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Harley FLSTF Fat Boy ST 2004 Service Repair Manual

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$141.00
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🏷️ Basic Information Identification Make: Harley-Davidson Model: FLSTF Fat Boy Year: 2004 Trim: ST Codes Engine Family Code: Evolution (commonly referred to as 'Evo' or 'Big Twin Evo') 👋 Introduction Market Position Target Audience: Do-it-yourself (DIY) owners and experienced mechanics seeking detailed repair information Competitive Analysis Advantage: Cost-effective alternative to printed manuals and dealership services, offering convenience and accessibility Key Features Key Selling Point: Complete official full factory service repair manual in PDF format with extensive coverage and hundreds of photos/illustrations Convenience: Printable pages, access on multiple devices, no expiry dates 📋 Manual Details Coverage Areas Coverage Scope: Complete factory service and repair Styles Covered: All styles covered (implying variations within the FLSTF Fat Boy ST designation for that year). Page Count Estimated Page Count: Hundreds Manual Type Type: Service Repair Manual / Workshop Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Cooling System, Lubrication System, Clutch, Drive, Transmission, Final Drive Chassis And Suspension: Chassis, Wheels/Tires, Brakes, Suspension, Steering, Frame Electrical: Electrical System, Wiring Diagrams General: General Information, Maintenance Procedures Included Maintenance And Scheduled Service: Step-by-step instructions for routine maintenance Disassembly And Assembly: Complete disassembly and reassembly procedures for major components Troubleshooting: Guidance for diagnosing and resolving common issues Repair And Rebuild: Detailed instructions for component repair and rebuilding Technical Depth Depth: Comprehensive factory-level detail for DIY and professional mechanics Illustrations And Photos: Includes hundreds of photos and illustrations to guide users through procedures. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Fully printable, allowing users to print specific pages or the entire manual Binding Type Binding: Digital (no physical binding) Paper Type Paper Quality: Not applicable (digital format) Additional Features Searchability: Likely searchable text within the PDF document Compatibility: Compatible with Windows, Mac, smartphones, and tablets via web browser Requirements Software Requirements: Adobe PDF Reader, Winzip (free) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, Twin Cam 88B V-Twin Displacement: 1450 cc (88 cubic inches) Bore X Stroke: 3.75 in. x 4.00 in. (95.25 mm x 101.6 mm) Compression Ratio: 8.7:1 (typical for Twin Cam 88B) Performance Horsepower: Approximately 65-70 HP (estimated, subject to tuning and exhaust) Torque: Approximately 70-75 ft-lbs (estimated, subject to tuning and exhaust) Fuel System Fuel Delivery: Carburetor (likely Keihin CV 40mm) or Electronic Fuel Injection (EFI - depending on specific sub-model or regional variant for 2004, though carburetors were common on FLSTF) Fuel Type: Unleaded gasoline, minimum 89 octane (premium) recommended Engine Lubrication System Oil Type: Harley-Davidson Genuine V-Twin Motorcycle Oil or equivalent SAE 20W-50 Oil Capacity: Approximately 3.0-3.5 US quarts (2.8-3.3 liters) with filter change Oil Filter Part Number: Harley-Davidson 63796-77 (common for this era, check manual for exact fitment) 🔧 Transmission Standard Type: 5-speed, constant mesh Gear Ratios: Specific ratios typically detailed within the manual (e.g., 1st: 10.110, 2nd: 6.802, 3rd: 4.736, 4th: 3.730, 5th: 3.150 - typical values) Features Transmission Fluid Type: Harley-Davidson Formula+ Transmission Lubricant or equivalent SAE 50 motorcycle transmission oil Transmission Fluid Capacity: Approximately 26-28 US fluid ounces (0.77-0.83 liters) Clutch Type: Wet, multi-plate 📐 Dimensions Exterior Length: Approximately 93.7 inches (2380 mm) Width: Approximately 36.8 inches (935 mm) Height: Approximately 50.0 inches (1270 mm) Weights Dry Weight: Approximately 631 lbs (286 kg) Gross Vehicle Weight Rating Gvwr: Not typically specified in the same way as cars; refer to payload capacity if available. Fuel Capacity: 5.0 US gallons (19.0 liters) 🛡️ Safety Features Ratings Crash Test Ratings: Not applicable (motorcycles are not rated by standard automotive crash test agencies like NHTSA or IIHS). Active Features Braking System: Dual-piston caliper front and rear disc brakes Lighting: Halogen headlamp, tail lamp, brake lamp, turn signals Passive Features Frame Construction: Steel frame and swingarm providing structural integrity 💡 Technology Features Infotainment Audio System: Not typically equipped with a factory-installed audio system on this model; aftermarket options are common. Driver Assistance ABS Availability: Anti-lock Braking System (ABS) was an optional feature for 2004 models and not standard. Connectivity Cruise Control: Optional feature, not standard on all FLSTF models. 