2005 Harley-Davidson Softail FLST/FXST & FLSTFSE Factory Service Manual Set (P/N 99482-05)

This 2005 Harley-Davidson Softail manual set combines the factory Service Manual (P/N 99482-05), Electrical Diagnostics (P/N 99498-05), and FLSTFSE Service Supplement (P/N 99494-05). It covers the listed carbureted and EFI FLST/FXST models, with additional procedures for the FLSTFSE.

• Engine repair: Twin Cam 88B top-end and bottom-end overhaul, cam support plate service, oil-pump inspection, and counterbalancer assembly work.

• Primary drive and transmission: Primary chaincase service, clutch disassembly and inspection, gearbox overhaul, and separate Japanese-market mainshaft and countershaft procedures.

• Carburetion and EFI: Carburetor service and adjustment, fuel-valve testing, fuel-pump and pressure-regulator service, fuel-pressure testing, and EFI sensor diagnosis.

• Forks, steering, and wheels: Hydraulic and Springer fork service, steering-head fall-away checks, rocker-bearing adjustment, wheel lacing, and laced-wheel truing.

• Maintenance and brakes: Scheduled-maintenance charts, brake-pad and disc inspection, master-cylinder and caliper repair, and brake-system bleeding.

• Electrical and security systems: Starter and charging tests, ICM/ECM diagnosis, TSM/TSSM configuration, key-fob assignment, password learning, diagnostic flowcharts, and wiring diagrams.

The procedures suit mechanically qualified owners and technicians with the service tools and test equipment required for the work.

Twin Cam Engine and Transmission Repair

Engine coverage extends from cylinder-head and piston inspection to crankcase separation and counterbalancer service. Exploded assembly views, wear limits, and inspection clearances support internal repair work. Component-specific torque data includes engine mounts and axle nuts.

The cam support plate section specifies tensioner unloader HD-42313 and warns that uncontrolled release of the spring-loaded cam chain tensioners can stretch the springs or crack the tensioner shoes.

Transmission chapters cover shaft removal, gear and bearing inspection, shifter-cam service, and reassembly. Appendix D provides separate instructions for Japanese-market shaft assemblies. The Drive Belt Wear Patterns illustrations distinguish damage requiring replacement from conditions that can be monitored.

Fuel-System Testing and Electrical Diagnosis

Carburetor sections cover the constant-velocity carburetor, float checks, enrichener, and vacuum-operated fuel valve. EFI coverage adds fuel-pump and sender removal, regulator service, injector checks, and pressure testing with gauge HD-41182.

Separate carbureted ICM and EFI ECM diagnostic charts help identify the applicable circuit tests before a sensor or control module is replaced. Distinguishing current from historic trouble codes requires Digital Technician HD-44750; speedometer-based code retrieval is also documented.

Illustrated references include Engine Oil Flow: Top End, Starting Circuit: Carbureted Models, Starting Circuit: EFI Models, and Speedometer Self Diagnostics. Model-specific wiring sheets include connector identifiers, pin assignments, and wire-color codes.

Security coverage explains a specific TSSM limitation: if no personal code has been assigned and both key fobs are lost or damaged while the system is armed, the TSSM must be replaced.

Springer Chassis and FLSTFSE Differences

Springer steering-head and rocker-bearing procedures are separated from hydraulic-fork service. The wheel chapters distinguish FLSTSC and FXSTS front assemblies and include sealed-bearing replacement, wheel lacing, and truing.

The FLSTFSE supplement covers its engine-component differences and hydraulic clutch master cylinder, fluid line, secondary actuator, release bearing, and bleeding procedures. It is used alongside the base Softail publications. Its Drive introduction also references a separate Touring Models Service Manual, which is not included in this set.

Brake service and work on a raised motorcycle require proper support and the safety precautions specified in the manual.

Fuel-Pressure and Brake-Wear Reference Examples

These figures are a small selection of the testing and inspection data included in the manuals.

For EFI fuel-pressure testing, the specified pressure is 55–62 psi (380–425 kPa) with the engine running as speed is varied during the test.

Brake-pad replacement limits differ by application: FLSTSC/FXSTS front pads reach the limit at 0.06 in. (1.6 mm) or less above the backing plate. The limit for the other brake pads is 0.04 in. (1.02 mm) or less above the backing plate.

Searchable Text, Bookmarks, and Publication Breakdown

Search and diagram detail: PDF text search and embedded bookmarks cover all three publications. Small pin numbers and wire-color labels on the dense wiring sheets are best read with zoom.

The three publications are combined in one printable 1,165-page PDF.

One shared contents page completes the total. The 25 blank pages are already included in the publication counts above.