Positioning:
Essential reference tool for Harley-Davidson Softail owners and independent mechanics seeking to maintain and repair their 2002 FLST/FXST models.
Comparison:
Provides factory-level detail often surpassing aftermarket manuals in accuracy and scope for this specific model year.
Features:
Original Harley-Davidson documentation, detailed diagrams, step-by-step procedures, troubleshooting guides, torque specifications.
Powertrain:
Engine, Transmission, Drivetrain
Chassis:
Frame, Suspension (Front & Rear), Wheels, Tires, Brakes
Electrical:
Ignition System, Lighting, Charging System, Starting System, Gauges, Wiring Diagrams
Fuel System:
Carburetion, Fuel Lines, Fuel Tank, Fuel Pump (if applicable)
Exhaust System:
Exhaust Pipes, Mufflers
Controls:
Throttle, Clutch, Brake Levers, Shift Lever, Pedals
Bodywork And Trim:
Fenders, Tanks, Seat, Handlebars, Fairings (if applicable)
Scheduled Maintenance:
Oil changes, filter replacements, lubrication, tune-ups, inspections
Disassembly And Assembly:
Engine components, transmission, forks, shocks, wheels, brakes
Troubleshooting:
Diagnostic charts for common problems and solutions
Repair:
Detailed repair procedures for all covered systems
Adjustments:
Carburetor, clutch, brakes, suspension
Electrical Diagnostics:
Wiring diagram interpretation, fault finding
Depth:
Comprehensive; covers everything from basic maintenance to complete engine and transmission rebuilds.
Diagnostics:
Includes diagnostic procedures and troubleshooting guides for identifying and resolving mechanical and electrical issues.
Rebuilds:
Detailed instructions for overhauling major components like the engine, transmission, and braking system.
Searchability:
Searchable text content for quick information retrieval.
Printability:
Printable pages for at-a-glance reference.
Resolution:
High-resolution for clear display of text and diagrams.
Illustrations:
Illustrated with clear, step-by-step diagrams and photographs.
Type:
N/A (Digital Download)
Type:
N/A (Digital Download)
Engine Family:
Harley-Davidson Evolution (Evo)
Engine Type:
Air-Cooled, 45-Degree V-Twin
Displacement:
1449cc (88 cubic inches)
Bore X Stroke:
3.50 in. x 4.47 in. (88.9 mm x 113.5 mm)
Compression Ratio:
8.8:1 (Typical)
Valve Train:
Overhead Valve (OHV), Pushrod Actuated
Carburetor:
Keihin CV 40mm (Constant Velocity)
Ignition System:
Electronic Ignition (CDI)
Horsepower:
Approx. 60-65 HP (Varies with exhaust and tuning)
Torque:
Approx. 70-75 ft-lbs @ 3500 RPM (Varies with exhaust and tuning)
Fuel Type:
Premium Unleaded Gasoline (91 Octane or higher recommended)
Fuel Tank Capacity:
4.0 US Gallons (15.1 Liters)
Type:
5-Speed Manual Constant Mesh
Primary Drive:
Duplex Chain
Final Drive:
Belt Drive (80-tooth rear pulley, 32-tooth front pulley)
Gear Ratios:
Provided in manual (specific ratios vary by model variant within Softail).
Transmission Fluid:
Harley-Davidson Formula+ Transmission Fluid (or equivalent 60W-90 gear oil).
Length:
Approx. 94.9 in. (2410 mm)
Width:
Approx. 34.8 in. (885 mm)
Height:
Approx. 47.3 in. (1200 mm)
Wheelbase:
Approx. 64.5 in. (1638 mm)
Dry Weight:
Approx. 640 lbs (290 kg)
Gross Vehicle Weight Rating:
Not explicitly stated, but typically around 1000 lbs (454 kg) for safe operation.
Weight Capacity:
Typically around 360 lbs (163 kg) for rider and passenger.
Crash Test Ratings:
N/A (Motorcycle safety is not rated by typical automotive crash test organizations).
Braking System:
Hydraulic Disc Brakes (Front and Rear)
Tire Design:
Bias-ply or radial construction, specific sizes noted in manual.
Lighting:
Headlight, Tail Light, Brake Light, Turn Signals
Infotainment System:
N/A (Base models are typically devoid of advanced infotainment systems; aftermarket options are available).
Driver Assistance Features:
N/A (No electronic driver aids like ABS or traction control were standard on these models).
Connectivity Features:
N/A (No Bluetooth or mobile connectivity is integrated into the factory system).
Oil Change Interval:
Every 2,500-5,000 miles (4,000-8,000 km) or annually, whichever comes first (refer to manual for precise intervals based on usage).
Primary Chain Tensioner:
Inspect and adjust/replace as needed, typically every 10,000-15,000 miles (16,000-24,000 km).
Spark Plugs:
Replace every 10,000-15,000 miles (16,000-24,000 km).
Brake Fluid:
Flush and replace every 2 years.
Engine Oil:
Harley-Davidson 20W-50 Synthetic Motorcycle Oil (or equivalent API CI-4 rated)
Engine Oil Capacity:
Approx. 3.0 US Quarts (2.8 Liters) with filter change.
Transmission Fluid:
Harley-Davidson Formula+ Transmission Fluid (or equivalent SAE 60W-90 Gear Oil)
Transmission Fluid Capacity:
Approx. 1 US Quart (0.95 Liters).
Primary Chain Case Fluid:
Harley-Davidson Primary Chain Lubricant (or SAE 20W-50 Motorcycle Oil)
Primary Chain Case Fluid Capacity:
Approx. 1.0 US Quart (0.95 Liters).
Brake Fluid Type:
DOT 4 (for hydraulic clutch, DOT 4 is also typical, verify specific model).
Primary Chain Tensioner:
The OEM plastic primary chain tensioner shoe is known to wear out and can cause chain slap or damage. Upgrade to an improved design is common.
Carburetor:
Keihin CV carburetor can sometimes require adjustments for optimal performance, especially at altitude or after modifications.
Cam Chain Tensioners:
While not as prevalent as on Twin Cam models, early Evolution engines can benefit from inspection or upgrade of cam chain tensioners.
Wiring Harness:
Older wiring harnesses can degrade over time, leading to intermittent electrical issues. Proper inspection and repair are crucial.
Rear Shocks:
Original rear shocks may show signs of wear or leakage after extensive mileage, affecting ride quality.
Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its cruiser-style motorcycles.
Softail Lineage:
The Softail platform, introduced in 1983, is characterized by its hidden rear suspension, mimicking the appearance of a rigid (hardtail) frame.
2002 Softail:
The 2002 Softail models (FLSTF, FLSTC, FXST, FXSTC, FXSTD, etc.) featured the 1449cc (88ci) Evolution engine, a significant upgrade from earlier models.
Production Period:
The Evolution engine was produced from 1984 until its replacement by the Twin Cam 88 in 1999, however, it continued in some models like the Softail Classic until its eventual phase-out.
Manufacturing Location:
United States (Milwaukee, Wisconsin)
