Number 29461-99 (or compatible aftermarket).

📚 Vehicle History

Brand Heritage

Brand Identity:

Harley-Davidson, established in 1903, is an iconic American motorcycle manufacturer known for its V-twin engines, distinctive styling, and strong brand loyalty.

Model Evolution

Fat Boy Origin:

The Fat Boy model, introduced in 1990, was a tribute to the post-WWII 'Liberator' bomber aircraft and gained significant popularity, including a prominent role in the movie Terminator 2: Judgment Day.

Twin Cam Introduction:

The Twin Cam 88 engine was introduced in 1999, representing a significant upgrade over the Evolution engine with increased displacement and improved performance and durability.

Production

Manufacturing Location:

United States (primarily Milwaukee, Wisconsin and Kansas City, Missouri for this era).

🏆 Awards & Recognition

Recognitions

Cultural Impact:

Recognized as an icon of American motorcycling, heavily influencing the cruiser market segment. Gained significant cultural relevance through media appearances.

Ratings

Customer Satisfaction:

Generally high customer satisfaction for its styling and riding experience, though performance metrics may be secondary to brand appeal for many owners.

Certifications

Emissions Compliance:

Compliant with US EPA and California ARB emissions standards for its model year.