Harley FXDX Dyna Super Glide Sport 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FXDX Dyna Super Glide Sport Year: 2004 Family: Dyna Codes Chassis Code: FXDX 👋 Introduction Market Position Vehicle Segment: Cruiser/Performance Cruiser Target Audience:...

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UGS: 483971

Mots clés: 2004 FXDX Dyna Super Glide Sport Harley Davidson Misc Motorcycle Motorcycles

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

FXDX Dyna Super Glide Sport

Year:

Family:

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Cruiser/Performance Cruiser

Target Audience:

Enthusiast riders seeking a blend of classic Harley styling with more aggressive performance and handling characteristics.

Competitive Analysis

Competitors 2004:

Other Harley-Davidson Dyna models, some Indian Chief models, and performance-oriented Japanese cruisers.

Key Features

Performance Focus:

The 'Sport' designation highlights its focus on improved handling and performance over more traditional cruisers.

Handling Enhancements:

Often features upgraded suspension components, dual front disc brakes, and a more aggressive riding position compared to other Dyna models.

Manual Value Proposition

Diy Support:

Essential for owners who perform their own maintenance and repairs, saving on dealership labor costs.

Diagnostic Tool:

Empowers riders to understand and diagnose issues, leading to more informed repair decisions.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Manual

Language:

English

Format:

Page Count

Estimated Page Count:

Approximately 500-700 pages (typical for Harley service manuals of this era)

📖 Manual Coverage

Systems Covered

Engine Service:

Engine assembly, disassembly, inspection, tuning, lubrication, cooling system, fuel system, exhaust system

Transmission Drivetrain:

Primary drive, transmission assembly, clutch operation, final drive (belt)

Chassis Suspension:

Frame inspection, front fork service (including cartridge type for FXDX), rear shock absorber and swingarm maintenance, wheel bearing service

Electrical System:

Battery maintenance, ignition system, lighting, starter system, charging system, instrument cluster, wiring diagrams, troubleshooting electrical faults

Braking System:

Front and rear brake caliper service, master cylinder overhaul, brake line replacement, ABS system (if equipped), brake fluid specifications

Fuel System:

Carburetor (Keihin CV) disassembly, cleaning, and adjustment, fuel pump, fuel lines, fuel tank service

Bodywork Fittings:

Fender removal and installation, fuel tank mounting, seat service, handlebar and control adjustments, fairing and saddlebag (if applicable) service

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, spark plug replacement, air filter service, lubrication points, belt tension adjustment

Troubleshooting Diagnostics:

Systematic diagnosis of common performance issues, electrical faults, and mechanical problems with step-by-step guides

Rebuild Procedures:

Complete engine rebuilds, transmission overhauls, and component-specific repair instructions with torque specifications

Electrical Diagnostics:

Use of multimeters, interpretation of wiring diagrams, fault code identification and resolution (where applicable)

Technical Depth

Diagnostic Level:

Advanced diagnostic procedures, including troubleshooting charts and component testing

Repair Scope:

Comprehensive repair instructions, from minor adjustments to major component overhauls and replacements

Specification Detail:

Detailed torque specifications, clearances, fluid capacities, and component tolerances

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF for easy keyword finding

Printability:

Printable, allowing users to create physical copies of sections or the entire manual

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity (typical for professional service manuals)

Binding Type

Digital Format:

N/A (Digital PDF)

Paper Type

Digital Format:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Evolution (Big Twin)

Engine Type:

Air-cooled V-twin, 45-degree cylinder angle

Displacement:

1450cc (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

Performance

Horsepower:

Approximately 65-70 HP (estimated, actual may vary based on tuning and emissions)

Torque:

Approximately 70-75 ft-lbs @ 3200 RPM (estimated)

Fuel System

Fuel Delivery:

Carbureted (Harley-Davidson Keihin CV 40mm)

Fuel Type:

Unleaded gasoline, 91 octane (R+M)/2 or higher recommended

Engine Components

Camshafts:

Stock cam specifications will be detailed in the manual for timing and lift

Valve Train:

Pushrod-actuated overhead valves

🔧 Transmission

Standard

Type:

5-speed constant mesh

Clutch:

Wet, multi-plate, diaphragm spring

Optional

Transmission Options:

N/A for stock 2004 FXDX

Features

Primary Drive:

Duplex chain

Final Drive:

Belt drive

Fluid Specifications

Transmission Oil Type:

Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant or equivalent API GL-4 SAE 80W-90 gear oil

Fluid Capacities

Transmission Oil Capacity:

Approximately 1 quart (0.95 L)

📐 Dimensions

Exterior

Length:

Approximately 90.4 inches (2296 mm)

Width:

Approximately 33.9 inches (861 mm)

Height:

Approximately 49.0 inches (1245 mm)

Wheelbase:

Approximately 63.4 inches (1610 mm)

Weights

Dry Weight:

Approximately 636 lbs (288 kg)

Gross Vehicle Weight Rating:

Approximately 1030 lbs (467 kg)

Cargo

Saddlebags:

Optional, typically rigid or semi-rigid, capacity varies

Wheels Tires

Front Tire Size:

100/90-19 57H

Rear Tire Size:

160/70-17 73V

Front Wheel:

19-inch cast aluminum

Rear Wheel:

17-inch cast aluminum

Bolt Pattern:

5x114.3mm (typically for Harley-Davidson)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles are not subject to the same crash test ratings as automobiles)

Active Features

Braking System:

Dual front disc brakes with 4-piston calipers, single rear disc brake with 4-piston caliper

Anti-lock Braking System (ABS) was an optional feature for some Harley models in this era, check specific VIN.

Passive Features

Lighting:

Halogen headlight, LED taillight and brake light, amber turn signals

Frame Construction:

Steel tube frame for rigidity and handling

💡 Technology Features

Infotainment

Audio System:

Base models typically did not feature integrated audio. Optional accessory radios and speakers were available.

Navigation:

N/A (No factory integrated navigation system)

Driver Assistance

ABS Availability:

Optional on this model. Manual will cover diagnostic and operational aspects if equipped.

Connectivity

Smart Phone Integration:

N/A (No factory smartphone integration)

🔧 Maintenance

Service Intervals

First Service:

Typically at 1,000 miles (1,600 km) for initial break-in service (oil change, filter, primary check, belt check)

Subsequent Oil Changes:

Every 5,000 miles (8,000 km) or annually, whichever comes first

Belt Tension Check:

Every 5,000 miles (8,000 km) or as per manual recommendation

Spark Plug Replacement:

Refer to manual, often around 10,000 - 15,000 miles (16,000 - 24,000 km)

Fluid Specifications

Engine Oil Type:

Harley-Davidson SYN3 Synthetic Motorcycle Oil or equivalent SAE 20W-50 motorcycle specific engine oil.

Engine Oil Capacity:

Approximately 3 quarts (2.8 L) with filter change

Brake Fluid Type:

DOT 4 recommended for hydraulic brake systems.

Fork Oil Type:

Refer to manual for specific weight (e.g., 10W or 15W) and type (e.g., Showa SS-8 or equivalent)

Known Issues

Cam Chain Tensioners:

Hydraulic cam chain tensioners in earlier Twin Cam models (prior to 2007) could wear prematurely. The manual will detail inspection and replacement procedures.

Carburetor Tuning:

CV carburetors may require periodic adjustment for optimal performance due to altitude, fuel variations, or wear.

Charging System Issues:

Rotor and stator failures can occur, leading to charging problems. The manual provides diagnostic steps.

Maintenance Parts

Oil Filter Part Number:

Commonly 63796-77A or equivalent aftermarket (refer to manual for exact fitment)

Air Filter Part Number:

Varies by filter type; manual will specify OE numbers or recommend types.

📚 Vehicle History

Brand Heritage

Harley Davidson Legacy:

Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer known for its V-twin engines and distinctive styling.

Model Evolution

Dyna Platform Introduction:

The Dyna platform was introduced in 1991, evolving from the earlier FXR models, offering a balance of handling and comfort.

Fxdx Positioning:

The FXDX Super Glide Sport was positioned as a more performance-oriented variant within the Dyna line, featuring upgraded suspension and brakes.

Production

Production Period Fxdx:

The FXDX model was produced from 1999 to 2005.

Manufacturer Location:

USA (assembly typically in York, Pennsylvania or Milwaukee, Wisconsin)

🏆 Awards & Recognition

Recognitions

Motorcycle Reviews:

The FXDX was generally well-received for its performance and handling capabilities relative to other Harley models of its time.

Ratings

Performance Metrics:

Praised for its ability to handle corners better than many traditional cruisers, making it more engaging for spirited riding.

Certifications

Epa Certification:

The manual will contain information related to emissions compliance for the 2004 model year as per EPA regulations.