Engine:
Twin Cam 88 (1450cc) V-Twin engine overhaul, diagnostics, performance tuning, lubrication system, cooling system (air-cooled), oil pump, oil filter, oil cooler integration.
Transmission:
5-speed constant mesh transmission (Traxion system), clutch operation, primary drive, gearbox disassembly and reassembly, lubrication, troubleshooting.
Electrical System:
Wiring diagrams, battery, starter motor, charging system (alternator), ignition system (electronic), lighting (headlight, taillight, signals), instrumentation, fuses, relays, diagnostics of electrical faults.
Fuel System:
Carburetor (Keihin CV 40mm typical) overhaul, jetting, adjustment, fuel pump, fuel lines, fuel tank, emissions controls.
Brakes:
Front and rear disc brakes, brake calipers, master cylinders, brake lines, brake fluid specifications, bleeding procedures, ABS system (if equipped, though less common on base FXD models of this era), pad replacement.
Suspension:
Front fork (Telescopic) overhaul, fork oil specifications, seals, rear shock absorbers, swingarm, bearings, alignment.
Chassis And Frame:
Frame inspection, steering head bearings, wheel bearings, pivot bearings, general chassis integrity, torque specifications for critical fasteners.
Bodywork And Trim:
Fenders, fuel tank removal and installation, seat, handlebars, controls, fairings (if applicable), trim pieces, paint repair guidance.
Maintenance:
Oil changes, filter replacements, spark plug replacement, air filter cleaning/replacement, belt tension adjustment, chain lubrication/adjustment (if applicable, though this model typically uses a belt), brake system maintenance, fork oil changes, battery care.
Repair:
Engine top-end rebuild, transmission rebuild, carburetor overhaul, brake system component replacement, suspension component replacement, electrical component diagnosis and replacement, clutch adjustment and replacement.
Troubleshooting:
Systematic diagnostic procedures for engine performance issues, starting problems, electrical gremlins, braking system faults, and chassis handling issues. Includes symptom-based troubleshooting charts.
Diagnostics:
Detailed diagnostic steps for identifying the root cause of malfunctions across all major vehicle systems, often referencing specific tools or tests.
Depth:
Comprehensive: Covers everything from basic scheduled maintenance and routine checks to complete engine and transmission rebuilds, advanced electrical troubleshooting, and chassis component overhauls.
Detail Level:
Factory-level detail, including torque specifications, clearances, component part numbers (for reference), and procedural flowcharts.
Engine Type:
Air-cooled, Twin Cam 88 V-Twin
Displacement:
1450 cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Compression Ratio:
8.8:1 (typical)
Valve Train:
Overhead valves (OHV), 2 valves per cylinder
Fueling:
Carbureted (Keihin CV 40mm)
Ignition:
Electronic ignition
Horsepower:
Approx. 65-70 HP (at crank, varies with tuning)
Torque:
Approx. 75-80 ft-lbs (at crank, varies with tuning)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Fuel Capacity:
4.8 U.S. gallons (18.2 L)
First Service:
1,000 miles (1,600 km) or 6 months (whichever comes first) for initial break-in service (oil change, filter, primary fluid check, primary chain adjustment, spark plug check).
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months for routine maintenance (oil change, filter, primary fluid check/change, belt check, brake checks).
Major Service:
Refer to manual for specific intervals on transmission fluid, brake fluid flush, spark plug replacement, and other major component checks/replacements.
Engine Oil:
Harley-Davidson Genuine V-Twin 20W-50, or Harley-Davidson Syn3 SAE 20W-50 Synthetic Motorcycle Oil.
Primary Chain Case Fluid:
Harley-Davidson Genuine Formula+ (or equivalent primary lubricant)
Transmission Fluid:
Harley-Davidson Genuine Formula+ (or equivalent transmission lubricant, often shared with primary)
Brake Fluid:
DOT 4 brake fluid (for clutch and brake systems, check manual for specific type)
Fork Oil:
Harley-Davidson Screamin' Eagle Type E Fork Oil (or equivalent, typically 10W or 15W)
Common Issues:
Primary chain tensioner wear (early models), cam chain tensioner wear (Twin Cam specific), oil leaks (from various seals), exhaust leaks, potential carburetor tuning issues, charging system issues (stator/regulator).
Troubleshooting Focus:
Manual provides detailed guidance on diagnosing and rectifying common issues such as starting problems, misfires, rough idling, and electrical system faults.
Heritage:
Harley-Davidson, founded in 1903, boasts a long and storied history in motorcycle manufacturing, synonymous with American culture and freedom.
Evolution:
The Dyna platform, introduced in 1991, evolved through various iterations. The 2005 model features the Twin Cam 88 engine, a significant upgrade from earlier Evo engines, offering improved torque and reliability.
Production Period:
The Dyna line, including the Super Glide, was produced from 1991 to 2017 before being replaced by the Softail platform.