2000 Harley Davidson FXSTD Softail Deuce Factory Service & Work Shop Manual
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I MAINTENANCE
11
I CHASSIS
21
31
2000
I ENGINE
SOFTAIL
I FUEL SYSTEM
41
51
SERVICE
I ELECTRIC STARTER
MANUAL
The Information in this Service Manual applies
I DRIVE
Sl
to all 2000 Softall models.
I TRANSMISSION
71
I ELECTRICAL
al
I APPENDIX
I
VISIT THE HARLEY-DAVIDSON WEe SITE
http://www.harley-davidson.com
I INDEX
I
CMI-3M-03/03
FOREWORD
GENERAL
This Service Manual has bee n prepared with two purposes in
mind. First, it will acquaint the user with the construction of
t he Harley-Davidson product and assist in the performance of
basic maintenance and repair. Secondly, it will introduce to
the professional Harley-Davidson Technician the latest field-
lested and factory-approved major repair methods. We sin-
cerely believe that this Service Manual will make your associ-
ation with Harley-Davidson products more pleasant and
profitable.
HOWTO USE
YOUR SERVICE MANUAL
Information is arranged as tollows:
• Section l - Maintenance
• Section 2- Chassis
• Section 3-Engine
• Section 4- Fuel System
• Section 5--Electric Starter
• Section 6-Drive
• Seclion 7- Transmissi on
• Section a- Elect ri cal
• Appendix A- Tools
• Appendix B-Wiring
• Appendix C- Metric Conversions
• Appendix D-FXSTD Service Supplement
Use the TABLE OF CONTENTS following this FOREWORD
or the INDEX at the back of the book to find the desired sub-
ject.
Note that each manual section contains sequentially num-
bered topi cs_ The numbering system allows qu ick cross refer·
ences throughout the document.
For example. the sixth topic (BRAKES) in section one (MAIN-
TENANCE) could be referred to as:
1.6 BRAKES
This cross reference directs the reader to section 1 (MAINTE-
NANCE) and topic 6 (BRAKES).
PREPARATION FOR SERVICE
AWAANING
Gasoline is extremely flammable and highly explosive.
Always stop the eng ine when refueling or servicing the
fuel system_ 00 not smoke or allow open flame or sparks
near the work site. Inadequate safety precauti ons could
result in death or serious Injury.
Good preparation is very important lor efficient service work.
A clean work area at the start of each job will allow you to per-
form the repair as easily and quickly as possible, and will
reduce the incidence of misplaced tools and parts. A motorcy-
cle that is excessively dirty should be cleaned before work
starts. Cleaning will occasionally uncover sources of trou ble.
Tool s, instruments and any parts needed for the job should be
gathered before work is started. Interrupting a job to locale
tools or parts is a distraction and causes needless delay. See
APPENDIX A-TOOLS for equipment required for special ser-
vice work.
NOTE
• To avoid unnecessary disassembly, carefully read all re/-
ative service information before repair work is started.
• In figure legends, the number which follows the name of
a part indicates the quantity necessary for one complete
assembly.
SERVICE BULLETINS
In addition to the information presented in this Service
Manual, Harley-Davidson Motor Company will periodically
issue Service Bulletins to Harley dealers. Service BUlletins
cover interim engineering changes and supplementary infor-
ma tion.
USE GENUINE
REPLACEMENT PARTS
AWAANING
When replacement p arts are required, use only genuine
Harley-Davidson parts or parts with equivalent charac·
teristics (whic h inc lu de type, strength and material ). Fail-
ure to do so may result in product malfunction. This
could result in death or serio us Injury.
To ensure satisfactory and lasting repairs, carelully lollow the
Service Manual instructions and use only genuine Harley-
Davidson {eplacement parts. This is your assurance that the
parts you are using will lit right. operate properly and last
longer.
L
WARNINGS AND CAUTIONS
Statements in this service manual preceded by the following
words are of special significance.
AWARNING
WARNING indicates a potentially hazardous situation
which , if not avoided, could result in death or serious
injury.
