🏷️ Basic Information

Make:

Harley-Davidson

Model:

Softail

Model Variant:

FXST (Softail Standard), FLST (Softail Heritage), FXSTB (Night Train), FXSTS (Softail Springer Classic), FLSTS (Heritage Springer)

Year:

2002

Oem Manual Part Number:

99482-02 (Note: This is a common part number for the 2002 Softail series service manual, specific to model variants might exist but this is the general identifier for the family)

👋 Introduction

Category:

Cruiser Motorcycle

Target Audience:

Harley-Davidson owners and independent repair shops seeking detailed technical information for maintenance and repair.

Competitors:

Other V-twin cruiser manufacturers such as Indian Motorcycles, Victory Motorcycles (later models).

Design Philosophy:

Classic cruiser styling, large displacement V-twin engine, comfortable riding position, iconic Harley-Davidson heritage.

Model Focus:

This manual covers a range of Softail models, known for their rigid-look frames with hidden rear suspension, offering a blend of classic aesthetics and modern engineering.

📋 Manual Details

Engine:

All engine configurations (e.g., Twin Cam 88, Twin Cam 88B)

Transmission:

5-speed Cruise Drive

Chassis:

Frame, suspension, steering, brakes

Electrical:

Wiring diagrams, ignition, lighting, starting, charging, instruments

Bodywork:

Fuel tanks, fenders, seating, controls, accessories

Estimated Pages:

Approximately 500-700 pages (typical for Harley-Davidson service manuals of this era)

Type:

Service Repair Workshop Manual

Language:

English

Format:

Downloadable Digital File (likely PDF)

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, assembly, inspection, internal components (pistons, cylinders, cams, valves), timing, lubrication system

Fuel System:

Carburetor (Keihin CV), fuel pump, fuel tank, fuel lines, emissions controls

Ignition System:

Ignition module, coils, spark plugs, timing analysis

Exhaust System:

Exhaust pipes, mufflers, heat shields, installation and removal

Drivetrain:

Clutch operation, primary drive, transmission internal components, final drive belt

Braking System:

Front and rear brake calipers, master cylinders, brake lines, brake fluid, rotor inspection and replacement

Suspension System:

Front forks (including Springer forks for specific models), rear shock absorbers, fork oil change, seal replacement, suspension tuning

Electrical System Detailed:

Battery, starter motor, alternator, regulator/rectifier, lighting circuits, horn, turn signals, diagnostic codes (if applicable)

Instrumentation:

Speedometer, tachometer, indicator lamps, fuel gauge, oil pressure gauge

Wheel And Tire:

Wheel bearing replacement, tire inspection and replacement, wheel balancing

Frame And Body:

Frame inspection, fender mounting, tank removal/installation, seat adjustment/removal

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, brake fluid flush, battery checks

Troubleshooting:

Diagnostic procedures for common problems, electrical circuit testing, engine performance issues

Repair:

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

Overhaul:

Engine, transmission, and carburetor overhaul procedures

Installation:

Installation of common accessories and replacement parts

Special Tools:

Identification and usage of specialized tools required for specific procedures

Depth:

Comprehensive from basic maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and troubleshooting.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable (if original digital scan or properly OCR'd)

Printability:

Printable pages

Quality Description:

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

Binding:

N/A (Digital download)

Paper:

N/A (Digital download)

⚙️ Engine Specifications

Engine Type:

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

Engine Displacement:

1450cc (88 cubic inches)

Engine Family:

Twin Cam 88 (or Twin Cam 88B for Softail models which feature a counterbalancer)

Bore X Stroke:

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

Compression Ratio:

8.8:1

Horsepower Estimated:

Approximately 65-70 HP (at crankshaft, actual varies)

Torque Estimated:

Approximately 85-90 ft-lbs (at crankshaft, actual varies)

Fuel Delivery:

Keihin CV (Constant Velocity) Carburetor, 40mm

Fuel Type:

Unleaded gasoline, 91 octane (AKI) or higher recommended

Oil Type:

Harley-Davidson 20W50 (or equivalent API SG, SAE 20W50 motorcycle oil)

Oil Capacity:

Approximately 4 quarts (3.8 liters) with filter change

🔧 Transmission

Transmission Type:

5-speed Manual, Cruise Drive

Gear Ratios:

