Target Audience:
Harley-Davidson owners, independent repair shops, DIY mechanics, motorcycle enthusiasts.
Value Proposition:
Provides detailed information to perform maintenance and repairs, saving on dealer labor costs and empowering owners.
Competitor Manuals:
Likely compares favorably to official Harley-Davidson service manuals in terms of content, but offers digital convenience and potentially lower cost.
Content Breadth:
Covers a wide range of models within the Softail family for the specific year, including both service and electrical diagnostics.
Instructional Method:
Emphasizes step-by-step instructions, diagrams, illustrations, and photos for clarity.
Diagnostic Tool References:
May reference specific diagnostic tools or software required for EFI systems, detailing their usage.
Engine Systems:
Engine disassembly, assembly, tuning, fuel system (carburetor/EFI), ignition system, lubrication, cooling (air-cooled), exhaust system
Drivetrain Systems:
Clutch, primary drive, transmission (gearbox), final drive (belt drive), wheel bearings, drive belts
Chassis Systems:
Frame, suspension (forks, rear shocks), steering, brakes (front and rear), wheels, tires, fenders, bodywork, seats
Electrical Systems:
Starting system, charging system (alternator, stator, regulator/rectifier), battery, ignition system, lighting (headlights, taillights, signals), instruments, gauges, switches, wiring diagrams, TSM/HFSM (Turn Signal Module/Handheld Fault Finder Module), engine management systems (ECM/VCM), EFI components
Fuel System Detail:
Covers carburetor identification, adjustment, disassembly, cleaning, and rebuilding; EFI system components (injectors, fuel pump, pressure regulator, sensors), diagnostics, and troubleshooting.
Ignition System Detail:
Includes ignition module, coil, spark plug selection and service, timing adjustments (if applicable to specific models/systems covered).
Maintenance Procedures:
Routine maintenance checks, lubrication intervals, filter replacement (oil, air), spark plug service, brake fluid flush, belt tension adjustment, tire pressure checks
Repair Procedures:
Engine rebuilds, transmission overhaul, brake caliper service, suspension fork seal replacement, electrical component troubleshooting and replacement, body panel removal and installation, clutch adjustment and replacement
Diagnostic Procedures:
Troubleshooting common problems, fault code reading (if applicable via diagnostic tools described), circuit testing, component testing, diagnostic flowcharts
Wheel And Tire Service:
Includes procedures for tire removal/installation, wheel balancing, spoke tensioning (if applicable), and wheel bearing replacement.
Frame And Suspension Service:
Covers fork disassembly, seal replacement, fluid changes, shock absorber inspection and replacement, and frame integrity checks.
Diagnostic Capabilities:
Detailed troubleshooting guides for electrical and mechanical issues, including symptom-based diagnostics and component-specific tests.
Rebuild Instructions:
Comprehensive instructions for complete engine, transmission, and driveline rebuilds, including torque specifications and clearances.
Diagrams And Illustrations:
Extensive use of detailed diagrams, exploded views, schematics, and photographs to illustrate procedures and components.
Wiring Diagrams Detail:
Extremely detailed wiring diagrams for all electrical circuits, color-coded and with component identification, essential for electrical diagnostics.
Troubleshooting Methodology:
Employs a systematic approach to troubleshooting, often using flowcharts and step-by-step diagnostic trees to isolate problems.
Engine Type:
Air-cooled V-Twin (Evolution or Twin Cam 88 depending on specific model variant, though 2002 Softails are primarily Twin Cam 88 based)
Engine Displacement:
Typically 1450cc (88 cubic inches) for Twin Cam 88 engines. Some models might have had Evolution engines earlier, but this set focuses on 2002. The manual will detail specific engine codes.
Engine Variants:
Includes EFI (Electronic Fuel Injection) and Carbureted versions of the Twin Cam 88 engine.
Horsepower:
Approx. 60-65 HP (manufacturer's estimate, actual may vary). Specific figures would be in the manual.
Torque:
Approx. 70-75 lb-ft (manufacturer's estimate, actual may vary). Specific figures would be in the manual.
Fuel Delivery:
Carburetor (e.g., Keihin CV) or Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, typically 91-93 octane (RON+MON)/91 AKI.
First Service:
Typically around 1,000 miles for initial break-in service (oil change, filter, primary chain adjustment, inspection). Manual will specify exact interval.
Regular Maintenance:
Scheduled maintenance typically every 5,000 miles or annually (whichever comes first), including oil changes, filter replacements, and inspections. Manual will provide a detailed schedule.
Engine Oil:
Harley-Davidson 20W50 motorcycle oil (or equivalent API SG, JASO MA certified) recommended for air-cooled V-twins. Capacity approx. 3-4 quarts. Manual will specify exact type and capacity.
Primary Chain Case Fluid:
Harley-Davidson Primary Lubricant (e.g., Formula+ or similar approved product). Capacity approx. 24 oz. Manual will specify exact type and capacity.
Transmission Fluid:
Harley-Davidson transmission lubricant or equivalent. Manual will specify exact type and capacity.
Brake Fluid:
DOT 4 recommended. Manual will confirm specification and flush interval.
Fork Oil:
Specific weight and quantity for front fork oil (e.g., 10W or 15W). Manual will provide precise details.
Common Softail Issues 2002:
Potential issues can include starter solenoid failures, cam bearing wear, fuel tank expansion (on certain materials), regulator/rectifier failures, and primary compensator sprocket wear. Manual will detail diagnostic and repair procedures for these and other potential issues.
Electrical Diagnostics Focus:
The dedicated electrical manual is crucial for addressing common electrical gremlins, such as intermittent charging issues, lighting problems, or fuel injection system faults.