ACAUTION
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
CAUTION
CAUTION without the safely alerl symbol indicates a
potentially hazardous situation which, If not avoided,
may result in property damage.
AWARNING
• Proper service and repair is important for the safe,
reliable operation of all mechanical products. The
service procedures recommended and described in
this Service Manual are effective methods for per-
forming service operations. Some of these service
operations require the use of tools specially
designed for the purpose. These special tools should
be used when and as recommended. It is important
to note Ihat some warnings agai nst the use of spe-
cific service methods, which could damage the
motorcycle or render it unsafe, are stated in this Ser-
vice Manual. However, please remember that these
warnings are not all-inclusive. Inadequate safety pre-
cautions could result in death or serious injury.
• Since Harley·Davidson could not possibly know,
evaluate or advise the service trade of all possible
ways In which service might be performed, or of the
possible hazardous consequences of each method,
we have not undertaken any such broad evaluation.
Accordingly. anyone who uses a service procedure
or tool which is not recommended by Harley·David·
son must first thoroughly satisfy himself that neither
his nor the operator's safety will be jeopardized as a
result. This could result in death or serious injury.
• Wear eye protection when using hammers, arbor or
hydraulic presses, gear pullers, spring compressors ,
slide hammers and similar tools. 8e especially cau·
tious when using pulling , pressing or compressing
equipment. The forces involved can cause parts to
fly outward with considerable force, possibly resull·
ing in death or serious injury.
II.
PRODUCT REFERENCES
AWARNING
Follow the directions listed on all products. Carefully
read all labels, warnings and cautions before use. Inade·
quate safety precautions could result In death or serious
injury,
When reference is made in Ihis Service Manual 10 a specific
brand name product, tool or in strument, an equivalent
product, tool or instrument may be substituted.
Kent-Moore Products
All tools mentioned in this manual with an "HO", "J" or "8"
preface must be ordered through :
Kent·Moore
SPX Corporation
28635 Mound Road
Warren. Michigan 46092·3499
Telephone: 1·800·345·2233
Sealing and Threadlocking Products
LOCTITE PRODUCTS
Some £ roced ures in this Service Manual call for the use of
Loctite products. If you have any questions regarding Loctite
product usage or retailer/wholesaler locations, please call
Loctite Corp. at 1-800· 323 · 5106 .
CONTENTS
All photographs, illustrations and procedures may not neces·
sari ly depict the most current model or component, but are
based on th e latesl production information available at the
time of publ ication.
Since product improvement is our continu al goal, Harley·
Davidson reserves Ihe right to change specifications, equip·
ment or designs at any time without noti ce and without incur·
ring obl igation.
TABLE OF CONTENTS
Page No .
SECTION 1-MAINTENANCE
1.1 General .. .
Servicing a New Motorcycle ...................... .
Safe Operating Maintenance ... .. ..
Shop Practices ....... ..... . .. .. ... ........
Repair Notes ... .. .. .. ....... .. ........ .
Safety ...... .... . ... .............. .. ..........
Removing Parts ...................... .. . ... .............. .
Cleaning ........................ .. .... .. . .. ..
Disassembly and Assembly . .. ...... ..............
Repair and Replacement Procedures .
Hardware and Threaded Parts
Wiring, Hoses and Lines .. ...... . .. . ............... .. ..
Instruments and Gauges
Bearings ...... .. ... .... ..... .. .. ... ... ... .... .
Bushings .. ........................ .... ... .... ... .
Gaskets ................ .. ..................................... .. .... .
lip Type Seals ........................ . .... .. ............... .
O·Rings (Preformed Packings)
Gears .. .. ... .. . .. . . .............. .
Shafts .. .
Part Replacement
Cleaning .. . .. ...... . .. .... ........ .
Part Protection .......................... .. .. ... .
Cleaning Process
Rust or Corrosion Removal ....... ..
Tool Safety . .. ..... .. ................ .... ............. .
Air Tools ... .... .. .................... .. .
Wrenches .. .. ..... .... ..................... ...... .
PlierS/Cutters/Prybars .
Hammers. ..... . ... .. .. ... ..... .
