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Harley Davidson FXSTDI Deuce ST 2003 Service Repair Manual
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Basic Information Identification Make: Harley-Davidson Model: FXSTDI Deuce ST Year: 2003 Codes Model Code: FXSTDI Introduction Market Position Target Audience: Harley-Davidson FXSTDI Deuce ST owners, independent repair shops, professional mechanics....
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| Basic Information | |
| Identification | |
| Make: | Harley-Davidson |
| Model: | FXSTDI Deuce ST |
| Year: | 2003 |
| Codes | |
| Model Code: | FXSTDI |
| Introduction | |
| Market Position | |
| Target Audience: | Harley-Davidson FXSTDI Deuce ST owners, independent repair shops, professional mechanics. |
| Competitive Analysis | |
| Value Proposition: | Provides essential technical data for maintaining, troubleshooting, and repairing the 2003 Harley-Davidson FXSTDI Deuce ST, enabling cost savings and ensuring optimal performance and longevity. |
| Key Features | |
| Document Type: | Comprehensive Workshop Manual |
| Reliability: | Authoritative source for accurate repair information. |
| Accessibility: | Instant PDF download for immediate use. |
| Manual Details | |
| Coverage Areas | |
| Manual Type: | Service Repair Workshop Manual |
| Language: | English |
| Format: | PDF Download |
| Models Covered: | All FXSTDI Deuce ST variants |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Complete engine overhaul, assembly, disassembly, lubrication, internal components, cylinder head, cylinders, pistons, connecting rods, crankshaft, camshafts, timing, valve train. |
| Fuel System: | Fuel injection system, fuel pump, fuel filter, injectors, throttle body, fuel lines, fuel tank, pressure regulator. |
| Ignition System: | Ignition module, spark plugs, ignition coils, wiring, troubleshooting. |
| Transmission Drivetrain: | Clutch operation, transmission assembly/disassembly, gear shifting mechanisms, final drive, belt, sprockets, bearings. |
| Electrical System: | Battery, charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlight, taillight, turn signals), horn, wiring diagrams, fuses, relays, switches, instrument cluster. |
| Brakes: | Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake pads, rotors, bleeding procedures, troubleshooting. |
| Suspension Steering: | Front forks (telescopic, hydraulic), rear shock absorbers, swingarm, steering head bearings, lubrication, adjustment, troubleshooting. |
| Frame Bodywork: | Frame inspection, body panels, fenders, seat, fuel tank, handlebars, controls, mounting hardware, cosmetic repairs. |
| Procedures Included | |
| Routine Maintenance: | Oil changes, filter replacements, spark plug maintenance, chain/belt adjustment, lubrication points, tire pressure checks, brake inspection. |
| Troubleshooting Diagnostics: | Step-by-step diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts, diagnostic codes (if applicable). |
| Repair Rebuild: | Detailed instructions for disassembly, repair, and reassembly of all major vehicle components and systems. |
| Electrical Troubleshooting: | Comprehensive use of wiring diagrams, testing electrical components, diagnosing short circuits, open circuits, and intermittent issues. |
| Engine Rebuild: | Detailed instructions for engine disassembly, component inspection, machining specifications, and reassembly with torque values. |
| Technical Depth | |
| Depth Level: | Comprehensive Professional Workshop Level |
| Scope: | Covers everything from routine maintenance to complete engine and transmission rebuilds, electrical system diagnostics, and chassis repairs. |
| Manual Specifications | |
| File Format | |
| File Type: | PDF (Portable Document Format) |
| Searchable Text: | Yes |
| Printable: | Yes |
| Print Quality | |
| Image Resolution: | High-resolution, clear diagrams and illustrations. |
| Binding Type | |
| Binding: | N/A (Digital Download) |
| Paper Type | |
| Paper: | N/A (Digital Download) |
| Engine Specifications | |
| Primary Engine | |
| Engine Family: | Evolution (Evo) |
| Engine Type: | Air-cooled, V-twin |
| Displacement: | 1450 cc (88 cubic inches) |
| Bore X Stroke: | 3.50 in. x 4.38 in. (88.9 mm x 111.3 mm) |
| Compression Ratio: | 9.0:1 |
| Valve Train: | Overhead valves (OHV), 2 valves per cylinder |
| Performance | |
| Horsepower Approximate: | Approx. 65-70 HP (varies with tuning and exhaust) |
| Torque Approximate: | Approx. 75-80 ft-lbs @ 3200 RPM (varies with tuning and exhaust) |
| Fuel System | |
| Fuel Delivery: | Electronic Sequential Port Fuel Injection (ESPFI) |
| Fuel Type: | Unleaded gasoline, 91 octane (95 RON) or higher recommended. |
| Lubrication | |
