Harley Davidson FLSTF Fat Boy 2002 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLSTF Fat Boy Year: 2002 Codes Chassis Code: FLSTF 👋 Introduction Market Position Segment: Cruiser Motorcycle Target Audience: Harley-Davidson FLSTF Fat Boy owners,...

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标签: 2002 FLSTF Fat Boy Harley Davidson Misc Motorcycle Motorcycles

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

FLSTF Fat Boy

Year:

Codes

Chassis Code:

FLSTF

👋 Introduction

Market Position

Segment:

Cruiser Motorcycle

Target Audience:

Harley-Davidson FLSTF Fat Boy owners, independent mechanics, and motorcycle enthusiasts performing their own maintenance and repairs.

Competitive Analysis

Value Proposition:

Provides comprehensive, factory-level repair information that is often difficult to find for older models, enabling owners to maintain their classic bikes.

Key Features

Iconic Design:

The Fat Boy is renowned for its distinctive styling, including the wide front fork, solid disc wheels, and teardrop fuel tank.

Platform Significance:

Represents a key model in Harley-Davidson's Softail family, known for its rigid frame appearance and comfortable ride.

📋 Manual Details

Coverage Areas

General Coverage:

Complete repair, maintenance, and troubleshooting for the 2002 Harley-Davidson FLSTF Fat Boy.

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Digital Format:

PDF (Portable Document Format)

📖 Manual Coverage

Systems Covered

Engine System:

Detailed coverage of the Twin Cam 88 engine, including disassembly, assembly, internal components, timing, and lubrication.

Fuel System:

Carburetor (Keihin CV), fuel pump, fuel tank, and related lines and components.

Ignition System:

Ignition module, spark plugs, coils, and wiring.

Electrical System:

Wiring diagrams, battery, charging system (alternator/stator, regulator/rectifier), lighting, instrumentation, and accessory circuits.

Transmission System:

5-speed constant mesh transmission, clutch, primary drive, and related components.

Drivetrain System:

Belt drive system, rear wheel, and drive belt inspection and replacement.

Suspension System:

Front fork (Telescopic) and rear shock absorber overhaul and adjustment.

Braking System:

Front and rear hydraulic disc brakes, including caliper, master cylinder, and bleeding procedures.

Wheel And Tire System:

Wheel bearing inspection and replacement, tire mounting and balancing.

Frame And Bodywork:

Frame inspection, fenders, fuel tank removal/installation, seat, and related body components.

Control Systems:

Handlebars, controls, cables, and linkages.

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, chain adjustment (if applicable), spark plug service, air filter cleaning/replacement, brake fluid changes, battery maintenance.

Repair Procedures:

Engine rebuilding, transmission overhaul, carburetor tuning, electrical troubleshooting, brake system repairs, suspension servicing, clutch replacement.

Troubleshooting Guides:

Systematic diagnostic procedures for common and uncommon issues, fault codes (if applicable), and problem-solving steps.

Assembly Disassembly:

Step-by-step instructions for removing and installing major components and sub-assemblies.

Technical Depth

Diagnostic Capability:

Advanced diagnostics for engine performance, electrical faults, and mechanical issues.

Rebuild Capability:

Comprehensive instructions for complete engine and transmission rebuilds.

Wiring Diagrams:

Detailed, component-level electrical wiring schematics with color coding and harness routing.

Torque Specifications:

Precise torque values for all critical fasteners.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution scans, searchable text (OCR'd), and printable pages.

Print Quality

Printability:

Designed for seamless printing of individual pages or sections.

Binding Type

Digital Binding:

N/A (Digital PDF)

Paper Type

Digital Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, Evolution (Evo) V-twin

Engine Displacement:

1449 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

Valve Train:

Overhead valves (OHV), pushrod actuated, two valves per cylinder

Performance

Horsepower Estimated:

Approx. 65-70 HP (at crankshaft, estimated)

Torque Estimated:

Approx. 85-90 lb-ft (at crankshaft, estimated)

Fuel System

Carburetor Model:

Keihin CV (Constant Velocity) 40 mm

Fuel Type:

Unleaded gasoline, minimum 87 octane

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh, sequential manual

Features

Primary Drive:

Double-row chain

Final Drive:

Enclosed belt drive

Clutch Type:

Wet, multi-plate

Fluid Specs

Transmission Fluid Type:

Harley-Davidson recommended Syn-3 or equivalent primary lubricant (e.g., SAE 50 or SAE 20W-50 motorcycle specific).

