Target Audience:
Harley-Davidson Dyna owners and independent repair shops seeking authoritative repair information.
Advantage Over Alternatives:
Provides official factory-level detail, unlike generic Haynes or Clymer manuals which may lack specific Harley-Davidson engineering insights.
Authenticity:
Represents the official service information used by Harley-Davidson dealerships and certified technicians.
Scope Of Detail:
Covers disassembly, assembly, inspection, measurement, adjustment, and troubleshooting.
Engine And Powertrain:
Detailed diagnosis, repair, and overhaul procedures for engine components, including top-end, bottom-end, fuel system, ignition, and exhaust.
Transmission And Drivetrain:
Service and repair for the transmission, clutch, primary drive, and final drive belt.
Chassis And Suspension:
Front fork service, rear shock absorber maintenance, frame inspection, and wheel bearing replacement.
Braking System:
Brake caliper service, master cylinder overhaul, brake line replacement, and ABS system diagnosis (if applicable).
Electrical System:
Wiring diagrams, component testing, diagnosis of lighting, starting, charging, and accessory systems.
Fuel System:
Fuel injection system diagnosis and repair (EFI models), carburetor service (carbureted models), fuel pump, and filter replacement.
Body And Trim:
Fairing removal and installation, fender repair, seat service, and control lever adjustments.
Diagnostics:
Includes procedures for diagnosing fault codes, electrical circuit testing, and mechanical component testing.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, brake fluid changes, and lubrication points.
Troubleshooting Guides:
Diagnostic charts and symptom-based troubleshooting for common mechanical and electrical issues.
Component Rebuilds:
Detailed instructions for rebuilding engine components, transmissions, and brake calipers.
Special Tool Usage:
Identification and application of specialized Harley-Davidson tools required for specific repair procedures.
Recalibration Procedures:
May include procedures for recalibrating throttle position sensors (TPS) and other electronic components.
Depth Of Coverage:
Detailed step-by-step instructions, torque specifications, clearances, and diagnostic procedures suitable for professional mechanics and experienced DIY enthusiasts.
Wiring Diagrams:
Detailed, color-coded wiring diagrams for all electrical systems are a critical feature.
Searchability:
Likely text-searchable (depending on original scan quality)
Accessibility:
Easily accessible and searchable on computers, tablets, and smartphones.
Print Readability:
High-resolution scans of original factory documents ensuring clarity of text and diagrams.
Binding For Download:
Not applicable (digital download)
Paper Type For Download:
Not applicable (digital download)
Engine Family:
Harley-Davidson Twin Cam 96
Displacement:
1584 cc (96 cubic inches)
Bore X Stroke:
3.75 in. x 4.38 in. (95.25 mm x 111.25 mm)
Compression Ratio:
9.2:1 (typical)
Valve Train:
Overhead valve (OHV), 8 valves (2 per cylinder)
Cooling System:
Air-cooled
Horsepower Estimate:
Approx. 70-75 HP (at crankshaft, varies by model/tuning)
Torque Estimate:
Approx. 85-90 ft-lbs (at crankshaft, varies by model/tuning)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI) for most models; Carbureted versions also exist.
Fuel Type:
Unleaded gasoline, 91 octane (R+M)/2 minimum recommended.
Ignition Type:
Electronic Ignition (CDI with electronic advance)
Transmission Type:
6-speed Cruise Drive
Gear Ratios Typical:
1st: 9.312, 2nd: 6.459, 3rd: 4.785, 4th: 3.824, 5th: 3.309, 6th: 2.790 (verify specific model ratios).
Clutch Type:
Multi-plate, wet
Primary Drive:
Duplex chain, hydraulic tensioner
Crash Test Data:
Motorcycles are not subjected to standardized crash testing like automobiles.
Braking System:
Dual disc front brakes, single disc rear brake. ABS was optional on some models.
Lighting:
Halogen headlight, LED tail light, incandescent turn signals.
Audio System Availability:
Optional or factory-fitted audio systems were available on some Dyna models, typically featuring AM/FM radio and CD player.
ABS Availability:
Anti-lock Braking System (ABS) was an optional feature on many 2008-2009 Dyna models.
Diagnostic Port:
Vehicle requires specific Harley-Davidson diagnostic tools (e.g., Digital Technician) for in-depth electronic diagnosis, which this manual will support.
Engine Oil Change:
Every 5,000 miles or annually, whichever comes first.
Transmission Oil Change:
Every 10,000 miles or every two years.
Primary Chain Case Oil Change:
Every 5,000 miles or annually.
Engine Oil Type:
Harley-Davidson SYN3 or equivalent SAE 20W-50 motorcycle oil (check manual for specific viscosity and API rating).
Transmission Oil Type:
Harley-Davidson Formula + or equivalent SAE 85W-140 gear oil.
Primary Chain Case Oil Type:
Harley-Davidson Formula + or equivalent SAE 85W-140 gear oil (shares with transmission).
Brake Fluid Type:
DOT 4, DOT 5.1 or DOT 5 (verify per model variant, DOT 5 is silicone-based and not miscible).
Coolant Type:
Not applicable (air-cooled engine)
Cam Chain Tensioner Wear:
Early Twin Cam models (pre-2007) had hydraulic tensioners that could wear prematurely, leading to noise. 2008-2009 models often feature improved or updated tensioners, but inspection is still recommended.
Oil Leaks:
Common areas include primary cover, transmission side cover, and engine crankcase seals.
Charging System Issues:
Stator or voltage regulator failure can lead to battery not charging.
Fuel Tank Expansion:
Some early Twin Cam fuel tanks could experience 'swelling' or expansion due to fuel vapors.
Engine Oil Capacity:
Approx. 4 quarts (3.8 L) (check manual for exact specification)
Harley Davidson Legacy:
Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer known for its V-twin engines and cruiser style.
Dyna Lineage:
The Dyna line, introduced in 1991, served as Harley-Davidson's mid-range cruiser platform, known for its traditional styling and Twin Cam engine integration.
Manufacturing Location:
Primarily manufactured in the United States (York, Pennsylvania and Milwaukee, Wisconsin).
