Model Years Covered:
2000, 2001, 2002, 2003, 2004, 2005
Chassis Codes:
FLST (Fat Boy, Heritage Softail, Springer Softail), FXST (Standard, Custom, Softail Deuce)
Target Audience:
Harley-Davidson owners, independent repair shops, and technicians working on 2000-2005 Softail models.
Value Proposition:
Provides dealer-level technical information, enabling accurate diagnostics, efficient repairs, and proper maintenance, reducing reliance on costly dealership services.
Manual Quality:
Equivalent to official Harley-Davidson factory service manuals, offering a high degree of accuracy and completeness.
Comprehensiveness:
The most detailed resource available for this specific model range, covering all aspects of the motorcycle.
Instructional Format:
Step-by-step instructions and clear, detailed diagrams facilitate understanding and execution of repairs.
Primary Coverage:
All factory specifications, diagnostic procedures, repair, maintenance, and troubleshooting for Harley-Davidson FLST and FXST Softail models.
Engine Coverage:
Twin Cam 88, Twin Cam 88B engines (carbureted and fuel-injected variants).
Transmission Coverage:
5-speed Cruise Drive transmission.
Estimated Page Count:
800-1200 pages (typical for comprehensive factory service manuals).
Manual Type:
Professional Workshop Service & Repair Manual
Format:
Downloadable Digital Format (PDF)
Engine Systems:
Engine assembly, disassembly, lubrication, cooling, fuel system (carburetor and EFI), ignition system, exhaust system, engine diagnostics.
Drivetrain Systems:
Clutch, transmission (5-speed Cruise Drive), final drive, primary drive, drive belts, chain adjustments.
Electrical Systems:
Battery, charging system, starting system, ignition, lighting, instrumentation, switches, relays, fuses, wiring diagrams, security system.
Chassis Systems:
Frame, front suspension (forks, steering head), rear suspension (shock absorbers, swingarm), wheels, tires, brakes (hydraulic front and rear), steering.
Bodywork And Trim:
Body panels, fenders, fuel tank, seat, handlebars, controls, fairings (if applicable), trim pieces.
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, brake fluid flush, clutch adjustment, cable adjustments, battery maintenance, tire pressure checks.
Repair Procedures:
Engine rebuilds, transmission overhauls, brake system repairs, electrical component replacement, suspension servicing, chassis repairs.
Troubleshooting Procedures:
Diagnostic charts, symptom-based troubleshooting, fault code interpretation, electrical system diagnostics, engine performance issues.
Special Tools And Jigs:
Identification and usage of specialized Harley-Davidson tools required for specific repairs and adjustments.
Depth Of Information:
Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
Diagnostic Capabilities:
Detailed diagnostic trees and fault code interpretations for the Electronic Control Module (ECM) and other control units.
Torque Specifications:
Precise torque values for all critical fasteners, engine components, and chassis fasteners.
Clearances And Tolerances:
Specifications for component clearances, piston-to-wall, ring end gap, valve lash, bearing clearances, etc.
Wiring Diagrams:
Detailed, color-coded electrical schematics for all model variations and electrical systems.
Engine Type:
V-Twin, Air-Cooled, Pushrod Actuated, Overhead Valves
Engine Family:
Twin Cam 88 / Twin Cam 88B
Displacement:
1449cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Compression Ratio:
Typically 8.8:1 to 9.2:1, depending on specific model and year.
Power Output:
Approx. 65-70 HP (Varies by model and tuning)
Torque Output:
Approx. 85-90 ft-lbs (Varies by model and tuning)
Carburetor Specifications:
Keihin CV (Constant Velocity) 40mm (for carbureted models)
Fuel Injection System:
Sequential Electronic Fuel Injection (EFI) with throttle body (for fuel-injected models)
Fuel Type:
Unleaded Gasoline, minimum 91 Octane (RON+MON)/2
Transmission Type:
5-Speed Manual Transmission
Transmission Gear Ratios:
Refer to manual for specific ratios (e.g., 1st: 9.312, 2nd: 6.650, 3rd: 4.945, 4th: 3.832, 5th: 3.152 - typical values)
Optional Transmission:
None for this model range
Clutch Type:
Wet, multi-plate, diaphragm spring
Transmission Fluid Type:
Harley-Davidson Formula+, SAE 50 Primary Chaincase Lubricant, or equivalent.
Primary Drive:
Chain drive, enclosed in primary chaincase.
Final Drive:
Belt drive (20mm width, 140T - typical)
Wheelbase:
Approx. 64.5 - 66.0 inches (varies by model)
Seat Height:
Approx. 25.5 - 27.0 inches (unladen, varies by model)
Ground Clearance:
Approx. 4.5 - 5.5 inches (varies by model)
Dry Weight:
Approx. 600 - 650 lbs (varies by model)
Gross Vehicle Weight Rating:
Refer to owner's manual or VIN plate.
Fuel Capacity:
Approx. 4.0 - 5.0 gallons (varies by model)
Safety Standards:
Designed to meet or exceed federal safety standards for motorcycles. Specific ratings not typically published for custom motorcycles.
Braking System:
Hydraulic disc brakes, front and rear. ABS (Anti-lock Braking System) was optional on some models during this period.
Suspension Stability:
Softail frame design provides a rigid chassis, contributing to stability.
Lighting:
Halogen headlamp, taillight, brake light, turn signals.
Security System:
Factory-installed H-D Smart Security System (optional on some models, standard on others) with siren and starter interrupt.
First Service:
1,000 miles (1,600 km) or 6 months, whichever comes first.
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first. Specific checks may be more frequent.
Engine Oil Type:
Harley-Davidson H-D 360 SAE 20W-50, or equivalent API CI-4 rated synthetic oil.
Engine Oil Capacity:
Approx. 3.5 quarts (3.3 Liters) with filter change.
Primary Chaincase Fluid:
Harley-Davidson Formula+, SAE 50, or equivalent.
Primary Chaincase Fluid Capacity:
Approx. 1.0 quart (0.95 Liters).
Transmission Fluid Type:
Harley-Davidson Formula+, SAE 50, or equivalent.
Transmission Fluid Capacity:
Approx. 24 fl oz (0.71 Liters).
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid.
Common Issues Wear Items:
Clutch wear, belt drive tensioner, wheel bearings, fork seals, spark plugs, battery longevity.
Common Issues Engine Related:
Potential oil leaks from base gaskets, rocker boxes, and cam cover; occasional cam chain tensioner wear on earlier Twin Cam models (addressed with upgraded components).
Common Issues Electrical:
Wiring harness chafing, regulator/rectifier failure, battery drain issues (often related to accessory wiring or charging system components).
Brand Legacy:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and cruiser-style motorcycles.
Softail Platform:
The Softail platform, introduced in 1984, features a hidden rear shock absorber system that mimics the appearance of a hardtail frame while providing modern suspension comfort.
Engine Transition:
The 2000-2005 models represent the era of the Twin Cam 88 and Twin Cam 88B engines, which replaced the Evolution (Evo) big twin engine.
Manufacturing Location:
United States (primarily York, Pennsylvania and Milwaukee, Wisconsin).
