🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLSTF Fat Boy

Year:

2002

Platform:

Softail

👋 Introduction

Market Segment:

Cruiser motorcycle, iconic American styling.

Target Audience:

Owners and independent repair shops seeking detailed, authoritative information for maintenance and repair.

Competitive Advantage:

Provides essential technical data and procedures for a specific, popular model year, bridging the gap for owners who prefer self-service.

Key Selling Point:

Facilitates in-depth understanding and execution of maintenance and repair tasks for the 2002 FLSTF Fat Boy.

📋 Manual Details

Manual Type:

Service Repair Manual / Workshop Manual

Language:

English

Format:

PDF

Coverage Scope:

Comprehensive repair and overhaul for Harley-Davidson FLSTF Fat Boy Softail 2002

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, assembly, inspection, and repair of Twin Cam 88B engine components (e.g., cylinders, pistons, crankshaft, camshafts, valves).

Fuel System:

Carburetor (Keihin CV) or EFI (Electronic Fuel Injection) system diagnosis, repair, and adjustment, fuel pump, fuel lines, and fuel tank service.

Ignition System:

Ignition module, spark plugs, ignition coils, and related wiring diagnosis and repair.

Electrical System:

Wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid, battery), lighting system, instruments, switches, and accessory wiring.

Transmission:

5-speed gearbox disassembly, assembly, inspection, fluid change, and troubleshooting (e.g., clutch operation, gear selection).

Drivetrain:

Primary drive system (clutch, compensator sprocket, chain), final drive (belt drive system, belt tensioner, rear pulley inspection).

Suspension:

Front fork (fork tubes, seals, oil change, damper rod inspection) and rear shock absorber service, adjustment, and replacement.

Braking System:

Front and rear brake caliper service, hydraulic system bleeding, master cylinder and slave cylinder repair, brake pad replacement, and rotor inspection.

Wheels And Tires:

Wheel bearing inspection and replacement, tire mounting and balancing, spoke tension adjustment (if applicable), and wheel alignment checks.

Frame And Bodywork:

Frame inspection, fender removal and installation, fuel tank mounting, seat assembly, handlebar replacement, and basic cosmetic repair guidance.

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, battery maintenance, lubrication points, and bolt torque checks.

Troubleshooting:

Diagnostic procedures for common starting, running, electrical, and braking issues, with symptom-based troubleshooting charts.

Component Overhaul:

Detailed step-by-step instructions for complete disassembly and reassembly of major engine, transmission, and suspension components.

Wiring Diagrams:

High-quality, detailed electrical schematic diagrams for accurate diagnosis and repair of the vehicle's electrical system.

Special Tool Requirements:

Identification and usage instructions for specialized tools required for specific repair procedures.

Depth Level:

Comprehensive, suitable for professional technicians and experienced DIY mechanics.

📊 Manual Specifications

File Format:

PDF

Searchability:

Searchable text for quick access to specific information.

Print Quality:

High-resolution scans ensuring clarity of text and diagrams.

Binding Type:

Not applicable (digital PDF)

Paper Type:

Not applicable (digital PDF)

⚙️ Engine Specifications

Engine Type:

Harley-Davidson Twin Cam 88B V-Twin

Displacement:

1450 cc (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)

Valvetrain:

OHV, 2 valves per cylinder, pushrod actuated.

Horsepower:

Approximately 60-65 HP (at crankshaft, estimated for the era)

Torque:

Approximately 75-80 ft-lbs (at crankshaft, estimated for the era)

Fuel Delivery Method:

Carburetor (Keihin CV 40mm) or Electronic Fuel Injection (EFI) depending on exact build specification.

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON+MON)/2.

Oil Type:

Harley-Davidson 20W-50 Genuine Motorcycle Oil or equivalent API SG rated motorcycle oil.

🔧 Transmission

Transmission Type:

5-speed constant mesh, helical gears.

Clutch Type:

Wet, multi-plate, diaphragm spring.

Primary Drive:

Chain drive, 34/46 tooth ratio (approximate).

Final Drive:

Belt drive, 32/66 tooth ratio (approximate) with carbon fiber reinforced belt.