Punches/Chisels ............... .. .................... .. .. ..... .
Screwdrivers ... .. .. ......... ..... .
Ratchets and Handles . .. . ... .
Sockets
Storage Units .... .. ... . .. ... ... .. .... .
1.2 Fuel and Oil ...................... .. . ................ .. .
Fuel .. ...................................................... .. . ......... ... .
Gasoline Blends
Engine Oil
W in ter Lubrication .. . .. .. .. ......... ... .... ... .
1.3 Maintenance Schedule ..
1.4 Engine Oil and Filter .............. .
Checking and Adding Oil ............................ .. ..... _ ... .
Type of Oil .. ............................... .
Checking Oil level . .. ......... ... ... . ... . .. .
Recommended Oil Grades (table) ..
Changing Oil and Filter ....................... .. .. .. .............. .
1· 1
1-1
1· 1
1· 1
1· 1
1·1
1·1
1· 1
1·2
1·2
1·2
1·2
1·2
1·2
1·2
1·2
1·2
1· 2
1· 2
1· 2
1·2
1·3
1· 3
1·3
1·3
1·3
1·3
1·3
1·3
1·3
1·3
1·3
1·4
1·4
1·4
1·5
1·5
1·5
1·5
1·5
1·6
,."
1-11
1-11
1-11
1- 11
1-12
Page No .
1.5 Battery Maintenance ...
General .......... ..... .. ............. .... .
Battery Electrolyte Antidotes (table) ......... .... . .. ..
Disconnection and Removal .... ... .. .
In stallation and Connection . .. .. ... .
Inspection ...... ... .. .. .... ... .. .. .
Storage .......... .. ............. .............
1.6 Brakes ....... ................... ............... .
Fluid Inspection .. ........
Rear Brake Pedal
Pedal Height .... . .. .. .. .
Pedal Lubrication .....................
1.7 Bleeding Brakes .. . ... .
General ... ....
Procedure ........... .. ....................................... .. ........... .
1.8 Brake Pads and Discs ... ..... ....... .
Inspection .. .. ... . ... . .. . .. .. ... ......
Brake Pads ............ .. .. .. .
Brake Disc Thickness .. .
Brake Disc latera l Runout
Brake Pad Replacement .............. .. .............. .
Rear Brake Caliper ... ... .... ... .
Front Brake Caliper: All But FLSTS/FXSTS
1.9 Tires and Wheels . ... ....... .
Tires
Wheel Bearings ... .. .... .... .. .. .. .. ....... .
Wheel Spokes ... ....
Tire Pressures (table) ... ...
1.10 Primary Chain.
Inspection.
1.11 Primary Chaincase
LubricanL ... .. .... . .. .... . ... ....................... .
Changing Lubricant . .. . ... ..... ........ .
1.12 Clutch
Adjustment .. . .... ....................... .
1.13 Transmission Lubricant
Changing l ubricant ..... .. .................. .... ....................... .
1.14 Rear Belt Deflection .
In spection .. . ... .
1- 13
1-13
1-13
1- 14
1-14
1- 15
1-15
1016
1-16
1-17
1-17
1- 17
1- 1B
1-18
1-18
1-19
, -19
1- 19
1- 19
1-19
, -19
1-19
1-21
1-22
1-22
1-22
, -22
1-22
1-23
1-23
1-24
1-24
1-26
1-26
1-28
1-28
1· 29
1-29
iit.
Page No. Page No.
1.15 Rear Belt and Sprockets
General ... .... .
Cleaning .... ... .. . .. .. .. ..
Inspection
Sprockets
Rear Belt . ... . .. . ... . .. . .. .. .. .. .... ... .. ... . ... ... . ... .
Drive Belt Wear Analysis (table) ..
1.16 Suspension Adjustments ..
Rear Shock Preload .... ... . .. .............. .
1.17 Steering Head Bearings:
All But FLSTS/FXSTS
Adjustment ................... .. ..... ............. ...... ... . .. .
Bearing Adjustment (Fall-away) '"'
LUbrication .......... ..... .
