Harley-Davidson Softail, Fat Boy, Springer, Night Train (2000) Service Manual (P/N 99482-00A)

The English-language 2000 Harley-Davidson Softail Models Service Manual, P/N 99482-00A, covers FLSTC, FLSTF, FLSTS, FXST, FXSTB, FXSTS, and FXSTD models. Appendix D contains the FXSTD Softail Deuce Service Supplement, which is used with the main manual’s Sections 1–8.

PDF Bookmarks and Wiring Detail

Search, navigation, and diagram labels: PDF text search is not available. Embedded bookmarks open the main sections, appendices, wiring diagrams, and index; the printed contents and index provide more detailed topic references. Small connector numbers, pin labels, and wire-color codes on the main-harness, lighting, and charging/starting diagrams are readable when enlarged.

The ZIP download contains one printable PDF with 633 pages, including the original cover and front matter, the 41-page integrated FXSTD supplement, and seven full-page wiring diagrams. These sections are already included in the total.

Softail Chassis, Twin Cam Repair, and Electrical Diagnosis

The following selected coverage highlights summarize the main workshop areas rather than reproduce the complete contents. Other topics include seasonal storage and jiffy-stand service.

• Maintenance and chassis: Scheduled service, brake bleeding, wheel-bearing service, wheel lacing and truing, tire balancing, vehicle alignment, and conventional or Springer front-end repair.

• Twin Cam 88B engine: Step-by-step engine removal and installation, top-end and bottom-end overhaul, compression and cylinder-leakage testing, and counterbalancer service.

• Fuel and exhaust: C.V. carburetor disassembly, inspection, assembly, and adjustment; vacuum fuel-valve testing; tank, air-cleaner, exhaust, and California evaporative-emissions service.

• Electric starter: Activation-circuit diagnosis, voltage-drop and current-draw tests, relay and solenoid checks, starter-motor repair, and jackshaft service.

• Primary drive and transmission: Primary chaincase removal, compensating-sprocket service, sprocket alignment, clutch-pack inspection and repair, drive-belt removal, and internal transmission procedures.

• Electrical troubleshooting: Trouble-code retrieval, Scanalyzer and breakout-box testing, no-start and misfire flowcharts, charging-system diagnosis, and domestic/international wiring diagrams.

The major repair material is written for professional Harley-Davidson technicians. Experienced owners undertaking these procedures need the specified workshop tools, measuring equipment, and relevant mechanical knowledge.

Maintenance and Model-Specific Chassis Work

Routine service includes engine and transmission lubricant changes, primary-chain and clutch adjustments, rear-belt inspection, steering-head bearing adjustment, and throttle-cable and enrichener checks.

The chassis procedures distinguish conventional forks from the FLSTS/FXSTS Springer front end, with separate wheel, brake-caliper, fork-rocker, steering-head, and fender instructions. Rear-fork work and shock replacement are covered alongside controls, seats, saddlebags, and windshield hardware.

Rear-shock coverage includes preload adjustment and removal/installation. The shock absorber itself is a non-repairable assembly.

Engine Overhaul and Repair Limits

Cylinder-head service extends to valves, guides, and seats. Cylinder and piston work includes boring, honing, inspection, and upper connecting-rod bushing service. Other sections address lubrication flow, oil-pressure diagnosis, the cam support plate, cam-chain tensioners, oil pump, crankcase bearings, and counterbalancer timing.

The Engine Oil Flow: Top End and Balance Chain illustrations show the lubrication passages and balancer alignment involved in this work.

Flywheel/connecting-rod coverage includes inspection and assembly replacement. The manual directs factory service or replacement of the combined assembly rather than independent replacement of its flywheels or connecting rods.

Rear cam bearing: A production change effective December 14, 1999, introduced a rear cam roller bearing in the Twin Cam 88B. The manual refers the affected bearing service and earlier-bearing conversion to Service Bulletin M-1097, which is not included.

Assembly cautions: A displaced lifter anti-rotation pin can allow lifter rotation and severe engine damage. Sealant on the balance-shaft housing edge can misalign the balance sprockets and damage the engine.

Carburetor Service and FXSTD Differences

Fuel-system coverage follows the original carbureted configuration, including float-level and accelerator-pump work, enrichener adjustment, and vacuum-operated fuel-supply-valve diagnosis. It does not provide an EFI repair chapter.

The FXSTD appendix adds Deuce-specific front-wheel hardware, fork covers, cable and hose routing, rear bodywork, seat service, fuel-tank procedures, and the center-console fuel-gauge sender arrangement. It also covers the model’s lighting and electrical installation differences.

The FXSTD shares its exhaust system with the FLSTF. Its front and rear brake pads are not interchangeable.

Primary Drive and Internal Transmission Service

The transmission sections cover the shifter cam, shifter forks, clutch-release cover, mainshaft, countershaft, side-door bearings, main-drive gear, and transmission case. Assembly-specific torque tables, wear limits, clearances, and adjustment specifications accompany the procedures.

Starting, Charging, and Ignition Diagnosis

Starter voltage-drop tests address poor connections under load, helping distinguish cable and ground faults from starter or solenoid problems. The Starter Operation illustration explains the relationship between the relay, solenoid, drive, and motor.

Ignition diagnosis includes current and historic trouble codes, wiggle tests, DVOM checks, and the two-part Diagnostic Check flowchart. Code-specific sections address MAP sensing, battery voltage, ignition coils, crank and cam position sensors, the bank-angle sensor, ignition-module faults, and sensor timing.

Charging coverage includes alternator output and regulator tests. Separate sections address speedometer diagnosis, the turn-signal canceller, gauges, lamps, switches, and the main harness.

Wiring References and Required Workshop Equipment

The wiring material includes Lights, Speedometer & Indicators and Charging & Starting Circuits, connector locations, and terminal service for Amp Multilock, Deutsch, Mini-Deutsch, and Packard connectors.

Appendix A identifies tools such as the HD-42310 engine/transmission stand with HD-42310-25 Softail cradle, HD-44062 balancer-shaft retention pins, and HD-44064 sprocket alignment tool. Transmission and diagnostic equipment includes the HD-35316A main-drive-gear remover/installer and HD-41325-95B Scanalyzer cartridge.

Follow the manual’s fire-prevention, motorcycle-support, electrical-isolation, and eye-protection requirements during fuel-system, brake, lifting, pressing, and electrical work.

Selected Oil-Pressure and Compression Specifications

The engine specifications list oil pressure of 30–38 PSI at 2,000 RPM with the oil at its normal operating temperature of 230°F (110°C). The oil-pressure section provides the corresponding gauge-test information.

Compression-test guidance considers final readings of at least 90 PSI normal when cylinder-to-cylinder variation does not exceed 10%. The test calls for normal engine operating temperature when possible, open choke and throttle plates, and readings after five to seven compression strokes. The accompanying interpretation table distinguishes ring trouble from valve or head-gasket leakage.