Target Audience:
Harley-Davidson Dyna owners, independent repair shops, motorcycle technicians.
Value Proposition:
Provides essential knowledge for maintaining and repairing the 2004 Harley-Davidson Dyna, offering significant cost savings compared to dealership service. Replaces worn-out paper manuals with a convenient, searchable digital format.
Convenience:
Digital PDF format allows for easy access, searchability, and printing on demand.
Comprehensiveness:
Covers all essential aspects of maintenance, repair, and troubleshooting for the 2004 Dyna models.
Engine:
V-Twin Evolution Engine (1450cc / 88ci)
Engine Systems:
Engine assembly, disassembly, lubrication, cooling system, fuel system (carburetor and fuel injection variants), ignition system, exhaust system, starting system, charging system.
Transmission:
5-Speed Manual Transmission
Drivetrain:
Primary drive, clutch, secondary drive (belt drive), final drive assembly.
Chassis And Suspension:
Frame, front fork assembly, rear shock absorbers, swingarm, wheel bearings, steering system.
Brakes:
Front and rear hydraulic disc brakes, brake system components, bleeding procedures, master cylinder, calipers, pads.
Electrical System:
Wiring diagrams, lighting system, battery, charging system (alternator, regulator), ignition system components, starter motor, switches, indicators, horn, security system (if equipped).
Body And Accessories:
Fenders, fuel tank, seat, handlebars, controls, footpegs, saddlebags, fairings (if equipped), instrumentation, mirrors.
Maintenance:
Routine maintenance checks, oil changes, filter replacements, spark plug replacement, chain adjustment, brake fluid checks, battery maintenance, lubrication points.
Troubleshooting:
Diagnostic procedures for common issues, symptom-based troubleshooting guides, electrical system diagnostics, engine performance problems.
Repair:
Step-by-step repair instructions for all major mechanical and electrical components, including engine rebuilds, transmission overhauls, suspension repairs, brake system overhauls, and electrical component replacement.
Special Tools:
Identification and usage of specialized Harley-Davidson tools required for specific repair and maintenance procedures.
Scope:
Comprehensive coverage from basic owner maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics.
Engine Type:
Air-cooled, Evolution V-Twin
Displacement:
1450 cc (88 cubic inches)
Bore X Stroke:
3.497 in. x 3.812 in. (88.83 mm x 96.83 mm)
Compression Ratio:
8.8:1 (typical)
Horsepower:
Approx. 65-70 HP (at crankshaft, model dependent)
Torque:
Approx. 70-75 ft-lbs (at crankshaft, model dependent)
Fuel Delivery:
Keihin CV carburetor (most models) or Electronic Sequential Port Fuel Injection (ESPFI) for California models and some international markets.
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended.
Oil Capacity:
Approx. 3.5 US quarts (3.3 liters) with filter change.
Oil Type:
Harley-Davidson Genuine V-Twin Oil 20W-50 or equivalent API SG classification or higher.
Transmission Type:
5-speed constant mesh, manual
Gear Ratios:
1st: 10.110, 2nd: 6.857, 3rd: 4.830, 4th: 3.823, 5th: 3.254 (typical)
Primary Drive:
Duplex chain, 34/46 tooth sprockets
Secondary Drive:
Belt drive, 32/65 tooth sprockets (7000 series belt)
Clutch Type:
Wet, multi-plate, diaphragm spring
Transmission Fluid Type:
Harley-Davidson Genuine Formula+ Transmission and Primary Chain Case Oil or equivalent SAE 50.
Transmission Fluid Capacity:
Approx. 24 US fluid ounces (0.7 liters)
Overall Length:
Approx. 88.2 inches (2240 mm)
Overall Width:
Approx. 35.0 inches (889 mm) (handlebars)
Overall Height:
Approx. 46.5 inches (1181 mm)
Seat Height Laden:
Approx. 25.2 inches (640 mm)
Ground Clearance:
Approx. 4.5 inches (114 mm)
Dry Weight:
Approx. 575 lbs (261 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 970 lbs (440 kg)
Payload Capacity:
Approx. 395 lbs (179 kg)
Saddlebag Capacity:
Varies by model and configuration; typically soft or hard saddlebags are available.
Crash Test Results:
Motorcycles are not subjected to standardized crash testing in the same manner as passenger vehicles.
Brakes:
Dual disc front brakes, single disc rear brake with hydraulic actuation.
Lighting:
Headlight, taillight, brake light, turn signals.
Frame Construction:
Steel cradle frame designed for stability.
Ignition Cutoff:
Sidestand switch that cuts ignition if bike is in gear and sidestand is down (on some models).
Audio System:
Optional accessory audio systems were available, typically AM/FM radio with cassette or CD player, often handlebar-mounted.
Instrumentation:
Analog speedometer, tachometer (optional on some models), fuel gauge, oil pressure light, neutral indicator, turn signal indicators, and warning lamps.
Cruise Control:
Available as an optional accessory on many 2004 Dyna models.
Diagnostics:
Onboard diagnostics (OBD-II compliant for fuel-injected models) accessible via a diagnostic port, requiring specialized Harley-Davidson diagnostic tools.
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, whichever comes first. Specific items may have shorter intervals (e.g., brake fluid flush).
Engine Oil:
Harley-Davidson Genuine V-Twin Oil 20W-50 or SAE 20W-50 API SG, Jaso MA or MA2.
Transmission Primary Fluid:
Harley-Davidson Genuine Formula+ Transmission and Primary Chain Case Oil or SAE 50 motorcycle oil.
Brake Fluid:
DOT 4 Hydraulic Fluid.
Fork Oil:
Refer to manual for specific weight, typically a light-weight fork oil (e.g., 5W or 10W).
Cam Chain Tensioners:
Early Twin Cam engines (pre-2007) had composite cam chain tensioners that could wear out and cause engine noise or damage. Later models (post-2006) use hydraulic tensioners.
Carburetor Tuning:
CV carburetors can require periodic adjustment or cleaning for optimal performance, especially with aftermarket modifications.
Belt Drive Tension:
Maintaining correct belt tension is crucial to prevent premature wear on the belt and pulley bearings.
Electrical Connections:
Corrosion or loose connections in the electrical system can lead to intermittent faults or system failures.
Brand Origin:
Harley-Davidson Motor Company, founded in 1903 in Milwaukee, Wisconsin.
Core Philosophy:
Iconic American motorcycle manufacturer known for its V-twin engines, custom styling, and rider community.
Dyna Lineage:
The Dyna line, introduced in 1991, utilized a new frame with a rubber-mounted powertrain, offering improved vibration isolation compared to earlier rigid-mount Big Twin models.
2004 Updates:
The 2004 model year saw the continuation of the 1450cc Evolution engine and refinements to various components, maintaining the Dyna's reputation for customizable cruiser performance.
Production Location:
United States (Milwaukee, Wisconsin and other facilities).