🔧 Maintenance Service Intervals Engine Oil And Filter Change: Every 2,500-3,000 miles (4,000-4,800 km) or 6 months, whichever comes first (refer to manual for exact interval). Transmission And Primary Chain Case Oil Change: Every 5,000-6,000 miles (8,000-9,600 km) or annually (refer to manual for exact interval). Spark Plug Replacement: Every 10,000-15,000 miles (16,000-24,000 km) or as needed based on inspection (refer to manual). Fluid Specifications Brake Fluid Type: DOT 4 brake fluid (refer to manual for specific Harley-Davidson recommended fluid) Fork Oil Type: Harley-Davidson Motorcycle Fork Oil or equivalent, typically SAE 10W (check manual for exact viscosity and type) Fork Oil Capacity: Approximately 13.7 US fluid ounces (405 ml) per fork leg (verify with manual) Known Issues Common Wear Items: Clutch wear, brake pad wear, belt drive wear, potential for primary chain...
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Harley FLSTF Fat Boy ST 2004 Service Repair ManualHarley FLSTF Fat Boy ST 2004 Service Repair ManualHarley FLSTF Fat Boy ST 2004 Service Repair ManualHarley FLSTF Fat Boy ST 2004 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FLSTF Fat Boy
Year:
2004
Trim:
ST
Codes
Engine Family Code:
Evolution (commonly referred to as 'Evo' or 'Big Twin Evo')
👋 Introduction
Market Position
Target Audience:
Do-it-yourself (DIY) owners and experienced mechanics seeking detailed repair information
Competitive Analysis
Advantage:
Cost-effective alternative to printed manuals and dealership services, offering convenience and accessibility
Key Features
Key Selling Point:
Complete official full factory service repair manual in PDF format with extensive coverage and hundreds of photos/illustrations
Convenience:
Printable pages, access on multiple devices, no expiry dates
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete factory service and repair
Styles Covered:
All styles covered (implying variations within the FLSTF Fat Boy ST designation for that year).
Page Count
Estimated Page Count:
Hundreds
Manual Type
Type:
Service Repair Manual / Workshop Manual
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Cooling System, Lubrication System, Clutch, Drive, Transmission, Final Drive
Chassis And Suspension:
Chassis, Wheels/Tires, Brakes, Suspension, Steering, Frame
Electrical:
Electrical System, Wiring Diagrams
General:
General Information, Maintenance
Procedures Included
Maintenance And Scheduled Service:
Step-by-step instructions for routine maintenance
Disassembly And Assembly:
Complete disassembly and reassembly procedures for major components
Troubleshooting:
Guidance for diagnosing and resolving common issues
Repair And Rebuild:
Detailed instructions for component repair and rebuilding
Technical Depth
Depth:
Comprehensive factory-level detail for DIY and professional mechanics
Illustrations And Photos:
Includes hundreds of photos and illustrations to guide users through procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Fully printable, allowing users to print specific pages or the entire manual
Binding Type
Binding:
Digital (no physical binding)
Paper Type
Paper Quality:
Not applicable (digital format)
Additional Features
Searchability:
Likely searchable text within the PDF document
Compatibility:
Compatible with Windows, Mac, smartphones, and tablets via web browser
Requirements
Software Requirements:
Adobe PDF Reader, Winzip (free)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, Twin Cam 88B V-Twin
Displacement:
1450 cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Compression Ratio:
8.7:1 (typical for Twin Cam 88B)
Performance
Horsepower:
Approximately 65-70 HP (estimated, subject to tuning and exhaust)
Torque:
Approximately 70-75 ft-lbs (estimated, subject to tuning and exhaust)
