2002 Harley-Davidson Softail Standard, Deuce, Classic, Custom & Night Train Factory Service Manual (P/N 99482-02
940 Pages • 35.93 MB • Instant, Printable PDF
Harley-Davidson Models Covered & Key Technical Specifications
Models: Harley-Davidson Softail Standard, Night Train, Deuce, Classic, Custom
Sub-models / Variants: FLSTC, FLSTF, FLSTS, FXST, FXSTB, FXSTD, FXSTSI, FLSTCI, FXSTFI, FLSTSI, FXSTDI, FXSTBI
Trade Names: Softail
Model Years: 2002
Serial Numbers: 1HD1BRY102Y110000 (Sample)
Technical Data:
- Engine: Twin Cam 88B (Carbureted/EFI)
- Displacement: 88 cubic inches
- Transmission capacity: 20–24 oz (591.5–709.8 ml)
- Primary chaincase capacity: 26 oz (768.9 ml)
- Oil tank capacity: 3.5 qt (3.3 liters)
- Engine idle speed: 950–1050 RPM
- Spark plug gap: 0.038–0.043 in (0.97–1.09 mm)
- Brake disc lateral runout limit: 0.008 in (0.2 mm)
- Rear axle torque limit: 60–65 ft-lbs (81.3–88.1 Nm)
Harley-Davidson Manual Features & Content Preview
- Covers 2002 Harley-Davidson Softail models, including Standard, Night Train, Deuce, Classic, and Custom variants equipped with the Twin Cam 88B engine.
- Official OEM publication (P/N 99482-02) for the 2002 model year.
- Delivers 940 pages of factory technical data, exploded-view diagrams, and maintenance specifications.
- Documents engine, chassis, electrical, and fuel-injection systems.
- This reference material provides professional-grade specifications. Always consult a certified technician before performing any service on your motorcycle to ensure safe and proper operation.
Maintenance and Chassis Coverage
Having accurate specs is critical when working on a Twin Cam 88B. This publication lays out the exact factory data for the entire 2002 Softail lineup. It details essential service intervals for oil, fuel, and transmission systems. You also get specific parameters for brake care and rear belt deflection measurement. To streamline routine shop work, the maintenance section includes complete capacity tables and precise fluid requirements.
Chassis and Suspension Data
Diagnosing suspension or handling issues requires the right numbers. This manual provides detailed specifications for wheel lacing, disc runout limits, and bearing inspections. Exact torque values are clearly documented for fasteners like axle nuts, caliper bolts, and riser hardware. For front-end work, a dedicated section covers steering head bearing adjustments, offering precise fall-away measurements specific to FLSTS and FXSTS models. It also includes the factory suspension preload settings for rear shock assemblies.
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