🏷️ Basic Information

Make:

Harley-Davidson

Model:

Fat Boy

Model Codes:

FLSTF, FLSTFI

Year Range:

2000-2006

👋 Introduction

Positioning:

The Harley-Davidson Fat Boy is an iconic cruiser, recognized for its distinctive styling and powerful V-twin engine. This manual targets owners and technicians seeking to maintain and repair these classic motorcycles.

Competition:

Competes with other large-displacement cruiser motorcycles from brands like Indian, Victory (now defunct but relevant for the era), and some Japanese manufacturers in the cruiser segment.

Features:

Heritage styling, strong V-twin performance, customizability. The EFI models represent a technological advancement over carbureted predecessors.

📋 Manual Details

Primary Coverage:

Workshop Service Repair Manual

Secondary Coverage:

Parts Catalog Manual

Estimated Page Count:

Detailed (specific page count not provided, but comprehensive for workshop and parts)

Type:

Comprehensive Service and Repair Manual with Integrated Parts Catalog

Language:

English

Format:

Likely PDF or Digital Download (typical for modern workshop manuals)

Searchability:

PDF format typically allows for text searching of keywords, greatly enhancing diagnostic and repair efficiency.

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, overhaul, tuning, lubrication system, cooling system (air-cooled specifics), cylinder heads, cylinders, pistons, connecting rods, crankshaft, camshafts, valve train.

Fuel System:

Fuel injection system (EFI - Electronic Fuel Injection) diagnostics, components, tuning, fuel pump, injectors, throttle body, fuel lines, fuel tank. Carbureted models (if applicable for certain years/sub-models not explicitly stated but often included in broader ranges).

Ignition System:

Ignition timing, spark plugs, ignition coils, ignition module, wiring.

Transmission Drivetrain:

Clutch operation and adjustment, gear shifting mechanism, transmission disassembly and assembly, final drive belt inspection and replacement, primary drive system.

Electrical System:

Battery, charging system (alternator, regulator/rectifier), starting system (starter motor), lighting (headlight, taillight, signals), instrumentation, wiring diagrams, fuses, relays, sensors.

Suspension Steering:

Front fork (telescopic) service, rear shock absorber replacement, steering head bearing adjustment and replacement, wheel bearings.

Brakes:

Front and rear brake system hydraulics, caliper service, brake pad replacement, brake fluid flush and bleeding, master cylinders, brake lines.

Frame Bodywork:

Frame inspection, body panel removal and installation, fenders, fuel tank mounting, seat, handlebars, control levers, footpegs.

Wheels Tires:

Wheel removal and installation, tire inspection and replacement, wheel balancing, spoke adjustment (if applicable).

Maintenance:

Scheduled maintenance (oil changes, filter replacements, lubrication, chain/belt adjustment), inspections, fluid checks and top-offs.

Troubleshooting:

Diagnostic procedures for common problems, fault codes (for EFI models), systematic problem identification.

Repair:

Step-by-step instructions for component repair, replacement, and overhaul for all major systems.

Overhaul:

Complete engine and transmission rebuild procedures.

Diagnostics:

Electrical system diagnostics, fuel system diagnostics, engine performance diagnostics.

Parts Identification:

Detailed diagrams and part numbers for all components, enabling accurate part ordering.

Depth:

Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and EFI system management.

Diagnostic Tools:

Covers procedures that may require Harley-Davidson's diagnostic tools (e.g., Screamin' Eagle diagnostic software, though potentially limited for older models) for EFI models.

📊 Manual Specifications

Format Details:

Digital (PDF) format typically offers searchability, bookmarking, and easy navigation. Print quality would be dependent on the source reproduction, but professional manuals aim for clarity.

Quality:

Expected to be high-quality with clear diagrams and text for workshop use.

Binding:

N/A (Digital Format)

Paper Quality:

N/A (Digital Format)

Manual Type Inclusion:

Includes both a comprehensive service/repair manual AND a parts catalog manual, offering complete coverage for identification, maintenance, repair, and parts ordering.

⚙️ Engine Specifications

Engine Type:

Four-stroke, air-cooled, 45-degree V-twin

Engine Displacement:

1449 cc (88 cubic inches)

Engine Designation:

88B (indicating specific engine configuration for the era, often referred to as Twin Cam 88B)

Bore X Stroke:

Typically 3.75 in. x 4.00 in. (95.25 mm x 101.6 mm) for Twin Cam 88

Compression Ratio:

Typically 8.8:1

Horsepower Estimate:

Approx. 65-70 HP (at crankshaft, actual figures vary slightly by model year and tuning)

Torque Estimate:

Approx. 85-90 ft-lbs @ 3000 RPM (at crankshaft)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI) for FLSTFI models. Carbureted for FLSTF models in earlier years, but the product description specifies EFI.

