🏷️ Basic Information

Make:

Harley-Davidson

Model:

Softail

Variant:

FXST / FLST Fat Boy / Springer

Year:

2002

Chassis Code Fxst:

FXST

Chassis Code Flst:

FLST

👋 Introduction

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 models with cruiser styling).

Platform:

Softail chassis, known for its hidden rear suspension mimicking a hardtail look.

Styling:

Iconic Fat Boy styling with wide fenders, teardrop fuel tank, and Springer front end on specific variants, emphasizing retro aesthetics.

📋 Manual Details

Primary Coverage:

Service, Repair, Workshop

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics, Overhaul

Estimated Pages:

Approximately 600-800 pages (typical for this era and scope)

Type:

Factory Service Manual (FSM) / Workshop Manual

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Engine:

V-Twin Evolution Engine (EFI and Carbureted variants), Cylinder Heads, Pistons, Crankshaft, Camshafts, Valvetrain, Lubrication System, Cooling System (Air-Cooled), Ignition System, Fuel System (Carburetor/EFI), Exhaust System

Transmission:

5-Speed Cruise Drive Transmission (Assembly, Disassembly, Gear Ratios, Clutch, Primary Drive, Final Drive, Shift Mechanism)

Chassis And Frame:

Frame Structure, Swingarm, Front Forks (including Springer Fork mechanisms), Rear Shocks, Suspension Tuning, Steering Head Bearings

Brakes:

Front and Rear Hydraulic Disc Brakes, Caliper Overhaul, Master Cylinder, Brake Lines, Fluid Specifications

Electrical:

Battery, Charging System (Stator, Regulator/Rectifier), Starting System (Starter Motor, Solenoid), Ignition System, Lighting System (Headlight, Taillight, Turn Signals), Instrumentation, Wiring Harness Diagrams, Fuses, Relays, Sensors (Crank Position, VOES, etc.), EFI Control Module (ECM) Diagnostics

Fuel System:

Carburetor (e.g., Keihin CV) Tuning and Overhaul, Electronic Fuel Injection (EFI) System Components (Injector, Fuel Pump, Pressure Regulator, Throttle Body), Diagnostic Codes

Bodywork And Trim:

Fenders, Fuel Tank, Seat Assembly, Handlebars, Controls, Fairings (if applicable), Body Panels, Graphics

Maintenance:

Scheduled Maintenance (Oil Changes, Filter Replacements, Spark Plugs, Chain Adjustments/Drive Belt Inspection), Fluid Flushes, Lubrication Points, Tire Pressure

Repair And Rebuild:

Complete Engine Rebuilds, Transmission Overhauls, Fork Seal Replacement, Brake Pad Replacement, Electrical Component Diagnosis and Replacement, Starter/Generator Service

Troubleshooting:

Diagnostic Flowcharts for Common Issues (e.g., Starting Problems, Misfires, Electrical Faults), Symptom-Based Troubleshooting Guides

Technical Specifications:

Torque Values, Clearances, Tolerances, Measurement Procedures, Wiring Diagrams, Component Identification

Depth:

Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, including electrical system diagnostics and wiring schematics.

📊 Manual Specifications

Quality:

High-Resolution PDF, Searchable Text, Bookmarked Sections (typical for quality service manuals)

Printability:

Printable on standard home/office printers

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Air-Cooled, 45-Degree V-Twin, Pushrod Actuated Valves

Displacement Efi:

1450cc (88 cubic inches)

Displacement Carb:

1450cc (88 cubic inches)

Bore X Stroke Efi:

3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)

Bore X Stroke Carb:

3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)

Compression Ratio Efi:

8.8:1 (Typical)

Compression Ratio Carb:

8.8:1 (Typical)

Horsepower Efi:

Approx. 65-70 HP (estimated, dependent on tuning)

Torque Efi:

Approx. 75-80 ft-lbs @ 3200 RPM (estimated, dependent on tuning)

Horsepower Carb:

Approx. 65-70 HP (estimated, dependent on tuning)

Torque Carb:

Approx. 75-80 ft-lbs @ 3200 RPM (estimated, dependent on tuning)

Efi Type:

Sequential Port Fuel Injection (SpFi)

Carburetor Type:

Keihin CV (Constant Velocity) 40mm (Typical)

🔧 Transmission

Type:

5-Speed Manual Constant Mesh

Drive Type:

Belt Drive (Primary), Belt Drive (Final)

Optional Features:

N/A (Standard 5-speed for this model year)

Clutch Type:

Wet, Multi-Plate, Cable Actuated

Gear Ratios:

Specific ratios detailed in the manual (e.g., 1st: 9.19, 2nd: 6.41, 3rd: 4.77, 4th: 3.93, 5th: 3.15)

