Harley Davidson FLSTF Fat Boy ST 2003 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLSTF Fat Boy ST Year: 2003 Model Designation: FLSTF Nickname: Fat Boy Generation Generation Code: First Generation Fat Boy (pre-2000s redesign) Codes Vin...

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标签: 2003 FLSTF Fat Boy ST Harley Davidson Misc Motorcycle Motorcycles

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

FLSTF Fat Boy ST

Year:

Model Designation:

FLSTF

Nickname:

Fat Boy

Generation

Generation Code:

First Generation Fat Boy (pre-2000s redesign)

Codes

Vin Engine Family:

HTF (Harley-Davidson Twin Cam 88 Softail)

👋 Introduction

Market Position

Segment:

Cruiser Motorcycle

Positioning:

Iconic American cruiser, known for its distinctive styling and comfortable ride

Competitive Analysis

Competitors 2003:

Other Harley-Davidson models, Indian Motorcycles, certain American V-twin cruisers from Japanese manufacturers

Key Features

Styling:

Wide front tire, teardrop fuel tank, chrome accents, distinctive Fat Boy silhouette

Engine:

Harley-Davidson Twin Cam 88B engine, offering robust torque and classic V-twin sound

Ride Comfort:

Softail rear suspension system designed to mimic the look of a hardtail while providing ride comfort

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete factory service and repair for 2003 Harley-Davidson FLSTF Fat Boy ST

Secondary Coverage:

Includes specific components and systems relevant to the FLSTF Fat Boy ST model variant

Page Count

Estimated Page Count:

Hundreds (specific count not provided, indicative of comprehensive coverage)

Manual Type

Type:

Factory Service Repair Manual

Purpose:

Diagnostic, repair, maintenance, and overhaul

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine:

Twin Cam 88B V-Twin, carburetion, ignition, lubrication, cooling (air)

Transmission:

5-speed constant mesh, clutch, primary drive, final drive belt

Chassis:

Frame, front fork (Telescopic), rear suspension (Swingarm with dual shock absorbers), steering

Brakes:

Front disc brake, rear disc brake, hydraulic system

Electrical:

Battery, charging system (alternator, regulator), ignition system, lighting, starter, instrumentation, wiring diagrams

Fuel System:

Carburetor (Keihin CV), fuel tank, fuel lines, fuel filter

Bodywork:

Fenders, fuel tank, seat, handlebars, controls, side covers, chrome components

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacement, lubrication, tire pressure

Diagnostics:

Troubleshooting guides, symptom-based diagnostics, fault code interpretation (if applicable for the era)

Repair:

Engine overhaul, transmission disassembly/assembly, brake system repair, electrical component replacement, suspension service

Installation:

Component replacement procedures, adjustment procedures

Technical Depth

Depth:

Comprehensive, covering routine maintenance to complete engine and transmission rebuilds

Detail Level:

Includes torque specifications, clearances, component identification, diagnostic flowcharts

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable for efficient information retrieval

Print Quality

Quality:

High-resolution, suitable for printing with clear diagrams and text

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Harley-Davidson Twin Cam 88

Engine Configuration:

45-degree V-twin, pushrod actuated overhead valves

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 for TC88B)

Cooling System:

Air-cooled

Performance

Horsepower:

Approx. 60-65 HP (estimated, not officially published by Harley-Davidson for this era)

Torque:

Approx. 75-80 ft-lbs @ 3000 RPM (estimated)

Fuel System

Fuel Delivery:

Keihin CV (Constant Velocity) 40mm carburetor

Fuel Type:

Unleaded gasoline, minimum 87 octane

Oil System

Oil Type:

Harley-Davidson Genuine V-Twin Motor Oil SAE 20W50 or equivalent API CG-4 rated oil

Oil Capacity:

Approx. 4 quarts (3.8 liters) with filter change

🔧 Transmission

Standard

Type:

5-speed constant mesh, sequential manual gearbox

Drive System:

Primary chain drive, secondary belt drive

Optional

Transmission Options:

None (standard 5-speed for this model)

Features

Clutch Type:

Wet, multi-plate, diaphragm spring

Transmission Oil Type:

Harley-Davidson® Genuine Formula Plus (or Syn3) or Formula SAE 75W90 Synthetic Transmission Lubricant

