2002 Harley-Davidson FLT Family Service Manual

2002 Harley-Davidson FLT Touring Service Manual

• Covers 2002 Harley-Davidson FLT family touring motorcycles including FLHT, FLHTC, FLHR, and FLTR variants with either carbureted or fuel-injected engines
• Official OEM publication P/N 99483-02, documenting maintenance, chassis, engine, fuel, and electrical systems
• Includes 1107 pages of technical specifications, torque values, exploded-view diagrams, and maintenance procedures
• File link appears in your order confirmation straight away
• OCR text layer lets you jump to a torque spec by keyword
• This official 2002 edition serves as the foundational technical reference for the 2002 FLT model year platform, including critical alignment and engine mount procedures specific to the touring chassis

Document Content Overview

This 2002 Harley-Davidson FLT service manual provides comprehensive technical guidance for the touring platform, spanning nine distinct sections and a detailed appendix. Documentation includes maintenance schedules, engine and transmission service procedures, chassis alignment, fuel system diagnostics, and electrical system schematics. The manual details the specific requirements for both carbureted and fuel-injected configurations, offering clear guidance on component removal, inspection, and assembly.

Additional chapters cover the starter motor, drive components, and dedicated sections for electrical diagnostics, ensuring that owners and technicians have access to the complete factory-specified data required for professional-grade maintenance. Detailed exploded views illustrate the internal composition of major assemblies, including the master cylinder, front and rear brake calipers, and fork assemblies.

Specification Highlights

Technical data is provided for all major systems, listing torque settings in both imperial and metric units to ensure accuracy during assembly. Transmission drain plug torque is specified at 14–21 ft-lbs (19–28 Nm). Steering head bearing lubrication uses special purpose grease, part number 99857-97. Fuel tank capacity is documented at 5 gallons (18.9 L).

Maintenance intervals for engine oil and filter changes are specified at 1,000 miles and every 5,000 miles thereafter. Primary chain tension and clutch adjustment procedures are documented with specific free-play tolerances for both hot and cold engine conditions. Reference values for brake disc minimum thickness are listed at 0.04 inches (1.02 mm) across the 2002 Harley-Davidson FLT family of models. Reference only — always consult a certified technician before performing service on this equipment.

This official 1107-page 2002 Harley-Davidson FLT motorcycle service manual covers the FLHT, FLHTC, FLHR, and FLTR touring models, providing factory-authorized technical documentation for the complete 2002 model year powertrain and chassis configuration.