Positioning:
The FLSTFI Fat Boy ST was a prominent cruiser model in Harley-Davidson's lineup, known for its iconic styling and comfortable ride, appealing to riders seeking classic American motorcycle aesthetics and performance.
Competitors:
Competed with other American V-twin cruisers from brands like Indian, and select Japanese cruiser models offering similar displacement and styling.
Styling:
Distinctive wide front fork, fat front tire, tank console, and chrome accents that define the Fat Boy's classic look.
Engine Platform:
Powered by the robust Harley-Davidson Twin Cam 88 engine, a staple of the brand for many years.
Engine:
Detailed diagnosis, repair, disassembly, assembly, and adjustment of Twin Cam 88 engine and its components (carburetion, ignition, lubrication, cooling).
Transmission:
Disassembly, assembly, maintenance, and repair of the transmission and clutch systems.
Electrical System:
Wiring diagrams, troubleshooting electrical faults, component testing, lighting, ignition system, charging system, starter, and battery.
Chassis:
Frame, suspension (front and rear forks, shocks), steering, brakes (front and rear), wheels, and tires.
Fuel System:
Carburetor (Mikuni HSR42 or similar), fuel tank, fuel lines, and fuel pump operation.
Bodywork:
Fenders, tank, seat, handlebars, controls, and related trim components.
Routine Maintenance:
Oil changes, filter replacement, spark plug service, chain adjustment, brake checks, fluid level checks, and lubrication schedules.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems across all major vehicle systems.
Repair And Rebuild:
Detailed step-by-step instructions for component disassembly, repair, and reassembly, including internal engine and transmission work.
Adjustments:
Carburetor adjustments, clutch adjustment, brake adjustments, and suspension adjustments.
Installation And Removal:
Comprehensive guides for removing and installing all major components and sub-assemblies.
Depth:
In-depth, comprehensive coverage suitable for professional mechanics and experienced DIY enthusiasts, covering everything from basic adjustments to complete engine rebuilds.
Special Tools:
References to specific Harley-Davidson special service tool numbers for specialized procedures, ensuring correct application and accuracy.
Torque Specifications:
Detailed torque values for critical fasteners across all systems, essential for safe and correct assembly.
Wear Limits:
Provides specific wear limits and allowable tolerances for engine components, brakes, and other wear items.
Completeness:
100% complete and intact, with no missing pages or sections, offering a comprehensive resource.
Illustrations:
Includes detailed illustrations, exploded diagrams, drawings, and photographs to visually guide users through service procedures.
Language Clarity:
Prepared with simple, precise explanations making it accessible to both professional mechanics and DIY users.
Quality:
High-resolution PDF, ensuring clarity of text and diagrams.
Printable:
Yes, all pages are printable for convenient workshop use.
Binding:
N/A (Digital Download - PDF)
Paper Type:
N/A (Digital Download - PDF)
Software Requirement:
Adobe Reader (or compatible PDF viewer)
Operating Systems:
Windows, Mac OS, Linux OS
Engine Type:
Air-cooled, 45-degree V-twin, Twin Cam 88
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Compression Ratio:
8.9:1 (typical)
Horsepower Approximate:
Approx. 65-70 HP (at crankshaft, model dependent)
Torque Approximate:
Approx. 70-75 ft-lbs (at rear wheel, model dependent)
Fuel Delivery:
Carburetor (e.g., Mikuni HSR42)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Ignition System:
Electronic ignition with single spark and electronic timing advance.
Length:
Approx. 93.5 inches (2375 mm)
Width:
Approx. 37.0 inches (940 mm)
Height:
Approx. 50.0 inches (1270 mm)
Dry Weight:
Approx. 687 lbs (311.6 kg)
Gross Vehicle Weight Rating:
Approx. 1050 lbs (476.3 kg)
Front Tire:
130/90-16 (wide profile)
Wheel Type:
Polished aluminum disc wheels with chrome spokes (often referred to as 'mille-flange' or similar in documentation)
First Service:
Typically around 1,000 miles (1600 km) or 1 month, covering oil change, filter change, primary chain adjustment, and general inspection.
Subsequent Services:
Regular intervals of 5,000 miles (8,000 km) or annually for oil changes, filter replacements, and other periodic checks as detailed in the manual's maintenance schedule.
Engine Oil Type:
Harley-Davidson SYN3 Synthetic Motorcycle Oil or equivalent SAE 20W-50 API SG, JASO FD rated oil.
Engine Oil Capacity:
Approx. 4 quarts (3.8 liters) with filter change.
Primary Chain Case Oil Type:
Harley-Davidson Primary Chaincase Lubricant or equivalent SAE 80W-90 API GL-4.
Primary Chain Case Oil Capacity:
Approx. 2.5 pints (1.2 liters).
Brake Fluid Type:
DOT 4 hydraulic fluid (check manual for specific recommendations).
Common Wear Items:
Clutch plates, brake pads, wheel bearings, and fork seals are typical wear items requiring regular inspection and replacement.
Electrical Connections:
Corrosion or looseness in electrical connectors can sometimes lead to intermittent faults.
Carburetor Tuning:
Carburetor tuning may require periodic adjustment to maintain optimal performance, especially with aftermarket modifications.
Heritage:
Harley-Davidson boasts a long and rich heritage dating back to 1903, synonymous with American motorcycle culture, freedom, and a distinctive V-twin engine sound.
Fat Boy Lineage:
The Fat Boy model was introduced in 1990 and quickly became an icon, influenced by custom bikes of the post-WWII era. The 2003 model represents a mature iteration of this popular cruiser, benefiting from continuous development.
Manufacturing Location:
Primarily manufactured in the United States by Harley-Davidson.
