Description
This Clymer Harley 2000 2001 2002 2003 2004 2005 FLS/FXS Twin Cam 88B 95B 103B Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2000-2005 Harley-Davidson FXSTS/FXSTSI Springer Softail, 2001-2005 Harley-Davidson FXSTD/FXSTDI Softail Duce, 2000-2005 Harley-Davidson FLSTC/FLSTCI Heritage Classic, 2000-2005 Harley-Davidson FLSTF/FLSTFI Fat Boy and 2000-2005 Harley-Davidson FLSTS/FLSTSI Heritage Springer motorcycles.
This manual contains the following topics:
QUICK REFERENCE DATA
CHAPTER ONE, GENERAL INFORMATION
Manual organization, Warnings, cautions and notes, Safety, Serial numbers, Fasteners, Shop supplies, Basic tools /Special tools, Precision measuring tools, Electrical system fundamentals, Basic service methods, Storage, Specifications
CHAPTER TWO, TROUBLESHOOTING
Operating requirements, Starting the engine, Engine performance, Starting system, Charging system, Ignition system, Engine management system diagnostic codes, Fuel system, Engine noises, Engine lubrication, Clutch, Transmission, Lighting system, Excessive vibration, Front suspension and steering, Brake problems, Specifications
CHAPTER THREE, LUBRICATION, MAINTENANCE AND TUNE-UP
Routine safety checks, Tires and wheels, Periodic lubrication, Periodic maintenance, Tune-up, Idle speed adjustment, Specifications
CHAPTER FOUR, ENGINE
Service precautions, Special tools, Servicing engine in frame, Engine, Rocker arms and pushrods, Cylinder head, Valves and valve components, Cylinder, Pistons and piston rings, Pushrods, Valve lifters, Oil pump, Oil tank and oil lines, Camshaft support plate, Crankcase and crankshaft, Counter balancer assembly, Engine break-in, Specifications
CHAPTER FIVE, CLUTCH AND PRIMARY DRIVE
Primary chaincase cover, Clutch assembly, Clutch shell, compensating sprocket and primary drive chain, Clutch shell, clutch hub and sprocket, Primary chain and guide inspection, Primary chain alignment, Compensating sprocket inspection, Primary chaincase housing, Starter jackshaft, Clutch cable replacement, Specifications
CHAPTER SIX, TRANSMISSION
Shifter assembly, External shift mechanism, Transmission top cover, Shift cam, Shift arm assembly, Shift forks, Transmission side door and transmission shaft assemblies, Transmission shafts, Main drive gear, Transmission clutch release mechanism cover, Transmission drive sprocket, Transmission case, Specifications
CHAPTER SEVEN, FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS
Air filter backplate, Carburetor, Intake manifold, Electronic fuel injection, Depressurizing the fuel system, Induction module, Throttle and idle cables, Starting enrichment valve (choke) cable replacement, Throttle and idle cables, Fuel tank console, Fuel hose and clamps, Fuel tank, Fuel tank inspection, Fuel pump and fuel filter, Fuel shutoff valve, Fuel tank gauge, Exhaust system, Evaporative emission control system, Specifications
CHAPTER EIGHT, ELECTRICAL SYSTEM
Electrical connectors, Battery, Charging system, Alternator, Voltage regulator, Ignition system, Starting system, Lighting system, Switches, Horn, Electrical panel, Turn signal module, Turn signal module and turn signal/security module, Speedometer speed sensor, Starter relay switch replacement, Speedometer and indicator lights, Fuses, Circuit breaker, Electrical connector service, Wiring diagrams, Specifications
CHAPTER NINE / WHEELS, HUBS AND TIRES
Motorcycle stands, Front wheel, Rear wheel, Front and rear hubs, Driven sprocket assembly, Drive sprocket, Drive belt, Wheel runout, Rim and laced wheel service, Disc and cast wheels, Wheel balance, Tires, Tire changing, Tire repairs, Tire runout, Specifications
CHAPTER TEN, FRONT SUSPENSION AND STEERING (TELESCOPIC FORK)
Handlebar, Front fork, Steering head and stem, Steering head bearing race replacement, Steering play adjustment, Specifications
CHAPTER ELEVEN, FRONT SUSPENSION AND STEERING (SPRINGER FORK)
Springer service precautions, Handlebar and risers, Shock absorber, Fork rockers, Springer fork, Rigid fork, Steering stem, Steering play adjustment, Specifications
CHAPTER TWELVE, REAR SUSPENSION
Spring preload adjustment, Shock absorbers, Rear swing arm, Specifications
CHAPTER THIRTEEN, BRAKES
Brake service, Front brake pad replacement, Front brake caliper, Brake reaction link, Front brake caliper, Front master cylinder, Rear brake pad replacement, Rear brake caliper, Rear master cylinder, Brake hose and line replacement, Brake disc, Bleeding the system, Rear brake pedal, Specifications
CHAPTER FOURTEEN, BODY
Seat, Front fender, Rear fender inner panel, Rear fender, Windshield, Saddlebags, Footboards and footrests, Jiffy stand
SUPPLEMENT, 2004-2005 MODEL SERVICE INFORMATION
Routine safety checks, Periodic lubrication, Periodic maintenance, Tune-up, Engine, Rocker arms and pushrods, Cylinder head, Valve and valve components (2005 models–except FXSTDSE2 and FLSTFSE models), Pistons and piston rings, Crankcase and crankshaft, Counter balancer assembly (FLSTFSE models), Clutch assembly (all 2005 models), Clutch assembly (FXSTDSE2 and FLSTFSE models), Clutch release bearing and pushrod (FXSTDSE2 and FLSTFSE models), Clutch service (FXSTDSE2 and FLSTFSE models), Clutch master cylinder (FXSTDSE2 and FLSTFSE models), Clutch release mechanism (FXSTDSE2 and FLSTFSE models), Clutch hydraulic hose replacement (FXSTDSE2 and FLSTFSE models), Clutch system flushing (FXSTDSE2 and FLSTFSE models), Clutch system bleeding (FXSTDSE2 and FLSTFSE models), Shifter assembly (FXSTDSE2 and FLSTFSE models), External shift mechanism (FXSTDSE2 and FLSTFSE models), Transmission side door and transmission shaft assemblies (FXSTDSE2 and FLSTFSE models), Air filter backplate (FXSTDSE2, FLSTFSE and FLSTFI-15th anniversary), Fuel tank console (FLSTFSE models), Fuel tank gauge, Starting system, Voltage regulator (FXSTDSE2 and FLSTFSE models), Lighting system, Switches, Speedometer and indicator lights (FLSTFSE models), Tachometer (FXSTDSE2 and FLSTFSE models), Front wheel, Rear wheel (FXSTDSE2 and FLSTFSE models), Front and rear hubs (FXSTDSE2 and FLSTFSE models), Driven sprocket assembly (FXSTDSE2 models), Handlebars and risers (FXSTDSE2 and FLSTFSE models), Front fork, Steering play adjustment, Rear swing arm removal/installation (FXSTDSE2 and FLSTFSE models, Front brake pad replacement (FLSTSC), Rear brake pad replacement (FXSTDSE2 and FLSTFSE models), Brake hose and line replacement (FXSTDSE2 and FLSTFSE models), Brake disc (FXSTDSE2 and FLSTFSE models), Seat, Front fender, Rear fender, Footboards and footrests, Front spoiler and frame side covers
INDEX
WIRING DIAGRAMS