1.18 Steering Head Bearings:
FLSTS/FXSTS . .. .. .. .... . ... ... .
General ........................ .
Lubrication . ... . ... .
Special Tool Fabrication .
FLSTS Models ... .. ... ... ... .. ...
FXSTS Models .
1.19 Rocker Bearings:
FLSTS/FXSTS .. .. .. .. .. .. .
Inspection .. .. .... . ... . .. ..... ... .. .. .... .. .
1.20 Front Fork OiL
Replacing Fork Oil .. .. ... .. .. ... .... .. .
1.21 Spark Plugs
Inspection .. .
1.22 Air Cleaner Filter
Removal .. ..... .. .. .. .. . ... . .. .. .. . ... .
Installation
1.23 Cable and
Chassis Lubrication .. .. .. . ... . .. .. .. .
General .................. .
Cables and Hand Levers
Foot Shift Lever ._ .. ... .. .... .. ......... .... .... ... ... ............
Jiffy Stand ... .... .. .. .. .....
iv .
1-30 1.24 Throttle Cables
1-30
1·30
1-30
1-30
1-30
1-31
1-32
1-32
1-33
1- 33
1· 33
1- 33
1-34
1-34
1-34
1·34
1-35
1-35
1-37
1-37
1-39
1-39
1· 41
1-41
1A2
1-43
1-43
1-43
1-43
and Enrichener .. .. . .
Cable Inspection, Lubrication and Adjustment .
Inspecti on and Lubrication.
Adjustment
Enrichener Adjustment _ ...... ... ... .. .
1.25 Idle Speed and
Ignition Timing .. .. .. .. . .. .. .. . .. .. .. ....... . ... .
Idle Speed Inspecti on
Ignition Timing ........ ......... ... .. . ... . ... . .. ..
1.26 Fuel Supply Valve Filter.
Inspection .
Fuel System Lines and Fittings
1.27 Engine Mounts ..
Inspecti on .... ..... .. .............. .. .... ... . .. ....... .
1.28 Headlamp Alignment . .. . ...... . ... . .
Inspection . __
Adjustment
FLSTS/FXSTS Models
All Models But FLSTS/FXSTS
1.29 Critical Fasteners ... . ... . ... . .. .
Inspection .
Critical Fasteners (table)
1.30 Storage . ........ . ... . ... .
General .
1-43 Removal From Storage .
1-44
1- 44
1- 44
1- 44
1-45
1-46
1-46
1-46
1-47
1-47
1-48
1-49
1-49
1-50
1-50
1-51
1- 51
1-52
1-52
1-52
1-53
1-53
1-54
1.31 Troub l eshooting
Page No.
1-55
General .................................................... .
Engine .... .......................................... .. ....... ............ ..
Starter Motor Does Not OperalelTurn Over
Engine Turns Over But Does Not Start ...... ..
Starts Hard ..... .. . .. .................................. .. .... .
Starts But Runs Irregularly or Misses ...... ........ ..
A Spark Plug Fouls Repeatedly ....................... .
Pre-Ignition or Detonation (Knocks or Pings) .. .. .
Overheating .... .. ........................ ' "'
Valve Train Noise .. ...... . .. .. ... ....
Excessive Vibration .................
Check Engine Light Illuminates
Du ring Operation ...... .... ...
Lubrication System ..................... _............................. .
Oil Does Not Relurn To Oil Tank .....
Engine Uses Too Much Oil Or
Smokes Excessively ......... ... ... ... .. .. .. .
Engine Leaks Oil From Cases, Push Rods
low Oil Pressure .............................. ..
High Oil Pressure ......... .... .. ... ..
Electrical System
Allernalor Does Not Charge
'·55
1-55
1-55
1-55
1-55
1-55
1-56
1-56
1-56
1-56
1-56
' -56
1-56
1-56
1-56
1-56
1-57
1-57
1-57
1-57
Page No.
2.4 Front Wheel:
All But FLSTS/FXSTS
Removal ......................... .
Disassembly .. ... ..... ......... .
Disc Wheel
Laced Wheel ......
Cleaning and Inspection
Assembly ..
