Target Audience:
Harley-Davidson owners seeking to perform their own maintenance and repairs, independent repair shops.
Competitors:
Other V-twin cruiser manufacturers (e.g., Indian, Japanese cruisers).
Design Philosophy:
Classic cruiser styling with custom touches, robust V-twin engine, rider comfort.
Custom Elements:
Chrome accents, custom paint options, sculpted fuel tank, often custom handlebars and seat.
Engine:
Engine assembly, disassembly, inspection, tuning, troubleshooting, cooling system (air-cooled specifics), lubrication system.
Fuel System:
Carburetor (Keihin CV 40mm) service, fuel pump, fuel lines, fuel tank, fuel filter replacement.
Ignition System:
Ignition module, spark plugs, ignition coils, troubleshooting ignition faults.
Transmission:
5-speed Cruise Drive transmission service, clutch operation and adjustment, gear inspection, shift mechanism.
Drivetrain:
Primary drive system, final belt drive maintenance, belt tension adjustment, sprocket inspection.
Brakes:
Front and rear brake systems, caliper service, brake pad replacement, brake fluid flush and bleeding, master cylinder service.
Suspension:
Front fork service (dismount, seal replacement, fluid level), rear shock absorber adjustment and replacement.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting system, horn, instrumentation.
Chassis And Frame:
Frame inspection, steering head bearing service, wheel bearing replacement, swingarm maintenance.
Bodywork And Trim:
Fender removal/installation, fuel tank mounting, seat service, handlebar replacement, control cable adjustment.
Exhaust System:
Exhaust pipe and muffler service, gasket replacement, mounting hardware.
Maintenance:
Routine maintenance checks, oil changes, filter replacements, lubrication points, seasonal storage procedures.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems across all major vehicle systems.
Repair:
Detailed step-by-step instructions for disassembly, component repair, and reassembly of all major systems.
Wiring Diagrams:
Comprehensive electrical system wiring schematics for easy fault diagnosis.
Specifications:
Torque specifications for all fasteners, fluid capacities, tolerances, and critical measurements.
Depth:
Comprehensive coverage from basic scheduled maintenance to complete engine and transmission overhauls, including diagnostic procedures.
Digital Format:
PDF (if digital). Searchable text and printable pages expected.
Print Quality:
High-resolution images, clear text, and diagrams suitable for workshop use.
Binding:
Spiral or perfect bound (if printed), designed for lay-flat use in a workshop environment.
Paper Type:
Durable, high-quality paper resistant to grease and workshop grime (if printed).
Engine Family:
Evolution (or 'Evo')
Engine Type:
Air-cooled, 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:
Approximately 65-70 HP (estimated at crankshaft)
Torque:
Approximately 86 ft-lbs @ 3200 RPM (estimated at crankshaft)
Carburetor:
Keihin CV 40mm, constant velocity carburetor
Fuel Type:
Unleaded gasoline, minimum 87 octane
Oil Capacity:
3.5 US quarts (3.3 liters) with filter change
Oil Type:
Harley-Davidson recommended V-Twin specific motorcycle oil (e.g., SAE 20W-50)
Type:
5-speed Cruise Drive constant mesh transmission
Clutch Type:
Wet, multi-plate, diaphragm spring
Gear Ratios:
Gear ratios are specific to the 5-speed Cruise Drive and detailed within the manual.
Transmission Oil Type:
Harley-Davidson transmission lubricant (Formula+, or equivalent GL-4 rated gear oil).
Length:
Approximately 93.1 inches (2365 mm)
Width:
Approximately 37.4 inches (950 mm) at handlebars
Height:
Approximately 50.0 inches (1270 mm) at windshield
Dry Weight:
Approximately 635 lbs (288 kg)
Gross Vehicle Weight Rating:
Approximately 1050 lbs (476 kg)
Front Tire Size:
100/90-19 57H
Rear Tire Size:
160/70-17 73V
Wheelbase:
63.5 inches (1613 mm)
Ground Clearance:
4.5 inches (114 mm)
Fuel Tank Capacity:
5.0 US gallons (18.9 liters)
Crash Test Ratings:
Not applicable to motorcycles in the same manner as automobiles. Focus is on design and handling safety.
Braking System:
Dual-piston front caliper, single-piston rear caliper, front and rear disc brakes.
Lighting:
Halogen headlight, LED tail light, standard turn signals.
Operator Interface:
Handlebar-mounted controls, intuitive rider interface.
Oil Change Interval:
Every 2,500 miles or 4 months, whichever comes first (typical for this era, refer to manual for exact)
Primary Chain Tensioner Inspection:
Inspect at 5,000-10,000 mile intervals (critical for Twin Cam engines).
Spark Plug Replacement:
Every 10,000-15,000 miles (typical)
Belt Drive Tension Check:
Every 5,000 miles
Engine Oil Viscosity:
SAE 20W-50
Transmission Oil Type:
Harley-Davidson Formula+ or equivalent (GL-4)
Primary Chain Case Oil Type:
Harley-Davidson Formula+ or equivalent
Primary Chain Tensioner:
The automatic primary chain tensioner (APCT) on early Twin Cam engines is a known wear item and can fail, leading to chain slap and potential damage. Manual inspection and replacement with upgraded components is recommended. (Detailed inspection procedures in manual).
Cam Chain Tensioner:
Similar to the primary chain, the cam chain tensioners (on the camshafts) are also subject to wear. Manual details inspection and replacement.
Carburetor Tuning:
Keihin CV carburetors can sometimes require fine-tuning for optimal performance, especially after modifications or at different altitudes. Manual provides jetting and adjustment guidance.
Founder:
William S. Harley, Arthur Davidson, Walter Davidson, William A. Davidson
Dyna Line Introduction:
The Dyna family was introduced in 1991, known for its rubber-mounted powertrain for reduced vibration.
Super Glide Custom Heritage:
The 'Custom' designation signifies a model with enhanced styling and often unique factory customizations.
2005 Updates:
For 2005, models like the FXDC typically featured the Twin Cam 88 engine, Cruise Drive transmission, and a focus on refined styling over previous Dyna generations.
Manufacturing Location:
United States (Milwaukee, Wisconsin; York, Pennsylvania; Kansas City, Missouri)
