Market Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson FLSTFI Fat Boy owners, independent repair shops, and DIY mechanics
Brand Strength:
Harley-Davidson is renowned for its iconic styling, V-twin engine performance, and strong brand loyalty.
Fat Boy Distinctiveness:
The Fat Boy is characterized by its wide front tire, solid disc wheels, and distinctive tank and fender styling, a tribute to the cast aluminum wheels and aerodynamic designs of the 1940s.
Manual Utility:
Provides essential technical information for maintaining the heritage and performance of this classic Harley-Davidson model.
Primary Coverage:
Repair, Maintenance, Troubleshooting, Servicing
Secondary Coverage:
Component Identification, Diagnostics, Wiring Diagrams
Manual Type:
Workshop Service Repair Manual
Format:
PDF (Digital Download)
Engine:
Detailed disassembly, assembly, troubleshooting, and specifications for the Twin Cam 88 engine (specific variant for FLSTFI)
Transmission:
Service, repair, and adjustment procedures for the 5-speed transmission
Fuel System:
Carburetor (likely Keihin CV 40mm) tuning, maintenance, and troubleshooting; fuel pump and filter service
Electrical System:
Comprehensive wiring diagrams, component testing, troubleshooting of ignition, lighting, charging system, and starter
Brakes:
Service, bleeding, caliper, and master cylinder repair; hydraulic system diagnostics
Suspension:
Front fork (likely Showa 41mm) overhaul, fluid changes, and adjustments; rear shock absorber service and replacement
Chassis And Frame:
Frame inspection, steering head bearing service, and general chassis component maintenance
Bodywork And Trim:
Fender, tank, and fairing (if applicable) removal, installation, and repair; chrome and paint care
Wheels And Tires:
Wheel bearing service, tire replacement, and balancing
Routine Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, lubrication points
Troubleshooting Guides:
Step-by-step diagnostic procedures for common issues across all major systems
Engine Rebuilds:
Complete instructions for engine disassembly, component inspection, measurement, and reassembly
Transmission Overhaul:
Detailed steps for transmission disassembly, gear inspection, and reassembly
Brake System Repair:
Hydraulic system bleeding, pad replacement, caliper rebuilds
Electrical Diagnostics:
Schematic interpretation, voltage/resistance testing, fault isolation
Fork Seal Replacement:
Detailed instructions for front fork seal and oil replacement
Carburetor Adjustment:
Idle speed, air/fuel mixture, and jetting recommendations
Depth Level:
Comprehensive: Covers basic maintenance to full engine and transmission rebuilds
Diagnostic Capabilities:
Advanced diagnostic procedures and symptom-based troubleshooting
Special Tool Requirements:
Lists necessary special tools for specific repair procedures
Engine Type:
Air-cooled, Twin Cam 88 V-twin (likely the 1450cc Evolution variant for this year/model)
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.75 in x 4.00 in (95.3 mm x 101.6 mm)
Compression Ratio:
Typically around 8.8:1 for this engine family
Horsepower:
Approx. 65-70 HP (specific to stock tune)
Torque:
Approx. 80-85 ft-lbs (specific to stock tune)
Fuel Delivery:
Carburetor (Keihin CV 40mm)
Fuel Type:
Unleaded gasoline, 91+ octane recommended
Ignition Type:
Electronic, breakerless
Initial Service:
Typically around 1,000 miles (1600 km)
Subsequent Service:
Every 5,000 miles (8,000 km) or annually, whichever comes first (includes oil/filter, inspection, adjustments)
Engine Oil Type:
Harley-Davidson SYN3 (synthetic) or Harley-Davidson 20W50 motorcycle oil
Engine Oil Capacity:
Approx. 4 US quarts (3.8 L) with filter change
Primary Chain Case Oil Type:
Harley-Davidson Formula+ (or equivalent SAE 50/60 motorcycle gear oil)
Primary Chain Case Oil Capacity:
Approx. 1 US quart (0.95 L)
Brake Fluid Type:
DOT 4 (for hydraulic systems)
Fork Oil Type:
Harley-Davidson Type E (or equivalent 10W fork oil)
Carburetor Tuning:
CV carburetor can sometimes require fine-tuning for optimal performance, especially with aftermarket exhaust or air filters.
Cam Chain Tensioner:
The automatic cam chain tensioner design in earlier Twin Cam engines can wear over time, potentially leading to noise or failure. Manual replacement with a hydraulic tensioner conversion is a common upgrade.
Regulator Rectifier:
Early Twin Cam models are known to have issues with the regulator rectifier component, leading to charging system problems. The manual will likely detail testing procedures.
Clutch Adjustment:
Clutch may require periodic adjustment as components wear.
Harley Davidson Legacy:
Founded in 1903, Harley-Davidson is America's oldest motorcycle manufacturer, known for its V-twin engines and cruiser culture.
Fat Boy Introduction:
The Fat Boy model was introduced in 1990 and quickly became an icon for its unique styling inspired by post-war automotive design. The FLSTFI designation typically signifies fuel injection, though the 2000 model still uses a carburetor. The manual likely covers the transition period or specific carburetor model.
Manufacturing Location:
United States (Milwaukee, Wisconsin, and York, Pennsylvania facilities)