Fuel Type:

Unleaded Gasoline, minimum 91 octane (RON+MON)/2

Valvetrain:

Overhead valves (OHV), 2 valves per cylinder, pushrod actuated.

Cooling System:

Air-cooled, with oil cooling capabilities through the engine oil.

Carburetor Specifications:

For non-EFI models (if included in broader interpretation): Keihin CV carburetor (typically 40mm).

🔧 Transmission

Type:

5-speed constant mesh, foot-shifted

Primary Drive:

Duplex chain

Final Drive:

Belt drive

Clutch:

Wet, multi-plate, diaphragm spring

📐 Dimensions

Length:

Approx. 93.7 inches (2380 mm)

Wheelbase:

Approx. 63.5 inches (1613 mm)

Seat Height:

Approx. 26.1 inches (663 mm) unladen

Dry Weight:

Approx. 634 lbs (288 kg)

Gross Vehicle Weight Rating:

Approx. 1030 lbs (467 kg)

Fuel Capacity:

4.8 US gallons (18.2 L)

Oil Capacity:

3.0 US quarts (2.8 L)

🛡️ Safety Features

Crash Safety:

Motorcycles are not typically rated by organizations like NHTSA or IIHS in the same way as cars. Safety is primarily dependent on rider skill and adherence to traffic laws.

Braking:

Hydraulic disc brakes front and rear. ABS was optional on some models during this period.

Lighting:

Halogen headlight, LED taillight and stoplight, front and rear turn signals.

Chassis:

Steel frame and swingarm construction.

💡 Technology Features

Infotainment System:

Typically not equipped with advanced infotainment systems in this era; focus is on essential instrumentation and rider controls.

Assistance Features:

Optional Anti-lock Braking System (ABS) on some models.

Connectivity Options:

No integrated smartphone connectivity or Bluetooth as standard.

Efi Control:

Engine Control Module (ECM) manages fuel injection, ignition timing, and other engine parameters for EFI models.

🔧 Maintenance

Initial Service:

First service typically around 1,000 miles (1,600 km).

Regular Maintenance:

Oil and filter changes every 2,500-5,000 miles (4,000-8,000 km) or annually. Transmission and primary chaincase oil changes typically every 5,000-10,000 miles (8,000-16,000 km). Spark plug replacement every 10,000-20,000 miles (16,000-32,000 km). Belt inspection and tension check at regular intervals.

Engine Oil:

Harley-Davidson SYN3 (Synthetic) SAE 20W50, or equivalent API CG-4 rated motorcycle oil.

Transmission Oil:

Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant, or equivalent API GL-4 rated gear oil.

Brake Fluid:

DOT 4 Heavy Duty Hydraulic Fluid.

Primary Chaincase Oil:

Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant, or equivalent API GL-4 rated gear oil.

Fork Oil:

Typically Harley-Davidson's own fork oil or equivalent, viscosity dependent on specific fork model and rider preference. Manual will specify.

Crankshaft Runout:

Early Twin Cam engines (pre-2001) could experience issues with crankshaft runout; later models and proper maintenance mitigate this.

Cam Chain Tensioners:

Hydraulic cam chain tensioners can wear over time and may require replacement, especially on higher-mileage units.

Oil Leaks:

Common areas for potential leaks include primary and transmission shaft seals, and rocker box gaskets.

Efi Diagnostics:

EFI systems can sometimes present diagnostic challenges, requiring specialized tools or knowledge for optimal performance tuning.

📚 Vehicle History

Heritage:

Harley-Davidson boasts a rich legacy dating back to 1903, known for its iconic V-twin engines and cruiser motorcycle designs that define American motorcycle culture.

Fat Boy Introduction:

The Fat Boy model was first introduced in 1990 and quickly became a cultural icon, famously featured in the film 'Terminator 2: Judgment Day'.

Engine Transition:

The 2000-2006 era for the Fat Boy represents the transition to the Twin Cam 88 engine, a significant evolution from previous Evolution (Evo) engines, introducing fuel injection (EFI) for improved performance and emissions.

Manufacturing Location:

United States (primarily York, Pennsylvania and Milwaukee, Wisconsin for various components and assembly)

Key Innovations Era:

Introduction and refinement of the Twin Cam 88 engine, advancement in electronic fuel injection systems.

🏆 Awards & Recognition

Awards History:

While specific awards for this particular model year range are not widely documented as single events, the Fat Boy has consistently been recognized for its iconic styling and enduring appeal within the motorcycle industry and popular culture.