Model Segment:
Cruiser Motorcycle
Brand Heritage:
Iconic American motorcycle manufacturer with a long-standing legacy of V-twin engines and classic styling.
Key Competitors 2002:
Indian Chief, Victory V92C, Custom Choppers
Distinctive Styling:
Wide front tire, chrome accents, teardrop fuel tank, wide handlebars, distinctive Fat Boy badging.
Engine Type:
Harley-Davidson Twin Cam 88 (carbureted variant for FLSTFI)
Primary Demographic:
Riders seeking classic styling, a comfortable riding position, and the unmistakable Harley-Davidson experience.
Engine Systems:
Engine disassembly, assembly, inspection, lubrication, cooling, fuel, ignition, exhaust
Transmission Systems:
Clutch, gearbox, primary drive, final drive, lubrication
Chassis Systems:
Frame, front suspension, rear suspension, wheels, tires, steering
Braking Systems:
Front and rear brake components, hydraulic systems, bleeding procedures
Electrical Systems:
Wiring diagrams, battery, charging system, ignition system, lighting, indicators, instrumentation, starter
Fuel System:
Fuel tank, fuel pump, fuel lines, carburetor (Keihin CV)
Bodywork And Trim:
Fenders, tank, seat, handlebars, controls, fairings (if applicable), decorative elements
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, drive belt adjustment, chain cleaning and lubrication (if applicable to variant, though Fat Boy typically belt drive), brake pad inspection
Troubleshooting:
Diagnostic procedures for common mechanical and electrical faults
Disassembly And Assembly:
Step-by-step instructions for component removal and installation
Rebuild Procedures:
Engine, transmission, and brake caliper rebuilds
Adjustment Procedures:
Clutch adjustment, throttle cable adjustment, brake lever adjustment
Wiring Diagram Interpretation:
Detailed explanation of electrical system schematics
Depth Of Information:
Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts
Diagnostic Capabilities:
Detailed fault finding charts and diagnostic flowcharts
Special Tool Requirements:
Identification of specific Harley-Davidson tools and their usage
Engine Family:
Twin Cam 88
Engine Displacement:
1450 cc (88 cubic inches)
Engine Configuration:
45-degree V-twin, air-cooled
Bore X Stroke:
3.75 in x 4.00 in (95.25 mm x 101.6 mm)
Horsepower:
Approx. 65-70 HP (est.)
Torque:
Approx. 75-80 ft-lbs @ 3500 RPM (est.)
Fuel Delivery:
Carburetor (Keihin CV 40mm)
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended
Ignition Type:
Electronic, single fire ignition
Exhaust Configuration:
Dual exhaust
Oil Type:
Harley-Davidson Syn3 or equivalent SAE 20W50 motorcycle oil
Oil Capacity:
3.5 US quarts (3.3 liters) with filter change
Crash Test Ratings:
Not Applicable (Motorcycle)
Braking System:
Dual disc front brakes, single disc rear brake with hydraulic actuation.
Lighting:
Halogen headlight, LED tail light, dual filament front and rear turn signals.
Frame Construction:
Steel frame and swingarm, designed for stability.
Suspension Design:
Telescopic front forks with gaiters, rear dual shock absorbers for compliant ride.
Audio System:
Optional factory or aftermarket audio systems available, not standard on all models.
Instrumentation:
Analog speedometer, tachometer (optional), fuel gauge, oil pressure indicator, voltage meter, odometer, trip meter, gear indicator.
ABS:
Not available as standard on the 2002 FLSTFI Fat Boy.
Cruise Control:
Not available as standard on the 2002 FLSTFI Fat Boy.
First Service:
1000 miles (1600 km) or 12 months
Subsequent Services:
Every 5000 miles (8000 km) or 12 months thereafter
Oil Change Interval:
Every 2500 miles (4000 km) or 6 months, whichever comes first
Engine Oil Specification:
SAE 20W50 Motorcycle Oil (Harley-Davidson Syn3 recommended)
Primary Chaincase Lubricant:
SAE 80W-90 Motorcycle Gear Lubricant
Brake Fluid:
DOT 4 (or specified by Harley-Davidson for that year)
Fork Oil:
Refer to manual for specific type and quantity
Potential Wear Items:
Clutch plates, brake pads, wheel bearings, drive belt, suspension bushings.
Common Faults:
Carburetor tuning issues (especially with aftermarket parts), starter solenoid failure, charging system issues (stator/regulator), leaks from primary or transmission seals.
Drive Belt Inspection:
Regular inspection for wear and proper tension is crucial.
Ignition System Check:
Regular checks of spark plugs, ignition coils, and wiring.
Brake System Maintenance:
Regular inspection of pads, rotors, fluid level, and periodic fluid flush.
Brand Philosophy:
American Made, custom culture, V-twin power.
Fat Boy Introduction:
Introduced in 1990 as a modern take on classic styling.
Twin Cam Introduction:
The Twin Cam 88 engine was introduced in 1999, representing a significant powertrain update for Harley-Davidson.
Flstfi Specifics:
The 'FI' designation in FLSTFI typically indicates Fuel Injection, however, the 2002 model year for the Fat Boy with the Twin Cam 88 was primarily carbureted. This manual covers the carbureted version.
Manufacturing Location:
United States
Key Milestones 2002:
Continued refinement of the Twin Cam 88 platform, maintaining its iconic Fat Boy aesthetics.