| Oil Type: | Harley-Davidson Genuine V-Twin Motor Oil SAE 20W50 or equivalent motorcycle-specific oil meeting Harley-Davidson specifications. |
| Oil Capacity W Filter: | 3.0 US quarts (2.8 liters) |
| Transmission | |
| Standard | |
| Transmission Type: | 5-speed constant mesh |
| Optional | |
| Optional Transmissions: | N/A (Single transmission offering for this model) |
| Features | |
| Clutch Type: | Wet, multi-plate |
| Final Drive: | Belt drive, 1.125 inch wide belt |
| Transmission Fluid Type: | Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant or Syn3 Synthetic Transmission, Primary Chaincase, and Engine Lubricant. |
| Dimensions | |
| Exterior | |
| Overall Length: | 94.2 inches (2393 mm) |
| Overall Width: | 35.0 inches (889 mm) |
| Overall Height: | 46.7 inches (1186 mm) |
| Wheelbase: | 64.8 inches (1646 mm) |
| Ground Clearance: | 4.7 inches (119 mm) |
| Weights | |
| Dry Weight: | Approx. 590 lbs (267.6 kg) |
| Gross Vehicle Weight Rating Gvwr: | Approx. 975 lbs (442 kg) |
| Cargo | |
| Fuel Capacity: | 4.0 US gallons (15.1 liters) |
| Safety Features | |
| Ratings | |
| Crash Test Ratings: | N/A (Motorcycles are not subject to the same crash testing as automobiles) |
| Active Features | |
| Braking System: | Dual front disc brakes, single rear disc brake. |
| Lighting: | Halogen headlight, LED taillight, amber incandescent turn signals. |
| Passive Features | |
| Frame Construction: | Steel tubing, rigid backbone and downtube. |
| Technology Features | |
| Infotainment | |
| Audio System: | Optional factory or dealer-installed audio systems may be present, often with handlebar-mounted controls. Manual covers integration points. |
| Driver Assistance | |
| ABS: | Anti-lock Braking System (ABS) was typically an option on this model. Manual covers ABS system components and diagnostics. |
| Connectivity | |
| Diagnostics Port: | Includes diagnostic connectors for electronic troubleshooting using specialized Harley-Davidson diagnostic tools. |
| Maintenance | |
| Service Intervals | |
| First Service: | 1000 miles (1600 km) or 6 months, whichever comes first (includes inspection, lubrication, fluid changes). |
| Subsequent Oil Changes: | Every 5000 miles (8000 km) or 12 months. Check manual for exact interval based on operating conditions. |
| Belt Tension Check: | Every 5000 miles (8000 km). |
| Spark Plug Replacement: | Refer to manual, typically around 10,000 - 15,000 miles, depending on plug type. |
| Fluid Specifications | |
| Primary Chaincase Oil: | Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant or Syn3. |
| Transmission Oil: | Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant or Syn3. |
| Brake Fluid: | DOT 4 brake fluid. |
| Fork Oil: | Refer to manual for specific type and viscosity (often Harley-Davidson front end oil or equivalent). |
| Known Issues | |
| Cam Chain Tensioner Wear: | Early models (pre-2007) are known for wear on the hydraulic cam chain tensioners, which can lead to engine noise and potential damage. The manual will detail inspection and replacement procedures. |
| Crankshaft Runout: | While less common on this specific model year, crankshaft runout is a critical factor. The manual provides specifications and inspection methods. |
| Electrical Connectors: | Corrosion or loose connections in electrical connectors can cause intermittent issues. The manual's wiring diagrams are crucial for diagnosis. |
| Vehicle History | |
| Brand Heritage | |
| Manufacturer: | Harley-Davidson Motor Company, established 1903. |
| Model Evolution | |
| Deuce Introduction: | The Deuce (FXSTD) was introduced in 1999, featuring a stretched-out Softail frame, unique styling with a solid rear wheel and often a larger front wheel, and the Evolution engine. |
| Fxstdi Specifics: | The FXSTDI designation indicates fuel injection and the 'ST' likely refers to a specific trim or package offered in 2003, often including upgraded components or styling elements. This generation marked a significant step in integrating modern technology like fuel injection into classic Harley designs. |
| Production | |
| Manufacturing Location: | United States (Various Harley-Davidson facilities) |
| Awards & Recognition | |
| Recognitions | |
| Model Recognition: | The FXSTDI Deuce ST, as part of the Softail family, is recognized for its classic styling combined with a comfortable ride, making it a popular choice for cruiser enthusiasts. |
| Ratings | |
| Owner Satisfaction: | Harley-Davidson generally receives high owner satisfaction ratings for its build quality and iconic design, especially for models in the Softail lineup. |
| Certifications | |
| Manual Certification: | This is a professional workshop manual, not a certified OEM document. However, its technical accuracy is derived from industry best practices and detailed vehicle engineering. |