Disc Wheel
Laced Wheel
Installati on .............. .
2.5 Front Wheel: FLSTS.
Removal ...................................... .. .. .. .. .
Disassembly ... .. . .. .............. .
Cleaning and Inspection .
Assembly ..
Installation ........ .. .... . .. ..... .
2.6 Front Wheel: FXSTS .. .. .... .. .. .. ..... .
Removal . .. .. ...... ... .. ........................... .. .
Disassembly ........................... .......... .. ..... .. .............. .. .
Cleaning and Inspection ........ .
Assembly .. .
Insta ll ation
2-5
2-5
2-5
2-5
2-5
2-7
2-7
2-7
2-7
2-7
2· '
2·'
2·'
2·'
2·'
2-10
2·11
2-11
2- 11
2-11
2-11
2-13
Alternator Charge Rate Is Bel ow Normal
Speedometer Operates Erratically ..
1·57 2.7 Rear WheeL ... 2- 14
2-14
2-14
2-15
2-15
2-16
Carburetor .. ................ ..................... .. .... .
Floods ............................................... ..
Transmission ...
Shifts Hard .................. ..
Jumps Out Of Gear ............................. ..
Clutch Sli ps .. .... ..... ... ... ... ... .. ............ .. ..
Clutch Drags Or Does Not Release ... .. .. .... ...... ..
Clutch Chaners
Handling ............ .. .
Irregula ri ties ................. .. . ............................... .
Brakes . ................................ ..
Brake Does Not Hold Normally .................... ..
SECTION 2-CHASSIS
2.1 Specifications .
2.2 Torque Values ........ .
2.3 Vehicle Identification
Number ............ ........... .. .. . ...... .. .
General_ . .............. .
1-57
' -57
1-57
1-57
1·57
1-57
1-57
1- 57
1-57
1·58
1-58
1-58
1-58
2-1
2-2
2-4
2-4
Removal ........ .. .. ... .. ........ ........ .. ....... . ..
Disassembly
Cleaning and Inspection ..
Assembly ... .
Installation ............ ... .... .. .... ... ....... ............ .......... ..
2.8 Sealed Wheel Bearings .
Inspection ....................... .
Removal ... .. .
Installation ..................... ........................... .. .. .. ......... .
2.9 Wheel Lacing: 16 In. Rim ... ... .. .
General .. .... .
Procedure .............................. .. _ .......... .. ................... .
2.10 Wheel Lacing: 21 In. Rim . ...
Procedure ................... ..
2.11 Truing Laced Wheel .......... ... .
Ge neral ....... .. ...
la teral Truing ..
Radial Truing .. . ................................................ .
2.12 Disc Rim Runout .....
General ............................................. .
la teral Runout
Radial Runout
2-17
2- 17
2-17
2-18
2· 19
2-19
2-19
2-21
2·21
2-23
2-23
2-23
2-24
2-25
2-25
2-25
2-25
v.
2.13 Tires ........... ............ ............. .
General ........ ... .................. .
Removal ........................................ .
Cleaning and Inspection ..... .
Installation ............ .
Checking Tire Aunout .......... .
Radial Aunout .......... .
Lateral Runout
Wheel Balancing ............... .
2.14 Vehicle Alignment .............. .
Page No.
2-26
2-26
2-26
2-26
2-27
2-26
2-26
2-26
2-29
TypeS of Misalignment ............ ___ ................................
2-30
2-30
2-30
2-30
2-31
2-31
2-32
Check For Horizontal Wheel Offset Misalignment ...... .
FXST, FXSTB, FXSTS Models .... .... .
FLSTC, FLSTF and FLSTS Models .......... .. ..
HorizonlallWheel Offset (table)
Check For Vertical Misalignment.
2.15 Front Brake
Master Cylinder
General ...... .. ..................... ........ _ ._ ............ .
Removal/Disassembly ...... ........ __ ......... .
Cleaning and Inspection ...... .
Assembly/Installation ., .......... ,
2.16 Rear Brake Master
Cylinder/Reservoir
Removal .......................... .
