Segment:
Cruiser Motorcycle
Target Audience:
Owners and technicians seeking detailed repair and maintenance information for the 2002 Harley-Davidson FLSTC Heritage Softail Classic.
Comparable Models:
Competes with other classic-style cruisers from manufacturers like Indian and custom motorcycle builders.
Model Appeal:
Retains classic styling with modern Harley-Davidson engineering, offering a comfortable and iconic riding experience.
Engine:
Full coverage including engine disassembly, assembly, tuning, and troubleshooting.
Transmission:
Complete coverage of the transmission and primary drive systems.
Electrical:
Detailed electrical schematics, wiring diagrams, and component testing.
Chassis And Suspension:
In-depth information on frame, forks, shocks, and steering.
Brakes:
Front and rear brake system servicing, including hydraulic components.
Fuel System:
Carburetor (Keihin CV) service, fuel lines, and fuel tank maintenance.
Bodywork And Trim:
Details on fender, tank, saddlebag, and windshield removal/installation.
Estimated Page Count:
Approximately 500-600 pages (typical for this model's comprehensive service manual).
Type:
Service Repair Manual
Engine Management:
Ignition system, carburation tuning, compression testing, and valve adjustment.
Drivetrain:
Clutch operation, primary drive chain adjustment, transmission gear inspection, and final drive belt maintenance.
Suspension And Steering:
Front fork seal replacement, rear shock absorber service, steering head bearing adjustment.
Wheel And Tire:
Wheel bearing replacement, tire mounting, spoke tensioning (if applicable to specific wheels), and balancing.
Lighting And Accessories:
Headlight, taillight, turn signals, horn, and accessory circuit troubleshooting.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, and brake fluid flushing.
Troubleshooting:
Step-by-step diagnostic guides for common starting, running, and electrical issues.
Component Overhaul:
Detailed procedures for rebuilding the engine (carburetor, ignition), transmission, and brake calipers.
Assembly And Disassembly:
Comprehensive instructions for removing and reinstalling major components and sub-assemblies.
Depth:
Comprehensive, covering everything from basic scheduled maintenance to complete engine and transmission rebuilds.
Engine Type:
Air-cooled, Twin Cam 88 V-Twin
Displacement:
1449 cc (88 cubic inches)
Bore X Stroke:
3.75 in x 4.00 in (95.25 mm x 101.6 mm)
Horsepower Est:
Approximately 65-70 HP (at crankshaft, dependent on tuning)
Torque Est:
Approximately 85-90 ft-lbs (at crankshaft, dependent on tuning)
Fuel Delivery:
Keihin CV (Constant Velocity) 40mm Carburetor
Fuel Type:
Unleaded Gasoline, 91 octane (RM) or higher recommended.
Ignition Type:
Electronic Ignition (Distributorless)
Transmission Type:
5-speed Manual Constant Mesh
Optional Transmission:
N/A for this model.
Primary Drive:
Plated Carbon Fiber Belt, 34-tooth front, 65-tooth rear
Final Drive:
Carbon Belt Drive, 32-tooth front, 66-tooth rear, 2.06:1 ratio.
Transmission Oil:
Harley-Davidson Formula+ (or equivalent SAE 50 engine oil if specified by manual for primary/transmission).
Transmission Oil Capacity:
2.7 U.S. quarts (2.5 Liters) for transmission, 1.0 U.S. quart (0.9 Liters) for primary.
Length:
94.9 inches (2410 mm)
Width:
37.0 inches (940 mm) (approx. at handlebars)
Height:
55.1 inches (1400 mm) (approx. at windshield)
Wheelbase:
63.2 inches (1605 mm)
Ground Clearance:
5.1 inches (130 mm)
Dry Weight:
670 lbs (304 kg)
Wet Weight:
Approximately 700 lbs (318 kg) (with fluids)
Saddlebag Capacity:
Integrated leather-covered saddlebags (capacity not typically quantified in liters, but substantial for touring).
Safety Standards:
Compliant with DOT and EPA regulations for its model year.
Braking System:
Dual-action, front hydraulic disc brake with 4-piston caliper; rear hydraulic disc brake with 2-piston caliper.
Suspension:
Front: Telescopic fork with 4.0 inch travel. Rear: Swingarm with dual shocks, adjustable preload, 3.1 inch travel.
Lighting:
Halogen headlight, taillight, brake light, and amber turn signals.
Chassis Design:
Steel, rigid-mounted, cradle frame for stability.
Initial Service:
First service typically recommended at 1,000 miles (1600 km) or 1 month.
Regular Oil Change:
Every 5,000 miles (8,000 km) or 6 months for engine oil and filter change.
Primary Chain Tension:
Inspect and adjust primary chain tension every 10,000 miles (16,000 km).
Brake Fluid Flush:
Recommended every 2 years, regardless of mileage.
Engine Oil:
Harley-Davidson 20W-50 Synthetic Motorcycle Oil (or equivalent meeting H-D specifications).
Engine Oil Capacity:
3.5 U.S. quarts (3.3 Liters) with filter change.
Brake Fluid:
DOT 4 Hydraulic Brake Fluid.
Cam Chain Tensioners:
Early Twin Cam engines (pre-2007) had plastic cam chain tensioners that could wear prematurely. Upgrade to hydraulic tensioners is a common modification.
Carburetor Tuning:
The Keihin CV carburetor may require periodic adjustment for optimal performance and emissions, especially with aftermarket exhaust or intake modifications.
Primary Drive Belt:
Regular inspection for wear and proper tension is crucial to prevent premature failure.
Oil Filter Hdp:
Harley-Davidson Part Number: 63731-37B (Note: Part numbers can be superseded, always verify with current H-D catalog).
Air Filter Hdp:
Harley-Davidson Part Number: 29461-99 (or equivalent for Twin Cam 88).
Brand Foundation:
Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer renowned for its V-twin engines and cruiser motorcycles.
Softail Lineage:
The Softail platform, introduced in 1984, features hidden rear suspension for a hardtail look. The Heritage Softail Classic (FLSTC) is a popular variant styled after classic touring bikes with added chrome and leather.
Manufacturing Location:
United States
Production Period:
The Twin Cam 88 engine was introduced in 1999, with the FLSTC model being a consistent offering within the Softail family.
Segment Recognition:
The Heritage Softail Classic is consistently recognized as a benchmark in the classic cruiser segment for its styling and comfort.
Reliability Perception:
Generally considered reliable with proper maintenance, although specific Twin Cam engine components require attention as noted in maintenance.
Emissions Compliance:
Meets EPA emissions standards for the 2002 model year.
