Harley-Davidson Softail (FXST, FLSTC, FLSTF, FXSTB, FXSTS, FXSTD) 2004 Service Manual (P/N 99482-04)

This 1,068-page PDF combines three Harley-Davidson factory publications for 2004 Softail motorcycles: the Softail Models Service Manual P/N 99482-04 (614 PDF pages), Electrical Diagnostics P/N 99498-04 (374 pages), and FXSTDSE2 Service Supplement P/N 99494-04 (79 pages), plus a one-page contents sheet. Its repair depth is suited to professional technicians and experienced owners who already understand motorcycle shop safety and have access to specialty tools, a DVOM, and model-appropriate diagnostic equipment.

• Covers the Twin Cam 88B carbureted and EFI versions of FXST/FXSTI, FLSTC/FLSTCI, FXSTS/FXSTSI, FLSTF/FLSTFI, FXSTD/FXSTDI, and FXSTB/FXSTBI, plus the PF-code FXSTDSE2 1550 EFI model.
• Documents engine removal and installation, top- and bottom-end overhaul, cylinder-head and piston service, cam support plate and oil pump work, crankcase repair, counterbalancer timing, and flywheel/connecting-rod service.
• Details wheel-bearing replacement, laced-wheel assembly and truing, disc-rim runout checks, brake master-cylinder and caliper service, brake bleeding, conventional and Springer fork work, steering-head service, rear suspension, and vehicle alignment.
• Follows the primary drive, clutch, transmission sprocket, final drive belt, five-speed transmission, shifter cam and forks, mainshaft/countershaft, and transmission case through removal, disassembly, inspection, reassembly, and adjustment.
• Separates carburetor and EFI service, including enrichener and fuel-supply valve work, carburetor adjustment, intake-leak testing, induction-module and sensor service, injector and fuel-pump work, and fuel-pressure diagnosis.
• Provides starting and charging tests, speedometer self-diagnostics, TSM/TSSM setup and fault isolation, carbureted ICM and EFI ECM diagnostic charts, connector servicing, and model-specific wiring diagrams for domestic and international machines.

Maintenance and Mechanical Repair Scope

Routine service sections cover approved fuel and lubricants, scheduled maintenance, engine oil and filter changes, battery care, brake inspection and bleeding, primary-chain and clutch adjustment, rear-belt inspection and tensioning, suspension preload, steering-head bearings, fork oil, spark plugs, throttle cables, carbureted idle and ignition timing, and critical fasteners.

The engine chapters go well beyond tune-up work. They include service wear limits, oil-flow and oil-pressure references, valve-guide and valve-seat work, cylinder and piston inspection, camshaft bearing service and timing-mark alignment, oil-pump service, crankcase assembly, counterbalancer setup, and final assembly checks. The transmission material also includes a separate appendix for the Japan-only mainshaft/countershaft build identified by the transmission case number.

Carbureted, EFI, and Electrical Diagnostics

The separate electrical diagnostic manual traces no-crank, no-start, starts-then-stalls, charging, misfire, sensor, serial-data, security, and instrument faults through factory test charts. It covers speedometer DTC access, breakout-box testing, wiggle tests, TSM/TSSM password learning, fuel-system electrical checks, and carbureted-versus-EFI fault paths.

Its wiring index contains 20 full model/circuit sheets, while the repair chapters add many focused schematics and views. Useful examples include “Engine Oil Flow: Cam Support Plate/Right Crankcase Half,” “Transmission Power Flow,” “Starting Circuit: Carbureted Models,” “Simplified TSM/TSSM Wiring,” “EFI Circuit Diagram,” and the three-sheet “2004 All EFI Softail Main Harness” series.

FXSTDSE2-Specific Material

The FXSTDSE2 supplement is not a replacement for the base service manual. It adds only the model-specific material: air-filter and hydraulic-clutch service; unique wheels, brake components, hand controls, handlebars, covers, and trim; 1550 engine tolerances and cylinder boring/honing; plus turn-signal, tachometer, handlebar-wiring, and regulator procedures. Its Fuel System, Starter, Drive, Transmission, and Fuel Injection sections contain no unique procedures and direct the reader back to the base manual.

Factory Data, Tools, and Repair Cautions

Specifications include component-specific torque tables, fluid and lubricant data, manufacturing tolerances, wear limits, pressure-test information, alignment checks, and electrical test values. The tools appendix identifies factory equipment by part number, including the HD-42310 engine/transmission stand, HD-43644 camshaft bearing remover/installer, HD-44060 wheel-bearing remover, HD-41182 fuel-pressure gauge, and HD-42682/HD-43876 breakout boxes.

Two manual-specific cautions matter during major repair work: piston-pin circlips are one-time-use parts whose reuse can cause severe engine damage, and the lifter anti-rotation pin must remain captured by the lifter cover or lifter rotation can damage the engine. ECM or ICM replacement requires Digital Technician P/N HD-44750 for programming, although the manual also covers the related password-learn procedure.

Brake, fuel, battery, and engine or transmission repairs can affect safe operation. Follow the factory warnings and use a qualified Harley-Davidson technician for work beyond your training or available equipment.