Installation .................................. .
Disassembly ..................... .
Cleaning and Inspection ...... ...... _ ................. ..
Assembly..... .. ............................ ... .
2.17 Front Brake Caliper:
All But FLSTS/FXSTS .......... .
Removal .......... _ ............ " .. ........... .
Disassembly ............................. .
Cleaning. Inspection and Repair
Assembly ............................ ..
Installation ................ .
2.18 Front Brake
Caliper: FLSTS
Front Brake Caliper
Removal
Installation ....
Brake link Removal . .. ........... .
vI.
Removal ....
Installation .
2·33
2-33
2-33
2-35
2-35
2-37
2-37
2-37
2-39
2-40
2-40
2-42
2-42
2-42
2-44
2-44
2-45
2-46
2-46
2-46
2-46
2-46
2-46
2-46
2.19 Front Brake
Caliper: FXSTS
Removal ........ . .. ............. .
Installation .......... .
Disassembly .................. .
Cleaning and Inspeclion ... .
Assembly ......
2.20 Rear Brake Caliper ..... .
Removal ............................ .
Disassembly .......................................... , .. ,
Cleaning, Inspection and Repair ..
Assembly ................... , ........ _ ................. .
In stallati on ............ ... . ... .
2.21 Front Forks:
Page No.
2-49
2-49
2-50
2-51
2-51
2-52
2·53
2-53
2·53
2-55
2-55
2·56
All But FLSTS/FXSTS .... ... . ....... . . 2-57
2-57
2-57
2-57
2-57
2-60
2-60
General ........................ .
Removal .... _ ................ ..
Disassembly .....
Cleaning and Inspeclion ........................ .
Assembl y....... ............. ................ .
Installation ...... ..................................... .
2.22 Springer Fork:
FLSTS/FXSTS ...... ............. .
General ............. .
Handlebar and Ri sers.
Removal .................................................. .
Installation
Front Shock Absorber ........... .
Removal .... ..... ... .
Installation ...... , .. .
Rigid Fork ......... , ... ,...... .
Removal .................................... ..
Installation .. .
Spring Fork ............... ,... ,..... .
Disassembly ......... ..
Assembly
Fork Rockers ... . ... .
Removal ................. .
Installati on ........................................... .
Fork Slem Bearings.
Removal/Installation
2·61
2·61
2-61
2-61
2-61
2-63
2-63
2-63
2-64
2·64
2-64
2-65
2-65
2·67
2-69
2·69
2-69
2-70
2·70
Page No.
2.23 Steering Head ..... ......... .............. ...... .
RemovalJDisassembly . ............................................
FlST C, FLSTF Models ............. .. ... .. _ .. .
FXST, FXSTB Models .................... _ ..
FlSTS , FXSTS Models ...... ....... .... .
Cleaning and Inspection ............................................ .
All Models
Removing lower Bearings From Fork Stem
Steering Head Bearing Race Removal .. .... ..... .. .
Assembly ................................. .. ...... ...... ... .
Installation .......... ..... _... ... ..... .. ................. .
FlSTC, FLSTF Models ................... .
FXST, FXSTB Models ....................................... .
FlSTS, FXSTS Models .,.................................. .
2.24 Rear Fork
Removal ........... .... ...
Cleaning and Inspection _.................... .
In stallation .......... ..
2.25 Rear Shock Absorbers
General .. .. .......................... .. ........... .. .
Removal ................. .
Installation
2· 71
2-71
2-7 1
2-71
2-72
2·72
2-72
2 ·72
2· 73
2·73
2·74
2·74
2·74
2·74
2·75
2·75
2·75
2·76
2-77
2·77
2·77
2·77
2.26 Throttle ControL ........... ........ ......... 2·78
Remova UDisassembly.. . .................... __
Cleaning and In spection ....................... .. ..
Assembly/Installation.. ..... .................. ..
Cable Routing ...... . .. ........................ .
All Models Except FLSTS/FXSTS ..... .............. ..
FXSTS Models ....................... .
FLSTS Models .
2.27 Clutch Hand Control ......... .. .. . .
Removal ... .