Fuel System
Fuel Delivery:
Carburetor (likely Keihin CV 40mm) or Electronic Fuel Injection (EFI - depending on specific sub-model or regional variant for 2004, though carburetors were common on FLSTF)
Fuel Type:
Unleaded gasoline, minimum 89 octane (premium) recommended
Engine Lubrication System
Oil Type:
Harley-Davidson Genuine V-Twin Motorcycle Oil or equivalent SAE 20W-50
Oil Capacity:
Approximately 3.0-3.5 US quarts (2.8-3.3 liters) with filter change
Oil Filter Part Number:
Harley-Davidson 63796-77 (common for this era, check manual for exact fitment)
🔧 Transmission
Standard
Type:
5-speed, constant mesh
Gear Ratios:
Specific ratios typically detailed within the manual (e.g., 1st: 10.110, 2nd: 6.802, 3rd: 4.736, 4th: 3.730, 5th: 3.150 - typical values)
Features
Transmission Fluid Type:
Harley-Davidson Formula+ Transmission Lubricant or equivalent SAE 50 motorcycle transmission oil
Transmission Fluid Capacity:
Approximately 26-28 US fluid ounces (0.77-0.83 liters)
Clutch Type:
Wet, multi-plate
📐 Dimensions
Exterior
Length:
Approximately 93.7 inches (2380 mm)
Width:
Approximately 36.8 inches (935 mm)
Height:
Approximately 50.0 inches (1270 mm)
Weights
Dry Weight:
Approximately 631 lbs (286 kg)
Gross Vehicle Weight Rating Gvwr:
Not typically specified in the same way as cars; refer to payload capacity if available.
Fuel Capacity:
5.0 US gallons (19.0 liters)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not applicable (motorcycles are not rated by standard automotive crash test agencies like NHTSA or IIHS).
Active Features
Braking System:
Dual-piston caliper front and rear disc brakes
Lighting:
Halogen headlamp, tail lamp, brake lamp, turn signals
Passive Features
Frame Construction:
Steel frame and swingarm providing structural integrity
💡 Technology Features
Infotainment
Audio System:
Not typically equipped with a factory-installed audio system on this model; aftermarket options are common.
Driver Assistance
ABS Availability:
Anti-lock Braking System (ABS) was an optional feature for 2004 models and not standard.
Connectivity
Cruise Control:
Optional feature, not standard on all FLSTF models.
🔧 Maintenance
Service Intervals
Engine Oil And Filter Change:
Every 2,500-3,000 miles (4,000-4,800 km) or 6 months, whichever comes first (refer to manual for exact interval).
Transmission And Primary Chain Case Oil Change:
Every 5,000-6,000 miles (8,000-9,600 km) or annually (refer to manual for exact interval).
Spark Plug Replacement:
Every 10,000-15,000 miles (16,000-24,000 km) or as needed based on inspection (refer to manual).
Fluid Specifications
Brake Fluid Type:
DOT 4 brake fluid (refer to manual for specific Harley-Davidson recommended fluid)
Fork Oil Type:
Harley-Davidson Motorcycle Fork Oil or equivalent, typically SAE 10W (check manual for exact viscosity and type)
Fork Oil Capacity:
Approximately 13.7 US fluid ounces (405 ml) per fork leg (verify with manual)
Known Issues
Common Wear Items:
Clutch wear, brake pad wear, belt drive wear, potential for primary chain tensioner wear (on some Twin Cam models, though less prevalent on the 88B).
Electrical Gremlins:
While generally reliable, older electrical connectors can sometimes cause intermittent issues if not properly maintained or sealed.
📚 Vehicle History
Brand Heritage
Manufacturer:
Harley-Davidson Motor Company, USA
Model Evolution
Fat Boy Introduction:
The Fat Boy model was first introduced in 1990 and quickly became an iconic cruiser, known for its distinctive styling reminiscent of post-WWII military vehicles, particularly the 'WLA'.
2004 Updates:
The 2004 model year featured the Twin Cam 88B engine, a significant upgrade over previous Evolution engines, offering increased displacement and improved torque delivery. Styling cues like the fluted headlight nacelle, wide fork spacing, and solid-disc wheels remained hallmarks of the Fat Boy.
Production
Manufacturing Location:
United States (typically York, Pennsylvania or Milwaukee, Wisconsin)
🏆 Awards & Recognition
Recognitions
Model Recognition:
The Fat Boy is a highly recognized and iconic model within the cruiser segment, lauded for its distinctive styling and powerful V-twin performance.
Ratings
Customer Satisfaction:
Generally high customer satisfaction for Harley-Davidson motorcycles, particularly for models that embody the brand's heritage.
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