Model Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Product Name:
Harley Davidson Dyna 1999-2005 Service Repair Workshop Manual
Segment:
Cruiser motorcycle segment, known for its V-twin engine and classic styling.
Key Competitors:
Competed with other V-twin cruisers from brands like Indian Motorcycles, Victory Motorcycles (though Victory launched later), and custom builders.
Drivetrain:
Harley-Davidson's signature Evolution (Evo) V-twin engine, known for its torque and distinctive sound.
Design Philosophy:
Emphasis on classic American motorcycle design, customization potential, and a riding experience focused on feel and sound.
Target Audience:
Owners, mechanics, and enthusiasts seeking to perform maintenance, repairs, and customization on their 1999-2005 Harley-Davidson Dyna models.
Engine Service:
Engine overhaul, tuning, component replacement, lubrication system, cooling system (air-cooled specific).
Transmission Service:
Gearbox inspection, repair, clutch assembly, final drive maintenance.
Electrical System:
Wiring diagrams, ignition system, lighting, charging system, battery service, starter motor, accessory installation.
Fuel System:
Carburetor (CV) service and tuning, fuel injection (EFI) diagnostics and component replacement, fuel pump, fuel lines, tank maintenance.
Brakes:
Brake system inspection, hydraulic component service (master cylinders, calipers, lines), pad replacement, bleeding procedures.
Suspension And Steering:
Front fork service (oil changes, seal replacement), rear shock absorber adjustment and replacement, steering head bearing maintenance.
Chassis And Frame:
Frame inspection, component mounting, bodywork removal and installation, seat maintenance.
Routine Maintenance:
Oil changes, filter replacements, spark plug servicing, chain adjustment (if applicable to specific models), battery care.
Troubleshooting:
Diagnostic charts, symptom analysis, common problem identification and solutions.
Repair And Rebuild:
Step-by-step instructions for component disassembly, repair, reassembly, and adjustment.
Diagnostic Procedures:
Techniques for identifying and resolving mechanical and electrical issues.
Depth:
Comprehensive, covering both basic servicing and in-depth mechanical and electrical repairs.
Engine Type:
Air-cooled, 45-degree V-twin Evolution engine.
Displacement Variants:
Primarily 88 cubic inch (1442cc) Twin Cam 88, with earlier models potentially featuring the Evolution Big Twin (though Twin Cam 88 became standard for Dyna in this period).
Bore X Stroke:
For Twin Cam 88: 3.75 in x 4.00 in (95.25 mm x 101.6 mm).
Compression Ratio:
Typically 8.8:1 to 9.0:1 depending on specific sub-model and tuning.
Horsepower:
Approx. 60-70 HP (Varies by specific year and model, actual figures may be higher in some configurations).
Torque:
Approx. 70-80 ft-lbs (Varies by specific year and model).
Fuel Delivery:
Carburetor (Keihin CV) for most models, with some later models offering Electronic Fuel Injection (EFI).
Carburetor Model:
Keihin CV (Constant Velocity) carburetor.
Oil Type Specification:
Harley-Davidson recommended V-Twin oil (e.g., SAE 20W-50 or similar motorcycle-specific lubricant).
Valve Train:
Overhead valve (OHV), two valves per cylinder, pushrod actuated.
Type:
5-speed constant mesh manual transmission.
Options:
N/A (5-speed was standard for the Dyna platform in this era).
Clutch Type:
Wet, multi-plate clutch.
Transmission Oil Type:
Harley-Davidson Transmission Oil (e.g., SAE 80W-90 hypoid gear oil, or specific Harley-Davidson synthetic blend).
Wheelbase:
Approx. 64.2 inches (1630 mm) - Varies slightly by specific Dyna model (e.g., Super Glide, Low Rider, Wide Glide).
Seat Height:
Approx. 26.5 - 27.5 inches (673 - 698 mm) (Unladen, varies by model).
Dry Weight:
Approx. 590 - 640 lbs (268 - 290 kg) (Varies by specific model).
Gross Vehicle Weight Rating Gvwr:
Typically around 900-1000 lbs (408-453 kg), consult specific model for exact figures.
Crash Test Data:
Motorcycles of this era were not subject to the same standardized crash testing as automobiles; safety is primarily inherent design and rider responsibility.
Braking System:
Dual-piston caliper front and rear brakes, hydraulic actuation.
Lighting:
Halogen headlamp, taillight, stoplight, turn signals.
Frame Construction:
Steel, tubular frame for rigidity and rider safety.
Standard Features:
Minimal by modern standards. Primarily mechanical gauges (speedometer, tachometer on some models), odometer, trip meter.
Features:
N/A - No electronic rider aids beyond basic braking and lighting.
Features:
N/A - No Bluetooth or smartphone integration.
Efi Systems:
If equipped with EFI, the manual will cover diagnostic codes and basic system checks, likely using Harley-Davidson's diagnostic tools (e.g., Digital Technician).
Engine Oil And Filter Change:
Typically every 2,500 to 5,000 miles or annually, whichever comes first. Consult the manual for exact intervals based on operating conditions.
Primary Chain Tensioner Inspection:
Regular inspection (e.g., every 5,000-10,000 miles) is critical for Twin Cam 88 engines due to potential wear. Manual will detail procedure.
Spark Plug Replacement:
Recommended every 10,000 to 15,000 miles, depending on plug type.
Engine Oil Capacity:
Approx. 3.0 - 4.0 quarts (2.8 - 3.8 liters) depending on filter change. Specific value required from manual.
Transmission Oil Capacity:
Approx. 1.0 - 1.2 quarts (0.95 - 1.14 liters).
Primary Chain Case Oil Capacity:
Approx. 1.0 quart (0.95 liters). Often shared with the transmission in older models, but separated in Twin Cam.
Primary Chain Tensioner Wear:
Hydraulic tensioner shoe wear on early Twin Cam 88 engines is a well-documented issue. The manual will detail inspection and potential upgrades (e.g., upgraded tensioners or conversion kits).
Cam Chain Tensioner Upgrade:
The manual will likely reference the recommended upgrade to a hydraulic tensioner system or conversion to a sealed bearing cam chain tensioner to prevent premature failure.
Carburetor Tuning:
Keihin CV carburetors may require periodic adjustment for optimal performance and idle quality, especially with altitude or temperature changes.
Exhaust Leaks:
Potential for exhaust header pipe leaks at the cylinder head; manual will cover proper sealing and torque procedures.
Foundation:
Harley-Davidson Motor Company, founded in 1903, is an iconic American motorcycle manufacturer.
Dyna Introduction:
The Dyna line was introduced in 1991, initially featuring Evolution Big Twin engines before transitioning to the Twin Cam 88 platform in late 1998/early 1999.
Twin Cam 88 Introduction:
The Twin Cam 88 engine, introduced for the 1999 model year, was a significant update designed to meet emissions standards and offer improved performance over the Evolution Big Twin.
Manufacturing Location:
Primarily assembled in the United States (e.g., York, Pennsylvania; Milwaukee, Wisconsin).
Dynas Legacy:
The Dyna platform was produced until 2017, when it was replaced by the Softail platform, with the Milwaukee-Eight engine.