Installation
2.28 Front Fender:
All But FLSTS/FXSTS ..
FXST, FXSTB Models
Removal
Installation .... ................................ .
FLSTC Models ..... ............................ .. ...... .
Removal ....... .
Installation .. ...... __ ................... ..
FLSTF Models ..... .................................. ......... ... .. . .
Removal .. ................ _ .......................... .......... . .
Installation ... .. ............... .. ......... ... .. .. .. .. .
2.29 Front Fender: FLSTS
Removal .......................... .. ......................................... .
Front Fender ... ... . .. . ... . .. ........ .
Front Fender Bearing Replacement ........... ...... ..
Installation .... . .. ... . .. ..... ........ ................ ..
2· 78
2-78
2-78
2-79
2-79
2-79
2-79
2-80
2-80
2-80
2- 81
2-81
2-81
2-81
2-8 1
2-81
2-81
2-81
2-81
2-81
2-82
2·82
2-82
2-82
2-83
Page No.
2.30 Front Fender: FXSTS ............... .
Removal .... ................................ .
Installation ........
2.31 Rear Fender ........ .
Removal ..................................................................... .
Installation .......................................... .
2.32 Belt Guardl
Debris Deflector ... ....... ... .
Removal .................. .. .................. .
Belt Guard .. ............................. .. ...................... .
Debris Deflector .................... .
Installation ......... .. . ..... ...................... .
Belt Guard . ... .
Debris Deflector .............. .. ..
2.33 Jiffy Stand ...... .. ....... .
Cleaning ..................................................................... .
Removal ................... .. . ... .............. .
Installation ............ ...... ... . .. .... .
2.34 Fork Lock
Removal ...... ............................................... ... .
Installation ...........
2.35 Seat/Strap Retention NuL . ...
Replacement.
2.36 Seat: FXST/FXSTB/FXSTS ...
Removal/Installation ........................... .
Seal Strap ... ............................ __ _
Seat ... .. . .. ............................ .
2.37 Seat: FLSTF/FLSTC ...... ... . ..... .
Removal/ In stallation ....... .
Seal .......... .. ..... ... .................... ... ...................... .
Sissy Bar: FLSTC Models .... .......................... .
2.38 Seat: FLSTS ...... .
Removal/Installati on ..................... .
2.39 Saddlebags: FLSTC
Removal ...... ........ ................................... .
Installation ..................... .. .................. .. ........... .
2.40 Saddlebags: FLSTS ..
Removal ... .. .. ..... .. . ... . .. .... . ... . .. .. ... ... . .. .
Installation .................................. .. . .. .
2.41 Windshie J d: FLSTC
Removal .. ..... ..
Installation ..................... .. ............... .
2-84
2-84
2-85
2-86
2-86
2-87
2-88
2-88
2-88
2-88
2-88
2-88
2·88
2-89
2·89
2-89
2·89
2-90
2-90
2-90
2-9 1
2-91
2-92
2-92
2-92
2-92
2-93
2-93
2-93
2-93
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2-94
2-95
2-95
2·95
2·96
2-96
2-96
2-97
2-97
2-97
vii.
Page No.
SECTION 3-ENGINE
3.1 Specifications
3.2 Torque Values ............... ....... ... ... .. .. . 3-3
3.3 Service Wear Limits
General ... ..... .. ....... . ... .
3.4 Engine Oil Flow
Oil Feed
Top En d
Bottom End .
Chain Guide Bracket .
Oil Return .. .... .. .. ................... .. _ __ __ .. ........... .. .
3.5 Oil Pump Operation ........ .
General .. .
Operation .. ............. ..... .. __ .............. .. . .. ..
3.6 Breather Operation
General ............. .. .. ... .
3.7 Oil Pressure .. .. .. .. . ... . .. .
Oil Pressure Indicator Lamp ..... .. .. .. .. .. . .. . ... .
Checki ng Oil Pressure
3.8 How To Use This Section
Top End Repair
Bottom End Repair
Typical Symptoms . .. ... .. .. . .. . .. ... ... .. . .. .... .... .
