Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson FXD Dyna owners, independent repair shops, motorcycle enthusiasts.
Comparison:
Provides official factory data, surpassing aftermarket manuals in accuracy and detail for this specific generation.
Oem Quality:
Official factory documentation ensuring accuracy and completeness.
Diagnostic Tools:
Essential for accurate troubleshooting and repair without guesswork.
Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Estimated Page Count:
Hundreds
Type:
Factory Service Repair Manual
Engine:
Engine disassembly, assembly, inspection, troubleshooting, and repair for Twin Cam 88 engines (carbureted).
Fuel System:
Carburetor servicing (Mikuni HSR42), fuel tank, fuel lines, fuel filter replacement.
Ignition System:
Ignition module, coils, spark plugs, wiring, troubleshooting.
Transmission:
5-speed manual transmission servicing, clutch operation and adjustment, gear shifter mechanism.
Drivetrain:
Primary drive system, secondary belt drive, wheel bearings, rear axle.
Suspension:
Front fork (41mm conventional) disassembly, rebuild, fluid changes, and adjustments. Rear shock absorber replacement and adjustment.
Brakes:
Front and rear disc brake system servicing, caliper maintenance, brake fluid replacement, bleeding procedures, master cylinder.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting circuits, switches, instruments.
Frame And Bodywork:
Frame inspection, body panel removal and installation, fender, seat, handlebar, and control mounting.
Wheels And Tires:
Tire inspection and replacement, wheel balancing, rim specifications.
Scheduled Maintenance:
Detailed maintenance schedules, oil changes, filter replacements, lubrication points.
Troubleshooting:
Diagnostic charts and procedures for common problems and system failures.
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly.
Overhaul:
Complete engine and transmission overhaul procedures.
Technical Adjustments:
Carburetor synchronization, ignition timing (if applicable via module), clutch and brake lever adjustments.
Depth:
Comprehensive, from basic maintenance to complete engine rebuilds and complex electrical diagnostics.
Quality:
High-resolution PDF, often with searchable text for efficient navigation.
Print Readability:
Designed for clear printing, ensuring legibility of diagrams and text.
Binding:
N/A (Digital PDF Download)
Paper Recommendation:
N/A (Digital PDF Download)
Engine Type:
Air-cooled, Twin Cam 88 V-twin
Displacement:
1449 cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Valvetrain:
Overhead valve (OHV), 2 valves per cylinder, pushrod actuated
Horsepower Est:
~60-65 HP (at crankshaft, model dependent)
Torque Est:
~75-80 lb-ft (at crankshaft, model dependent)
Carburetor:
Mikuni HSR42 (standard on most FXD models of this era)
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended
Oil Type:
Harley-Davidson Syn3 (20W50) or equivalent motorcycle-specific synthetic oil.
Oil Capacity:
Approx. 3.0 US quarts (2.8 liters) with filter change.
Type:
5-speed constant mesh, helical gear
Clutch:
Wet, multi-plate, diaphragm spring
Primary Drive:
Duplex chain, compensator sprocket
Secondary Drive:
Carbon fiber reinforced belt drive
Transmission Oil Type:
Harley-Davidson Formula+ Transmission and Primary Chain Lubricant or equivalent.
Certification:
Meets DOT and EPA standards for motorcycles of its era.
Braking:
Dual front disc brakes with dual-piston calipers, single rear disc brake with dual-piston caliper.
Lighting:
Halogen headlight, LED tail light and brake light, amber front and rear turn signals.
Audio System:
Optional factory or aftermarket stereo systems were available, not standard on all FXD models.
ABS:
Anti-lock Braking System (ABS) was an optional feature, not standard on all models.
Diagnostics:
On-board diagnostics are limited by today's standards; primarily rely on symptom-based troubleshooting and wiring diagrams.
First Service:
Typically at 1,000 miles (1,600 km) for initial check and oil change.
Regular Oil Change:
Every 5,000 miles (8,000 km) or annually, whichever comes first.
Belt Tension Check:
Inspect belt tension at every 5,000 mile service.
Primary Chain Case Oil:
Harley-Davidson Formula+ Transmission and Primary Chain Lubricant or equivalent (approx. 1 quart / 0.95 liter).
Brake Fluid:
DOT 4 recommended for brake systems.
Fork Oil:
Specify viscosity and volume as per manual (e.g., 10W fork oil, approx. 14.5 fl oz per leg for stock forks).
Carburetor Tuning:
Mikuni HSR42 can require fine-tuning for optimal performance and throttle response.
Cam Chain Tensioners:
Early Twin Cam 88 models had plastic cam chain tensioner shoes that could wear and require replacement with updated hydraulic tensioners. (Manual will detail inspection).
Belt Drive Tension:
Improper belt tension can lead to premature wear or tracking issues.
Electrical Connections:
Corrosion or loose connections can affect various electrical systems.
Legacy:
Harley-Davidson has a rich heritage of American V-twin motorcycle manufacturing since 1903.
Introduction Of Dyna:
The Dyna family was introduced in 1991, evolving from the FXR platform, known for its balance of style and performance.
Twin Cam 88 Era:
The 1999 model year marked the introduction of the new Twin Cam 88 engine, replacing the Evolution Big Twin, offering increased power and refinement.
Manufacturing Location:
York, Pennsylvania, USA and Milwaukee, Wisconsin, USA (assembly varies by component)
