The 2004 Harley Davidson FLSTFI Fat Boy ST EFI service repair workshop manual provides complete technical coverage of this iconic American cruiser. With 1068 pages, every procedure from basic oil changes through complete engine rebuilds is documented. The Delphi electronic fuel injection system, a significant upgrade for Harley-Davidson that year, receives thorough diagnostic treatment alongside the proven Twin Cam 88B engine and 5-speed transmission. Torque specifications, clearances, and adjustment values are provided throughout for professional-level service.
Harley Davidson FLSTFI Fat Boy ST EFI Service Repair Workshop Manual (2004)
VEHICLE/EQUIPMENT INTRODUCTION:
The 2004 Harley Davidson FLSTFI Fat Boy ST EFI represents one of the most visually striking and culturally significant motorcycles ever produced in the United States. The Fat Boy nameplate carried enormous brand recognition thanks to its massive solid-disc cast aluminum wheels, wide 200-series rear tire, and the unmistakable full-coverage fenders that gave the bike its commanding visual presence. The ST designation stood for Softail Tail section indicating the unique rear styling elements.
The introduction of Electronic Fuel Injection marked a pivotal moment for Harley-Davidson engineering. The 2004 FLSTFI replaced the traditional carburetor with a Delphi sequential port electronic fuel injection system mounted on the legendary 88 cubic inch 1450cc Evolution V-twin motor. EFI brought easier cold starts, smoother throttle response, better altitude compensation, and improved emissions without sacrificing the character and torque delivery Harley riders expected.
Beneath its bold exterior the Fat Boy used Harleys Softail frame design which concealed the rear suspension within the chassis tubes creating the illusion of a classic hardtail while providing actual ride compliance. The 5-speed transmission drove the rear wheel through a reinforced belt drive system. Every component of this motorcycle was designed to deliver comfort and style on long interstate journeys while maintaining an unmistakable American identity.
SERVICE & REPAIR SCOPE:
- Twin Cam 88B engine top-end service and bottom-end rebuild
- Delphi electronic fuel injection system diagnostics and injector service
- Throttle body sensor TPS calibration and IAC valve service
- 5-speed transmission bearing seal and gear inspection
- Primary chaincase inspection belt tension and clutch service
- Softail rear shock replacement and swing arm bolt torque
- Front fork seal oil replacement and damper cartridge inspection
- Brake system master cylinder caliper rebuild and pad replacement
- Complete electrical system including ignition module diagnostics
- Charging system stator voltage regulator diagnostics
- Exhaust system mounting gasket replacement
- Steering head bearing adjustment and replacement
TECHNICAL SPECIFICATIONS:
- Engine: Twin Cam 88B, 1450cc, air-cooled V-twin, 45-degree
- Fuel System: Delphi electronic fuel injection
- Transmission: 5-speed cruise drive with belt final drive
- Frame: Softail rigid-mount with concealed rear suspension
- Front Fork: 49mm telescopic
- Tire Size: Front 100/90-19, Rear 200/55-R16
- Wheelbase: 1715 mm
- Seat Height: 665 mm
DIAGNOSTIC INFORMATION:
- Delphi EFI diagnostic trouble code retrieval procedure
- TPS voltage range adjustment specifications
- Fuel pressure testing and regulator check
- Ignition control module spark output testing
- Voltage regulator charging output verification
- Compression test specifications and acceptable ranges
- Crankshaft position sensor gap and resistance specs
ILLUSTRATIONS & DIAGRAMS INCLUDED:
- Complete electrical wiring diagrams with connector locations
- Engine exploded views for Twin Cam 88B motor
- Transmission and primary drive assembly illustrations
- Frame and suspension mounting diagrams
- Fuel injection system component layout
COMPATIBILITY:
- 2004 Harley Davidson FLSTFI Fat Boy ST EFI only
- Covers all factory systems and components as equipped
FILE PROPERTIES:
- Format: Searchable PDF
- Language: English
- Delivery: Instant digital download
- Access: Download anytime after purchase
Harley Davidson FLSTFI Fat Boy ST EFI Service Repair Workshop Manual (2004)
VEHICLE/EQUIPMENT INTRODUCTION:
The 2004 Harley Davidson FLSTFI Fat Boy ST EFI represents one of the most visually striking and culturally significant motorcycles ever produced in the United States. The Fat Boy nameplate carried enormous brand recognition thanks to its massive solid-disc cast aluminum wheels, wide 200-series rear tire, and the unmistakable full-coverage fenders that gave the bike its commanding visual presence. The ST designation stood for Softail Tail section indicating the unique rear styling elements.
The introduction of Electronic Fuel Injection marked a pivotal moment for Harley-Davidson engineering. The 2004 FLSTFI replaced the traditional carburetor with a Delphi sequential port electronic fuel injection system mounted on the legendary 88 cubic inch 1450cc Evolution V-twin motor. EFI brought easier cold starts, smoother throttle response, better altitude compensation, and improved emissions without sacrificing the character and torque delivery Harley riders expected.
Beneath its bold exterior the Fat Boy used Harleys Softail frame design which concealed the rear suspension within the chassis tubes creating the illusion of a classic hardtail while providing actual ride compliance. The 5-speed transmission drove the rear wheel through a reinforced belt drive system. Every component of this motorcycle was designed to deliver comfort and style on long interstate journeys while maintaining an unmistakable American identity.
SERVICE & REPAIR SCOPE:
- Twin Cam 88B engine top-end service and bottom-end rebuild
- Delphi electronic fuel injection system diagnostics and injector service
- Throttle body sensor TPS calibration and IAC valve service
- 5-speed transmission bearing seal and gear inspection
- Primary chaincase inspection belt tension and clutch service
- Softail rear shock replacement and swing arm bolt torque
- Front fork seal oil replacement and damper cartridge inspection
- Brake system master cylinder caliper rebuild and pad replacement
- Complete electrical system including ignition module diagnostics
- Charging system stator voltage regulator diagnostics
- Exhaust system mounting gasket replacement
- Steering head bearing adjustment and replacement
TECHNICAL SPECIFICATIONS:
- Engine: Twin Cam 88B, 1450cc, air-cooled V-twin, 45-degree
- Fuel System: Delphi electronic fuel injection
- Transmission: 5-speed cruise drive with belt final drive
- Frame: Softail rigid-mount with concealed rear suspension
- Front Fork: 49mm telescopic
- Tire Size: Front 100/90-19, Rear 200/55-R16
- Wheelbase: 1715 mm
- Seat Height: 665 mm
DIAGNOSTIC INFORMATION:
- Delphi EFI diagnostic trouble code retrieval procedure
- TPS voltage range adjustment specifications
- Fuel pressure testing and regulator check
- Ignition control module spark output testing
- Voltage regulator charging output verification
- Compression test specifications and acceptable ranges
- Crankshaft position sensor gap and resistance specs
ILLUSTRATIONS & DIAGRAMS INCLUDED:
- Complete electrical wiring diagrams with connector locations
- Engine exploded views for Twin Cam 88B motor
- Transmission and primary drive assembly illustrations
- Frame and suspension mounting diagrams
- Fuel injection system component layout
COMPATIBILITY:
- 2004 Harley Davidson FLSTFI Fat Boy ST EFI only
- Covers all factory systems and components as equipped
FILE PROPERTIES:
- Format: Searchable PDF
- Language: English
- Delivery: Instant digital download
- Access: Download anytime after purchase
