Target Audience:
Harley-Davidson owners, independent repair shops, and motorcycle technicians specializing in Harley-Davidson motorcycles.
Value Proposition:
Provides the definitive guide for maintaining and repairing the 2003 FXD Dyna Super Glide, enabling cost-effective ownership and ensuring optimal performance and longevity.
Uniqueness:
This manual offers the most comprehensive and detailed factory-level information available for this specific model year and variant.
Illustration Quality:
Features exploded diagrams, step-by-step photos, and detailed schematics to clarify complex procedures.
Organizational Structure:
Systematic organization by major vehicle components and systems, with clear chapter divisions and index for easy navigation.
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly procedures for the Twin Cam 88 engine.
Fuel System:
Carburetor (Keihin CV) tuning, cleaning, overhaul, and fuel injection system components and diagnostics (if applicable to specific sub-models).
Ignition System:
Ignition module, spark plugs, ignition coils, timing procedures, and troubleshooting.
Transmission:
5-speed Cruise Drive transmission disassembly, assembly, clutch service, primary drive inspection, and gear oil specifications.
Electrical System:
Wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter, battery), lighting, indicators, and accessory circuits.
Suspension:
Front fork (Telescopic) overhaul, oil replacement, seal replacement, rear shock absorber inspection and replacement.
Brakes:
Front and rear brake caliper service, brake pad replacement, master cylinder overhaul, brake fluid flush and bleed procedures, hydraulic system troubleshooting.
Frame And Bodywork:
Frame inspection, body panel removal and installation, fenders, fuel tank mounting, seat assembly, and hardware specifications.
Wheels And Tires:
Wheel bearing inspection and replacement, tire mounting and balancing, spoke tensioning (if applicable), and recommended tire pressures.
Exhaust System:
Inspection, removal, and installation of the exhaust system components, including mufflers, headpipes, and heat shields. Torque specifications for exhaust mounting hardware.
Cooling System:
Air-cooled engine. Manual covers management of heat dissipation through airflow and proper engine operation.
Routine Maintenance:
Oil changes, filter replacement, spark plug service, chain/belt adjustment (if applicable), lubrication points, and inspection checklists.
Troubleshooting Guides:
Diagnostic flowcharts and symptom-based troubleshooting for common mechanical and electrical issues.
Component Rebuilds:
Detailed steps for rebuilding carburetors, brake calipers, master cylinders, and transmission components.
Diagnostic Procedures:
Methods for diagnosing ignition, fuel delivery, charging, and starting system faults.
Torque Specifications:
Comprehensive list of torque values for all critical fasteners across various systems.
Component Replacement:
Detailed instructions for replacing common wear items such as brake pads, clutch plates, spark plugs, air filter, and wheel bearings.
Wiring Diagram Analysis:
Comprehensive, clear wiring diagrams with component identification and circuit tracing for electrical troubleshooting.
Diagnostic Capabilities:
Advanced diagnostic procedures, including fault code interpretation (if applicable to the diagnostic system) and component testing.
Rebuild Scope:
Full engine, transmission, and major component rebuilds with detailed illustrations and part clearances.
Special Tools:
Identification and usage instructions for specialized Harley-Davidson tools required for specific repair procedures.
Diagnostic Tools Required:
Specifies standard hand tools, torque wrenches, electrical testers (multimeter), and potentially Harley-Davidson specific diagnostic tools or software interfaces if applicable.
Scope:
Covers all aspects of service, maintenance, repair, and troubleshooting from routine checks to full engine and transmission overhauls.
Engine Type:
Harley-Davidson Twin Cam 88
Engine Configuration:
45-degree V-twin, pushrod-actuated overhead valves
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Horsepower Rating:
Approx. 60-65 HP (Varies slightly by tuning and exhaust)
Torque Rating:
Approx. 75-80 lb-ft @ 3500 RPM (Varies slightly)
Fuel Delivery:
Keihin CV (Constant Velocity) Carburetor, 40mm
Fuel Type:
Unleaded gasoline, minimum 87 octane
Engine Oil Capacity:
3.0 US qt (2.8 L) with filter change
Primary Chain Case Oil Capacity:
1.0 US qt (0.95 L)
Engine Oil Recommendation:
Harley-Davidson SYN3 Synthetic Motorcycle Oil or equivalent API SG/SH/SJ certified oil with a viscosity of 20W50 (check manual for specific climate recommendations).
Primary Chain Case Oil Recommendation:
Harley-Davidson Formula+ Transmission and Primary Chaincase Lubricant or equivalent API GL-4 certified gear oil.
First Service:
1,000 miles (1,600 km) or 6 months, whichever comes first.
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months thereafter for routine checks and fluid changes. Engine oil changes recommended every 2,500 miles (4,000 km) in severe service or if not using synthetic oil.
Brake Fluid Flush:
Recommended every 2 years or as needed, based on inspection for moisture contamination.
Brake Fluid Type:
DOT 4 brake fluid
Fork Oil Type:
Harley-Davidson Suspension Oil (e.g., 10W or 15W, check manual for specific recommendations based on rider preference and conditions).
Transmission Oil Capacity:
0.95 L (1.0 US qt) for the transmission section of the primary drive case.
Common Wear Items:
Clutch wear, brake pad wear, wheel bearings, fork seals, and drive belt inspection/replacement.
Potential Concerns:
Potential for oil leaks from engine seals, carburetor tuning sensitivity, and charging system component longevity. Addressing these is a key benefit of this manual.
