Positioning:
The FLSTF Fat Boy was a flagship model for Harley-Davidson in the late 1990s, known for its iconic styling, substantial presence, and the robust Evolution engine. This manual is essential for owners and technicians maintaining or customizing these classic motorcycles.
Competition:
Competed in the cruiser segment against models from brands like Indian (during its revival periods) and custom motorcycle builders, but Harley-Davidson's brand cachet and the Fat Boy's distinct aesthetics set it apart.
Styling:
Plow-shaped front fork covers, solid-cast aluminum wheels (often chrome or polished), wide handlebars, Fat Bob fuel tank styling, extensive chrome plating.
Powertrain:
Reliable Harley-Davidson Evolution V-twin engine, known for its torque and distinctive sound.
Primary Coverage:
Mechanical, Electrical, Bodywork, Maintenance, Troubleshooting, Repair
Estimated Page Count:
300-500
Type:
Factory Service Manual / Workshop Manual
Engine:
Evolution (Evo) Big Twin engine, including top-end, bottom-end, lubrication, cooling, and fuel delivery systems.
Transmission:
5-speed Cruise Drive transmission, clutch, primary drive, gear shift mechanism.
Electrical:
Ignition system, lighting, charging system (stator, regulator/rectifier), starting system (starter, solenoid), battery, wiring diagrams, instrumentation.
Chassis:
Frame, front fork (including telescopic fork maintenance), rear suspension (shocks, swingarm), wheels, tires, brakes (front and rear disc brakes), steering head bearings.
Fuel System:
Carburetor (likely Keihin CV 40), fuel tank, fuel lines, fuel filter.
Exhaust System:
Exhaust pipes, mufflers, mounting hardware.
Bodywork:
Fenders, fuel tank, seat, handlebars, controls, fenders, saddlebags (if applicable).
Maintenance:
Routine service checks, oil changes, filter replacements, spark plug service, chain adjustment (if applicable, though likely belt drive for this model), brake fluid flush.
Troubleshooting:
Diagnostic charts and procedures for common issues related to engine performance, starting, electrical faults, and braking.
Repair:
Detailed step-by-step instructions for disassembly, reassembly, and repair of all major components and systems.
Diagnostics:
Guidance on identifying the root cause of problems, including electrical testing and mechanical checks.
Depth:
Comprehensive, covering from basic maintenance tasks to full engine and transmission rebuilds, including electrical system diagnostics and component-level repair.
PDF Quality:
High-resolution, searchable text, printable pages.
Printability:
Designed for clear printing, preserving all diagrams and text legibility.
Binding:
N/A (Digital PDF Download)
Paper Type:
N/A (Digital PDF Download)
Engine Type:
Harley-Davidson Evolution (Evo) V-twin, air-cooled
Displacement:
1338 cc (82 cubic inches)
Bore X Stroke:
3.500 in x 4.250 in (88.9 mm x 108.0 mm)
Compression Ratio:
8.5:1 (typical for this era Evo)
Horsepower Approximate:
Approx. 65-70 HP (at crankshaft, depending on tuning and specific year variation)
Torque Approximate:
Approx. 80-85 ft-lbs @ 3000 RPM (at crankshaft)
Carburetor:
Keihin CV (Constant Velocity) 40mm (standard)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Ignition System:
Electronic ignition, dual spark plugs per cylinder
Oil Type:
Harley-Davidson Genuine Motorcycle Oil 20W-50 or equivalent V-twin specific motorcycle oil
Oil Capacity:
Approx. 3 quarts (2.8 liters) with filter change
Transmission Type:
5-speed constant mesh, helical gear
Primary Drive:
Multi-plate, wet type clutch, chain drive to transmission
Transmission Oil Type:
Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant or equivalent
Transmission Oil Capacity:
Approx. 1 quart (0.95 liters)
Length:
Approx. 93.1 inches (2365 mm)
Width:
Approx. 38.0 inches (965 mm)
Height:
Approx. 48.5 inches (1232 mm) (to top of handlebars)
Dry Weight:
Approx. 645 lbs (293 kg)
Gross Vehicle Weight Rating:
Approx. 1050 lbs (476 kg)
Payload Capacity:
Approx. 405 lbs (184 kg)
Fuel Tank Capacity:
4.0 gallons (15.1 liters)
Wheel Type:
Solid-cast aluminum disc wheels
Crash Test Ratings:
N/A (Motorcycle safety ratings differ from automotive; focus is on design and component integrity.)
Braking System:
Dual disc front brakes, single disc rear brake. Hydraulic actuation.
Lighting:
Halogen headlight, LED tail light, incandescent turn signals, brake light.
Frame Construction:
Steel tube frame designed for stability and rider control.
Infotainment System:
Basic instrumentation; typically analog speedometer, tachometer (optional or integrated), fuel gauge, and indicator lights. No advanced infotainment systems present.
ABS:
Anti-lock Braking System (ABS) was not standard or widely available on this model in these years. Consult specific VIN if it has an aftermarket or dealer-installed ABS.
Connectivity Features:
None.
Initial Service:
First service typically around 1000 miles (1600 km), focusing on engine oil change, primary drive inspection, and general checks.
Regular Oil Change:
Every 5000 miles (8000 km) or annually, whichever comes first.
Primary Chain Adjustment:
Inspect and adjust as needed at regular service intervals, typically every 5000 miles.
Spark Plug Replacement:
Typically every 10,000-15,000 miles, but consult manual for specific type and gap.
Brake Fluid Flush:
Recommended every 2 years, regardless of mileage.
Engine Oil Viscosity:
20W-50 motorcycle specific
Transmission Primary Oil:
Harley-Davidson Formula+ or equivalent
Carburetor Tuning:
Keihin CV carburetors can require occasional fine-tuning for optimal performance across different altitudes and temperatures.
Oil Leaks:
As with many older V-twins, check for minor oil leaks from gaskets and seals; the manual will detail gasket replacement procedures.
Belt Drive Tension:
Regularly check and adjust belt tension to prevent premature wear on the belt and sprockets.
Electrical Connections:
Ensure all electrical connectors are clean and secure, especially in humid or corrosive environments.
Heritage:
Harley-Davidson, founded in 1903, has a deep-rooted history in American motorcycling, synonymous with freedom, customization, and the V-twin engine. The 'Fat Boy' nameplate itself evokes a powerful image in motorcycle culture.
Fat Boy Introduction:
The Fat Boy was first introduced in 1990 and quickly became an icon, significantly influencing motorcycle design and popularity in the cruiser segment. The 1997-1998 models represent a mature iteration of the original concept.
Manufacturing Location:
United States (Milwaukee, Wisconsin and York, Pennsylvania were primary manufacturing sites during this period).
Market Impact:
The Fat Boy was a significant sales success and a cultural touchstone, further cemented by its appearance in films like 'Terminator 2: Judgment Day' (though that was a slightly earlier model, the image persisted).