Transmission Oil Capacity:

Approx. 24 US fluid ounces (0.71 L)

📐 Dimensions

Exterior

Length:

Approx. 93.9 inches (2385 mm)

Width:

Approx. 39.0 inches (990 mm) at handlebars

Height:

Approx. 49.5 inches (1257 mm) at windshield (if equipped)

Wheelbase:

Approx. 63.7 inches (1618 mm)

Ground Clearance:

Approx. 4.8 inches (122 mm)

Seat Height Unladen:

Approx. 26.1 inches (663 mm)

Cargo

Fuel Capacity:

5.0 US gallons (18.9 liters)

Weights

Dry Weight:

Approx. 668 lbs (303 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 1060 lbs (481 kg)

Payload Capacity:

Approx. 392 lbs (178 kg)

🛡️ Safety Features

Ratings

Safety Ratings:

Motorcycles are not typically assigned NHTSA safety ratings in the same way as cars. Safety relies on rider skill and equipment.

Active Features

Brakes:

Dual disc front brake, single disc rear brake with hydraulic actuation

Lighting:

Headlight, taillight, brake light, turn signals

Passive Features

Frame Construction:

Steel, designed for stability and rider support

Tire Design:

Wide front tire (130/90-16) for stability and distinctive Fat Boy look

💡 Technology Features

Infotainment

Audio System:

Typically no integrated infotainment system on this model; aftermarket options are common.

Display:

Analog speedometer, tachometer, fuel gauge, oil pressure light, neutral indicator.

Driver Assistance

ABS was not a standard or commonly available option on the 2003 FLSTF Fat Boy.

Cruise Control:

Not standard; typically an aftermarket accessory.

Connectivity

Connectivity Features:

None from the factory.

🔧 Maintenance

Service Intervals

First Service:

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

Subsequent Services:

Every 5000 miles (8000 km) or 12 months

Major Maintenance Items:

Primary chain adjustment, belt tension check, spark plug replacement, brake fluid flush, fork oil change

Fluid Specifications

Engine Oil:

Harley-Davidson Genuine V-Twin Motor Oil SAE 20W50 (or equivalent)

Transmission Oil:

Harley-Davidson Genuine Formula Plus or Formula SAE 75W90 Synthetic Transmission Lubricant

Primary Chain Case Oil:

Harley-Davidson Genuine Primary Chain Case Lubricant or Formula SAE 75W90 Synthetic Transmission Lubricant

Brake Fluid:

DOT 4 compatible hydraulic fluid

Fork Oil:

Harley-Davidson Factory Fork Oil (e.g., Type E or equivalent viscosity, typically around 10W)

Known Issues

Cam Chain Tensioner:

Early TC88 models (pre-2007) had hydraulic tensioners that could wear out and cause noise or damage. Manual recommends inspection and potential replacement with upgraded components.

Carburetor Tuning:

Keihin CV carburetor can sometimes require fine-tuning for optimal performance, especially after modifications or altitude changes.

Belt Tension:

Proper final drive belt tension is crucial for longevity; incorrect tension can lead to premature wear.

Oil Leaks:

Common for older Harley-Davidsons to develop minor oil leaks from gaskets or seals; manual will cover seal replacement procedures.

📚 Vehicle History

Brand Heritage

Brand Established:

Brand Reputation:

Iconic American motorcycle manufacturer, synonymous with freedom and individuality

Model Evolution

Fat Boy Introduction:

Introduced in 1990, the Fat Boy quickly became one of Harley-Davidson's most popular models

2003 Fat Boy:

Represents the evolution of the original Fat Boy design, incorporating the Twin Cam 88 engine and Softail chassis refinements

Production

Manufacturing Location:

USA (primarily York, Pennsylvania and Milwaukee, Wisconsin for various components)

Significance 2003:

Part of the successful Twin Cam era, solidifying Harley-Davidson's market dominance in cruisers

🏆 Awards & Recognition

Recognitions

Model Awards:

While specific 'awards' for the 2003 model are not readily documented, the Fat Boy line itself has consistently been recognized for its iconic styling and enduring popularity in the cruiser market.

Ratings

Customer Satisfaction:

Generally high customer satisfaction for the Harley-Davidson brand and the Fat Boy model's iconic status and rider experience.