Category:
Cruiser Motorcycle
Target Audience:
Harley-Davidson owners, mechanics, restoration specialists.
Segment:
Custom cruiser segment, competing with models from Indian Motorcycle, custom builders.
Design Philosophy:
Classic cruiser styling with a modern interpretation, extended wheelbase, low seat height, polished chrome accents.
Engine Type:
V-twin engine, air-cooled.
Transmission Type:
5-speed constant mesh.
Primary Coverage:
Complete repair and overhaul of the Harley-Davidson FXSTDI Deuce Softail 2002 model.
Diagnostic Coverage:
Troubleshooting, fault diagnosis, and repair procedures for all major systems.
Maintenance Coverage:
Scheduled maintenance, routine service, and preventative maintenance procedures.
Estimated Page Count:
300-400 pages (typical for this type of manual)
Type:
Service Manual / Workshop Repair Manual
Format:
PDF (Portable Document Format)
Engine:
Complete engine overhaul, assembly, disassembly, performance tuning, fuel injection system, ignition system, exhaust system, cooling system (if applicable).
Transmission:
5-speed Cruise Drive transmission service, overhaul, clutch, shifting mechanisms, lubrication.
Frame And Suspension:
Softail frame inspection, front fork (gaiter-style) service, rear shock absorber replacement, swingarm service, wheel bearing replacement.
Brakes:
Front and rear brake system service, hydraulic system bleeding, pad and rotor replacement, caliper overhaul.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starting system, lighting system, ignition switch, gauges, diagnostic connectors.
Fuel System:
Fuel tank, fuel pump, fuel lines, fuel injectors, Electronic Fuel Injection (EFI) system diagnostics and calibration.
Bodywork And Trim:
Fender removal and installation, fuel tank mounting, seat service, handlebar service, fairing (if applicable) and panel removal/installation.
Maintenance:
Oil changes, filter replacement, spark plug service, chain adjustment (if applicable, though Deuce is belt drive), tire pressure checks, brake fluid checks, battery charging.
Troubleshooting:
Step-by-step diagnostic guides for common and uncommon problems, symptom-based troubleshooting.
Repair:
Detailed instructions for component disassembly, repair, reassembly, and replacement.
Overhaul:
Complete engine and transmission overhaul procedures, including parts specifications and tolerances.
Wiring Diagrams:
Comprehensive electrical system wiring diagrams with component identification.
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds. Suitable for professional technicians and experienced DIY enthusiasts.
Engine Type:
Evolution (V-twin, air-cooled)
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.50 in x 4.49 in (88.9 mm x 114.3 mm)
Horsepower:
Approximately 65-70 HP (at crank, estimated)
Torque:
Approximately 75-80 ft-lbs (at crank, estimated)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI) - Keihin
Fuel Type:
Unleaded Gasoline, 91 Octane (minimum recommended)
Oil Capacity:
3.5 US quarts (3.3 Liters) with filter change
Oil Type:
Harley-Davidson Genuine Motor Oil SAE 20W-50
Type:
5-speed constant mesh, helical gears
Optional Transmissions:
None for this model year and variant.
Clutch Type:
Wet, multi-plate, diaphragm spring
Final Drive:
Carbon fiber belt drive (32mm width)
Transmission Fluid Type:
Harley-Davidson Formula+ Transmission and Primary Chaincase Lubricant
Transmission Fluid Capacity:
1 US quart (0.95 Liters)
Safety Standards:
Meets or exceeds federal safety standards for motorcycles.
Braking System:
Dual-piston front caliper with 292mm disc, dual-piston rear caliper with 292mm disc. Integrated front and rear brake actuation.
Lighting:
Halogen headlight, LED tail light, front and rear turn signals.
Indicators:
Hazard warning lights, neutral indicator, oil pressure indicator, engine diagnostic indicator.
Infotainment System:
Basic system typically includes an analog speedometer, tachometer, fuel gauge, and indicator lights. No integrated infotainment as understood in modern vehicles.
Driver Assistance Features:
None typically found on this model; rider focus is on mechanical control.
Connectivity Features:
None.
Efi System:
Electronic Sequential Port Fuel Injection (ESPFI) provides precise fuel delivery and ignition timing, enhancing performance and emissions.
Diagnostic Interface:
OBD-II compliant diagnostic connector for electronic troubleshooting.
Initial Service:
1000 miles (1600 km) or 6 months (whichever comes first)
Subsequent Service:
Every 5000 miles (8000 km) or 12 months (whichever comes first)
Primary Chain Tension:
Check at 2500 mile intervals (or as per manual recommendation).
Engine Oil:
Harley-Davidson Genuine Motor Oil SAE 20W-50
Transmission Fluid:
Harley-Davidson Formula+ Transmission and Primary Chaincase Lubricant
Brake Fluid:
DOT 4 Hydraulic Fluid (refer to specific Harley-Davidson specification)
Typical Wear Items:
Clutch wear, belt drive wear, fork seals, wheel bearings, brake pads.
Potential Efi Issues:
Can include idle control issues or sensor failures; detailed diagnostics in the manual are crucial.
Belt Drive Maintenance:
Proper tensioning and alignment are critical for belt longevity and performance.
Brand Legacy:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and cruiser styling.
Deuce Introduction:
The FXSTDI Deuce was introduced to offer a more modern take on the classic Softail platform, featuring distinctive styling cues like the telescopic fork gaiters and longer wheelbase.
Softail Platform:
The Softail chassis, designed to visually mimic a hardtail frame while incorporating rear suspension, debuted in 1983.
Production Years:
The FXSTDI Deuce was produced from 2000 to 2007. This manual covers the 2002 model year.
Historical Acclaim:
Harley-Davidson motorcycles, in general, have received numerous awards for design, engineering, and cultural impact over decades.
Consumer Satisfaction:
Harley-Davidson owners typically report high levels of satisfaction with their motorcycles, often due to brand loyalty and lifestyle association.
Emissions Compliance:
Meets applicable EPA emissions standards for the model year.