3.9 Top End Service
Engine In Chassis .. ... . ... . ..... . ... ....
Engine Removed From Chassis ... ... .. ... .. . .. .. .. .
3.10 Bottom End Service .. . ... . .. ..... .
Engine In Chassis: Cam Compartment Service
Engine Removed: Flywheel Compartment Service
or Complete Engine Overhaul ... ... .... ......... .
3.11 Troubleshooting
3-7
3-7
3-8
3·8
3-12
3-12
3-13
3-13
3-13
3-14
3~ 14
3-15
3-15
3-15
3-16
3-16
3-16
3-16
3-17
3-17
3-18
3-19
3-19
3-20
3-21
Diagnosing Valve Train Noise .............. 3-21
Compression Test ... .... .... .. .. ............. 3-21
Compression Test Results (table) 3-21
Cylinder leakage Test ... . ... . .. ... . .. .... . 3-22
Diagnosing Smoking Engine or High Oil Consumption 3-22
Check Prior To Cylinder Head Removal . 3-22
Check After Cylinder Head Removal ....... 3-22
viii.
Page No.
3.12 Stripping Motorcycle
For Service .. ....... . .. .
Procedure .. ............ . .. .
3.13 Assembling Motorcycle
After Service
Procedure ... ... ... ...... .. ............ .. ........................ ... ...... .
3.14 Removing Engine
From Chassis ..... . .. .. .. .
Procedure ..
3.15 Installing Engine
In Chassis ..... . .. . ... . .. .
Procedure ... .. .............. .................................. .. ........... .
3.16 Top End Overhaul:
Disassembly .
General ...... .... .. .... ... ... ...... ... .
Breather Assembly .. .... ... ... .. ......... ...
Rocker Arm Support Plate ... .... .. ........ .. .. ... .... .. .. .. .
Pushrods, lifters and Covers ... ... .... ...
Cylinder Head .... .. ............ .
Cylinder .... ... .. .... .
Piston . ........ .. ... .. .
3.17 Top End Overhaul:
Assembly . .. ...... . .. . .
General ............. .. ..... ..... .
Piston ..... ............................ .... ... ........ .. ..... .. .. .. .. .. .
Cylinder .. ... . .. .. .. .... .. ..... .... ...... ....... ........... ....... .
Cylinder Head . . .. .. . .. .. ... .. .. ... ............ .. ... ... ... ... ....
Pushrods , lifters and Covers
Rocker Arm Support Plate .
Breather Assembly .
3.18 Bottom End Overhaul:
Disassembly
General ..................
Cover and Support Plate
Crankcase .. . .. . ... . ............. ......... .. .. .. .. ........................
Counterbalancer Assembly.
3.19 Bottom End Overhaul:
Assembly
Counterbalancer Assembly .
Balance Sprocket Spacers (table)
Crankcase .. ... . ... . ... . ... . ..... .. . .. . .. .
Cover and Support Plate .................. .. .
Rear Cam Sprocket Spacers (table)
3- 23
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3-24
3-24
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3-56
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Upon purchasing this manual, you will receive a .PDF file containing an email address for further assistance. After contacting the provided email, you will receive a reply with a link to access the manual for your 2000 Harley Davidson FXSTD Softail Deuce.
This comprehensive manual covers every aspect of your machine, providing detailed guidance on every nut and bolt. With its extensive content spanning hundreds of pages, it equips you to address various issues, from routine maintenance like oil changes to more complex tasks such as transmission swaps. The manual includes numerous illustrations to assist you in your work, accompanied by easily understandable text.
Utilize the search function to navigate the manual efficiently and print the necessary pages as needed. This Factory Service Repair Manual serves as a thorough resource, guiding you through the fundamentals of maintenance and repair in a step-by-step manner, imparting the expertise known to factory-trained technicians.
By leveraging the knowledge within this service repair manual, any owner can confidently make informed decisions regarding the maintenance and repair of their machine.
Our commitment extends beyond providing a high-quality service manual; we also ensure excellent customer service, guaranteeing your satisfaction.