📐 Dimensions

Exterior

Length:

93.5 in. (2375 mm)

Width:

37.0 in. (940 mm)

Height:

48.4 in. (1230 mm)

Weights

Dry Weight:

640 lbs. (290 kg)

Gross Vehicle Weight Rating Gvwr:

1000 lbs. (454 kg)

Fuel Capacity:

4.0 US gallons (15.1 L)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle safety ratings differ significantly from automotive; focus is on design integrity and rider protection measures).

Active Features

Braking System Features:

Dual-piston calipers, hydraulic disc brakes front and rear, engineered for effective stopping power.

Passive Features

Frame Construction:

Steel frame designed for stability and rider feedback.

💡 Technology Features

Infotainment

Audio System:

Factory or aftermarket audio systems may be present; manual covers basic wiring and integration.

Driver Assistance

Cruise Control:

Some models may have had factory or dealer-installed cruise control; wiring and operation may be covered.

Connectivity

Diagnostic Ports:

Covers diagnostic procedures, potentially including connections to Harley-Davidson's diagnostic tools (e.g., Digital Technician).

🔧 Maintenance

Service Intervals

First Service Mileage:

1,000 miles (1,600 km) or 6 months, whichever comes first.

Subsequent Service Mileage:

Every 5,000 miles (8,000 km) or 12 months thereafter.

Oil Change Interval:

Every 2,500 miles (4,000 km) or 6 months (recommended by many owners, consult manual for specifics).

Fluid Specifications

Engine Oil Type:

Harley-Davidson Syn-3 (20W-50) or equivalent motorcycle specific premium synthetic oil.

Engine Oil Capacity:

3.0 US quarts (2.8 L) with filter change.

Primary Chain Case Fluid Type:

Harley-Davidson recommended Syn-3 or equivalent primary lubricant (e.g., SAE 50 or SAE 20W-50 motorcycle specific).

Primary Chain Case Fluid Capacity:

2.8 US quarts (2.6 L).

Transmission Oil Type:

Harley-Davidson recommended Syn-3 or equivalent primary lubricant (e.g., SAE 50 or SAE 20W-50 motorcycle specific).

Transmission Oil Capacity:

2.8 US quarts (2.6 L).

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Clutch plates, drive belt, wheel bearings, fork seals, and brake pads are common wear items requiring periodic inspection and replacement.

Engine Specific Concerns:

While generally robust, early Twin Cam 88 engines could experience issues with cam chain tensioners and oil pressure (refer to manual for specific diagnostic procedures).

Electrical System Considerations:

Wiring harness integrity and voltage regulator function are critical checks for proper electrical system operation.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

United States

Brand Legacy:

Harley-Davidson is an iconic American motorcycle manufacturer with a legacy dating back to 1903, synonymous with freedom and the open road.

Model Evolution

Softail Platform:

The Softail platform, introduced in the early 1980s, mimicked the look of a hardtail frame with hidden rear suspension for comfort.

Fat Boy Introduction:

The Fat Boy model was introduced in 1990, quickly becoming a cultural icon, popularized by its distinctive styling and presence in the film 'Terminator 2: Judgment Day'.

Production

Production Period For This Generation:

The FLSTF Fat Boy, powered by the Twin Cam 88 engine, was produced for several years, with the 2002 model being a significant iteration.

🏆 Awards & Recognition

Recognitions

Cultural Impact:

The Fat Boy has achieved significant cultural recognition, often associated with a lifestyle and iconic status in popular culture.

Ratings

Owner Satisfaction:

Generally high owner satisfaction due to its iconic styling, V-twin rumble, and comfortable ride characteristics.