Gear Ratios:

1st: 9.312, 2nd: 6.477, 3rd: 4.716, 4th: 3.775, 5th: 3.165 (typical for 5-speed gearbox)

Transmission Fluid:

Harley-Davidson primary chaincase lubricant or equivalent SAE 50 API GL-4.

📐 Dimensions

Wheelbase:

64.5 inches (1638 mm)

Length:

93.1 inches (2365 mm)

Width:

37.4 inches (950 mm)

Height:

47.0 inches (1194 mm)

Seat Height Laden:

26.5 inches (673 mm)

Dry Weight:

635 lbs (288 kg)

Gross Vehicle Weight Rating:

1050 lbs (476 kg)

Fuel Capacity:

5.0 gallons (18.9 L)

Oil Capacity:

3.0 US qt (2.8 L)

🛡️ Safety Features

Safety Ratings:

Not applicable for motorcycles in the same way as cars; relies on rider skill and proper maintenance.

Braking System:

Hydraulic disc brakes front and rear. Dual piston front caliper, single piston rear caliper.

Lighting:

Halogen headlamp, LED taillight, incandescent front and rear turn signals.

Frame Construction:

Steel, divided into three sections: headstock, cradle, and rear section.

💡 Technology Features

Infotainment System:

Basic instrumentation: speedometer, odometer, trip meter, tachometer (optional/accessory), indicator lamps.

Driver Assistance Features:

None typically offered on this model; focus is on mechanical and rider control.

Connectivity Features:

None typically offered on this model.

🔧 Maintenance

Initial Service:

1,000 miles (1,600 km) - Engine oil and filter change, primary chain adjustment, inspection of all critical components.

Subsequent Service:

Every 5,000 miles (8,000 km) or annually, whichever comes first: Engine oil and filter change, primary chain inspection/adjustment, check all fluid levels, inspect brakes, check tire pressure and condition, inspect belt tension.

Fork Oil Change:

Recommended every 20,000 miles (32,000 km) or as needed based on performance.

Spark Plug Replacement:

Inspect every 5,000 miles, replace as needed or every 10,000-15,000 miles.

Engine Oil Capacity:

3.0 US quarts (2.8 L) of Harley-Davidson 20W-50 Genuine Motorcycle Oil.

Primary Fluid Capacity:

Approximately 1.0 US quart (0.95 L) of Harley-Davidson primary chaincase lubricant or SAE 50 API GL-4.

Brake Fluid:

DOT 4 Heavy Duty or DOT 5 Silicone Fluid (verify specific system requirement as some Harley models used DOT 5).

Fork Oil:

Harley-Davidson Type 'E' or equivalent 10W fork oil (specific weight may vary based on preference and conditions).

Common Wear Items:

Belt drive wear, wheel bearings, clutch plates, fork seals, and headstock bearings.

Potential Electrical Issues:

Voltage regulator failure, loose connections in wiring harness, starter solenoid issues are not uncommon in this era.

Engine Specific Notes:

Twin Cam 88B engines can develop cam bearing wear issues over time; early models may require specific attention to pushrod adjustments.

📚 Vehicle History

Brand Origin:

Founded in 1903 in Milwaukee, Wisconsin, USA.

Brand Identity:

Iconic American motorcycle manufacturer known for its V-twin engines and custom cruiser styling.

Softail Design:

The Softail chassis, introduced in 1983, mimics the appearance of a hardtail frame but incorporates hidden rear shock absorbers for a smoother ride.

Fat Boy Introduction:

The Fat Boy model debuted in 1990, characterized by its distinctive solid aluminum disc wheels, wide front fork, and teardrop-shaped fuel tank.

Production Era:

The 2002 model year represents a significant era for Harley-Davidson with the widespread adoption of the Twin Cam 88B engine.

🏆 Awards & Recognition

Industry Recognition:

The FLSTF Fat Boy is a highly recognizable and historically significant model within the Harley-Davidson lineup, often cited for its style and cultural impact.

Reliability Ratings:

Generally considered reliable with proper maintenance, though specific components can wear as expected for a vintage motorcycle.

Certification:

N/A for motorcycle maintenance manuals; manual itself is a key resource for maintaining certification/compliance with service standards.