Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson owners, independent repair shops, motorcycle enthusiasts
Competitors:
Other cruiser manufacturers of the era (e.g., Indian, some Japanese brands with V-twin offerings), custom motorcycle builders
Unique Selling Proposition:
Iconic Springer front fork design, classic Harley-Davidson styling, Softail frame for a rigid look with suspension comfort
Manual Benefit:
Empowers owners and technicians with the necessary information for comprehensive maintenance and repair, reducing reliance on dealerships and saving costs.
Powertrain:
Engine overhaul, transmission repair, clutch service, final drive maintenance
Chassis:
Frame, suspension (including Springer front fork), wheels, tires, brakes, steering
Electrical:
Ignition system, lighting, charging system, starting system, instrumentation, wiring diagrams
Fuel System:
Carburetor (Keihin CV) service and adjustment, fuel pump, fuel lines, fuel tank
Exhaust System:
Exhaust components, muffler service, heat shields
Bodywork And Trim:
Fenders, fuel tank, seat, handlebars, controls, lighting fixtures, decorative elements
Routine Maintenance:
Oil changes, filter replacements, spark plug service, chain adjustment (if applicable), lubrication points
Diagnostic Troubleshooting:
Step-by-step troubleshooting guides for common and uncommon issues, fault code interpretation (where applicable)
Major Repairs:
Engine rebuilds, transmission disassembly and reassembly, suspension overhauls, electrical system repairs
Component Replacement:
Detailed instructions for replacing components like brake pads, clutch plates, bearings, seals, cables, and electrical switches
Special Tools:
Identification and usage of specialized tools required for specific procedures
Diagnostic Level:
Advanced, including electrical diagnostics and component testing
Repair Scope:
Comprehensive, from minor adjustments to complete engine and drivetrain rebuilds
Specification Detail:
Torque specifications, clearances, fluid capacities, electrical resistance values, and timing specifications
Searchable:
Likely searchable text content (depending on PDF creation)
Image Resolution:
High-resolution images and diagrams (typical for reputable service manuals)
Binding Description:
N/A (Digital PDF format)
Paper Quality Recommendation:
Recommended to print on durable paper for workshop use
Engine Type:
Air-cooled, Evolution (Evo) V-twin pushrod engine
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.496 in. x 3.812 in. (88.8 mm x 96.8 mm)
Compression Ratio:
8.8:1 (typical for this era)
Valve Train:
Overhead valves (OHV), 2 valves per cylinder, pushrod actuated
Engine Oil Capacity:
Approximately 3.0 US quarts (2.8 Liters) with filter change
Recommended Oil Type:
Harley-Davidson 20W-50 motorcycle oil (or equivalent API CI-4/SJ rated oil)
Horsepower:
Estimated 65-70 HP (at crankshaft, varies slightly by year and tuning)
Torque:
Estimated 85-90 lb-ft @ 3500 RPM (at crankshaft, varies slightly)
Fuel Delivery:
Carbureted (Keihin 40mm constant velocity carburetor)
Fuel Type:
Unleaded gasoline, 87 octane (or higher)
Transmission Type:
5-speed constant mesh
Clutch Type:
Wet, multi-plate
Primary Drive:
Duplex chain
Gear Ratios:
Typically: 1st-3.15:1, 2nd-2.07:1, 3rd-1.45:1, 4th-1.17:1, 5th-0.92:1 (verify specific model year ratios)
Transmission Fluid Type:
Harley-Davidson primary fluid or equivalent (e.g., Syn3)
Transmission Fluid Capacity:
Approximately 1 US quart (0.95 Liters)
Length:
Approximately 93.3 in. (2370 mm)
Width:
Approximately 35.5 in. (901 mm)
Height:
Approximately 46.5 in. (1181 mm)
Wheelbase:
Approximately 65.0 in. (1651 mm)
Ground Clearance:
Approximately 4.5 in. (114 mm)
Dry Weight:
Approximately 660 lbs (300 kg)
Gross Vehicle Weight Rating:
Typically around 1000 lbs (454 kg)
Fuel Capacity:
4.2 US gallons (15.9 Liters)
Crash Safety Ratings:
N/A (Motorcycles are not rated by standard automotive crash test agencies like NHTSA or IIHS)
Braking System:
Hydraulic disc brakes front and rear. Typically dual piston calipers.
Tire Specifications Front:
MT90B16 or similar radial
Tire Specifications Rear:
130/90B16 or similar radial
Lighting:
Halogen headlight, LED tail/brake light, turn signals, running lights
Frame Construction:
Steel, double cradle, Softail design with hidden rear shock absorbers
Infotainment System:
Basic by modern standards. Typically consists of analog gauges (speedometer, tachometer, fuel level, oil pressure, voltmeter), indicator lights, and potentially an odometer/trip meter.
Driver Assistance Features:
None (N/A for this era and model type)
Connectivity Features:
None (N/A for this era and model type)
Taillight Type:
Incandescent or LED (depending on factory fitted or aftermarket upgrades)
First Service:
Typically at 1,000 miles (1,600 km) for initial break-in service (check engine oil, primary fluid, transmission fluid, adjust chain/belt, check all fasteners).
Regular Oil Change:
Every 2,500-5,000 miles (4,000-8,000 km) or annually, whichever comes first, depending on oil type and usage.
Spark Plug Replacement:
Typically every 10,000-15,000 miles (16,000-24,000 km).
Belt Tension Check:
Check belt tension every 2,500 miles (4,000 km) and adjust as needed.
Engine Oil Specification:
Harley-Davidson 20W-50 Motorcycle Oil, API CI-4/SJ or SAE 20W-50 Synthetic
Primary Chain Case Fluid:
Harley-Davidson Primary Chaincase Lubricant (Formula+), or Syn3
Transmission Fluid:
Harley-Davidson Transmission Fluid (Syn3 compatible) or SAE 75W-90 Synthetic Gear Lubricant
Fork Oil:
Refer to manual for specific weight (often 10W or 15W)
Cam Chain Tensioners:
Early Twin Cam engines (which the 1450cc Evo falls under the family umbrella for, though this is a Evolution, not Twin Cam) can experience wear on the cam chain tensioners. The manual would detail inspection and replacement procedures.
Carburetor Tuning:
Keihin CV carburetor may require periodic adjustment or cleaning for optimal performance and idle quality.
Harley Davidson Specific Issues:
Potential for oil leaks at seals and gaskets over time; primary compensator nut loosening. Manual covers inspection and torque specs.
Brand Origin:
Founded in Milwaukee, Wisconsin, USA, in 1903. A legendary manufacturer of motorcycles.
Softail Lineage:
The Softail chassis, introduced in 1984, mimics the appearance of a hardtail frame with concealed rear suspension for a classic look.
Springer Design:
The Springer front fork is a revival of an early motorcycle suspension design, characterized by its distinctive coil springs and exposed linkages.
Fxstsi Introduction:
The FXSTSI was a specific variant of the Softail model, often featuring custom paint and styling, and notably the Springer front end, produced within the specified model years.
Production Period:
This specific FXSTSI designation was prominent in the early 2000s.
Manufacturing Location:
Primarily manufactured in York, Pennsylvania, USA, and Milwaukee, Wisconsin, USA.
