Harley FLSTF Fat Boy ST 2004 Service Repair Manual
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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...
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)
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.