📐 Dimensions

Length:

Approx. 93.0 in. (2362 mm)

Width:

Approx. 37.0 in. (940 mm)

Height:

Approx. 47.0 in. (1194 mm)

Wheelbase:

Approx. 63.7 in. (1618 mm)

Ground Clearance:

Approx. 5.0 in. (127 mm)

Dry Weight:

Approx. 665 lbs (301.6 kg)

Gross Vehicle Weight Rating:

N/A (Motorcycle, typically specified as load capacity)

Fuel Capacity:

5.0 US gal. (18.9 L)

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycle safety is assessed differently than cars, focus is on rider protection and braking performance)

Braking System:

Dual Hydraulic Disc Brakes (Front), Single Hydraulic Disc Brake (Rear)

Lighting:

Halogen Headlight, LED Taillight, Amber Turn Signals

Frame Construction:

Steel Tube Frame

Rider Controls:

Handlebar mounted controls, footpegs, shifter, and brake pedal.

💡 Technology Features

Audio System:

Optional factory or aftermarket audio systems were available; not standard on all models.

Display:

Analog speedometer, tachometer, and indicator lights.

ABS:

Anti-lock Braking System (ABS) was generally not a standard or common option for this model year and configuration.

Connectivity Features:

N/A (No integrated Bluetooth or smartphone connectivity on factory stock models of this era).

Efi System:

Electronic Fuel Injection (EFI) was available on some models for improved emissions and throttle response compared to carburetors.

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles (8,000 km) or annually, whichever comes first (typical for this era).

Primary Chain Tensioner Inspection:

Inspect at 1,000 miles and every 10,000 miles thereafter (crucial for belt drive longevity).

Spark Plug Replacement:

Every 10,000 miles (16,000 km) or as needed.

Drive Belt Inspection:

Inspect at 1,000 miles and every 10,000 miles for wear and tension.

Engine Oil Type:

Harley-Davidson SYN3 Synthetic (20W-50) or equivalent motorcycle-specific oil meeting Harley-Davidson specifications (e.g., HD-360).

Engine Oil Capacity:

Approx. 3.0 US quarts (2.8 L) with filter change.

Primary Chain Case Oil Type:

Harley-Davidson Primary Chaincase Lubricant (Formula+ or equivalent) or SAE 50 motorcycle oil.

Primary Chaincase Oil Capacity:

Approx. 1.0 US quart (0.95 L).

Transmission Oil Type:

Harley-Davidson Transmission Lubricant (Syn3 or equivalent) or SAE 75W-90 synthetic gear oil meeting GL-5 specification.

Transmission Oil Capacity:

Approx. 24 US fl oz (0.71 L).

Brake Fluid Type:

DOT 4 Hydraulic Fluid.

Primary Chain Tensioner:

The original thermoplastic primary chain tensioner shoe can wear out, leading to excessive chain slap and potential damage. Upgraded hydraulic tensioners are a common aftermarket solution.

Cam Chain Tensioners:

Similar to the primary tensioner, the inner cam chain tensioners can wear, particularly on models with the Twin Cam engine (though 2002 Softails typically use the Evolution engine, this is a consideration for later years or related models).

Oil Leaks:

Common areas for minor oil leaks can include the rocker box gaskets, pushrod tube seals, and crankcase seals, often due to age and vibration.

Electrical Connector Corrosion:

Corrosion in electrical connectors can lead to intermittent electrical faults. Regular inspection and cleaning are recommended.

Carburetor Performance:

The Keihin CV carburetor can require periodic adjustments or rebuilds due to wear or clogging, especially if fuel quality is inconsistent.

📚 Vehicle History

Heritage:

Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903, renowned for its V-twin engines and cruiser styling.

Softail Origin:

The Softail concept, featuring a hidden rear suspension system, was introduced in 1984, offering the classic look of a hardtail with modern ride comfort.

Fat Boy Introduction:

The Fat Boy model debuted in 1990 and quickly became a cultural icon, distinguished by its wide fenders, distinctive paint schemes, and solid disc wheels.

Springer Front End:

The Springer front end, a mechanical suspension system reminiscent of early motorcycles, was offered on specific Softail models, including variants of the Fat Boy and dedicated Springer models, adding a unique visual and tactile element.

Manufacturing Location:

United States (Various Harley-Davidson assembly plants)

🏆 Awards & Recognition

Iconic Status:

The Harley-Davidson Fat Boy is recognized as a cultural icon, significantly popularized by its appearance in films like 'Terminator 2: Judgment Day'.

Reliability Perception:

Generally considered reliable with proper maintenance, though specific components like tensioners are known wear items.

Emissions Compliance:

Meets EPA emissions standards for the year of manufacture.