1st: 9.312, 2nd: 6.405, 3rd: 4.774, 4th: 3.834, 5th: 3.150 (approximate, refer to manual for precise ratios)

Optional Transmission:

N/A (5-speed was standard across Softail models)

Clutch Type:

Wet, multi-plate

Primary Drive:

Plated duplex chain, 1.483:1 ratio

Final Drive:

Belt drive, 32/66 tooth sprockets (48/49 tooth rear pulley on some models), 1:2.06:1 ratio

Transmission Oil Type:

Harley-Davidson Syn3 (20W50) or suitable HD transmission fluid

Transmission Oil Capacity:

Approximately 24-26 fl. oz. (0.71-0.77 liters)

📐 Dimensions

Wheelbase:

Approx. 64.75 in. (1645 mm) for FXST/FXSTS, Approx. 65.5 in. (1664 mm) for FLST/FLSTS

Seat Height:

Approx. 26.0 in. (660 mm) (unladen)

Ground Clearance:

Approx. 4.5-5.0 in. (114-127 mm)

Dry Weight:

Approx. 600-650 lbs (272-295 kg) depending on model variant

Gross Vehicle Weight Rating:

Approx. 950-1000 lbs (431-454 kg)

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycles are not subjected to standardized crash testing like automobiles)

Braking System:

Dual piston front brake caliper with 292mm disc, dual piston rear brake caliper with 292mm disc. (No ABS standard on these models).

Lighting:

Halogen headlight, tail light, brake light, front and rear turn signals.

💡 Technology Features

Audio System:

Optional radio/audio systems available on some touring-oriented Softail variants (e.g., Heritage models), but typically not standard on FXST or FXSTB. Manual may cover installation/basic operation if equipped.

ABS:

Anti-lock Braking System (ABS) was not a standard feature on 2002 Softail models.

Connectivity Features:

No advanced connectivity features like Bluetooth or USB ports. Primarily mechanical and basic electrical systems.

🔧 Maintenance

First Service:

500 miles (800 km) - Includes oil change, primary chain adjustment, inspection of all critical fasteners, controls, and brake systems.

Subsequent Oil Change:

Every 5,000 miles (8,000 km) or annually, whichever comes first. Primary and transmission fluid changes also typically follow this interval.

Belt Tension Check:

Every 5,000 miles (8,000 km)

Spark Plug Replacement:

Every 10,000 - 15,000 miles (16,000 - 24,000 km), depending on plug type and condition.

Brake Fluid Type:

DOT 4 (refer to manual for specific formulation).

Fork Oil Type:

Harley-Davidson Type E or equivalent SAE 15W fork oil (capacity varies by model, approximately 11-13 fl oz per fork leg).

Cam Chain Tensioner:

Early Twin Cam 88 engines (pre-2007) used spring-loaded cam chain tensioners that could wear prematurely, leading to potential engine damage. This manual will detail inspection and replacement procedures.

Carburetor Issues:

Keihin CV carburetor can require tuning and adjustment for optimal performance and idle. Manual covers carburetor disassembly, cleaning, and adjustment.

Electrical Connections:

Corrosion in electrical connectors can lead to intermittent issues; manual provides wiring diagrams for diagnosis.

📚 Vehicle History

Founding:

Founded in 1903 in Milwaukee, Wisconsin, Harley-Davidson is an iconic American motorcycle manufacturer.

Softail Introduction:

The Softail concept, featuring hidden rear suspension to mimic a hardtail frame, was introduced in 1984 with the FXST Softail Standard.

2002 Model Year:

The 2002 model year saw the continued refinement of the Twin Cam 88 engine, introduced in 1999. Models like the Fat Boy (FLSTF), Heritage Softail (FLST), Heritage Springer (FLSTS), Springer Softail (FXSTS), and Night Train (FXSTB) were part of the Softail family.

Manufacturing Location:

Milwaukee, Wisconsin, USA

🏆 Awards & Recognition

Brand Recognition:

Harley-Davidson is consistently recognized as a leader in the cruiser motorcycle segment, with a strong brand loyalty and cultural icon status.

Owner Satisfaction:

High owner satisfaction generally reported for the Softail platform, due to its styling, comfort, and classic V-twin experience.

Oem Standard:

This manual adheres to Harley-Davidson's factory service standards for the 2002 model year.