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Harley FXDXI Dyna Super Glide Sport EFI 2005 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FXDXI Dyna Super Glide Sport Year: 2005 Chassis Code: FXDXI Platform: Dyna Market Segment: Cruiser / Sport Cruiser 👋 Introduction Market Position Positioning:...
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Harley FXDXI Dyna Super Glide Sport EFI 2005 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FXDXI Dyna Super Glide Sport
Year:
2005
Chassis Code:
FXDXI
Platform:
Dyna
Market Segment:
Cruiser / Sport Cruiser
👋 Introduction
Market Position
Positioning:
The Harley-Davidson FXDXI Dyna Super Glide Sport was positioned as a sport-oriented cruiser, offering a blend of traditional Harley styling with more aggressive ergonomics and handling characteristics for riders seeking a more dynamic riding experience.
Competitive Analysis
Competitors:
Competed with models from other American manufacturers and Japanese manufacturers offering performance-oriented cruisers, such as certain Yamaha V-Stars, Suzuki Boulevard models, and potentially some Indian Motorcycles offerings of the era.
Key Features
Features:
Distinctive dual-disc front brakes, performance-oriented suspension, forward-mounted foot controls, lower handlebars, and the powerful Twin Cam 88 engine.
📋 Manual Details
Coverage Areas
Engine:
Included
Transmission:
Included
Chassis:
Included
Electrical System:
Included
Fuel System:
Included
Ignition System:
Included
Suspension:
Included
Brakes:
Included
Wheels And Tires:
Included
Bodywork:
Included
Accessories:
Included
Troubleshooting:
Included
Wiring Diagrams:
Included
Page Count
Approximate Pages:
600+
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, component diagnostics, internal component replacement (pistons, rings, valves, camshafts, crankshaft), timing procedures.
Engine Management:
Fuel injection system (EFI) diagnosis and repair, electronic control module (ECM) troubleshooting, sensor testing and replacement (TPS, MAP, IAT, O2), idle speed control.
Exhaust System:
Exhaust pipe and muffler replacement, catalytic converter information (if applicable).
Transmission Drivetrain:
Clutch operation and adjustment, gear inspection, bearing replacement, final drive belt inspection and adjustment, primary drive inspection.
Brake System:
Brake fluid replacement, caliper overhaul, master cylinder inspection, brake pad replacement, bleeding procedures, rotor inspection.
Suspension Steering:
Front fork disassembly, seal replacement, oil level and type specification, rear shock absorber inspection and replacement, steering head bearing adjustment and replacement.
Electrical Charging:
Battery testing and replacement, charging system diagnosis (stator, regulator/rectifier), starter motor operation.
Electrical Ignition:
Ignition coil testing, spark plug specifications and replacement, ignition timing verification (ECM controlled).
Lighting Signals:
Headlight, taillight, turn signal bulb replacement, wiring harness troubleshooting.
Instrumentation:
Speedometer, tachometer, indicator lights, diagnostic trouble codes (DTCs) display.
Frame Body:
Frame inspection, fender removal and installation, fuel tank removal and installation, seat assembly, fairing components.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug replacement, drive belt adjustment, brake inspection.
Diagnostic Troubleshooting:
Systematic approach to identifying and resolving common and uncommon issues, DTC lookup and interpretation.
Component Replacement:
Step-by-step guides for replacing wear items and major components.
Rebuilds Overhauls:
Detailed instructions for engine and transmission internal work.
Electrical Diagnostics:
Testing of circuits, sensors, actuators, and control modules using multimeter and diagnostic tools.
Suspension Tuning:
Fork oil changes, adjustments, and basic tuning principles.
Wheel Tire Service:
Tire pressure checks, tire replacement guidance, wheel balancing.
Technical Depth
Depth:
Comprehensive, covering basic owner maintenance through advanced mechanical and electrical repairs suitable for professional technicians and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
Readability:
High-resolution PDF, searchable text for quick information retrieval.
Printability:
Printable pages, allowing for on-the-go use or creating a physical copy.
Binding Type
Digital Format:
N/A (PDF document)
Paper Type
Digital Format:
N/A (PDF document)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, Twin Cam 88 EFI
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
Valve Train:
Overhead valves (OHV), pushrod actuated, 2 valves per cylinder
Cooling System:
Air-cooled
Performance
Horsepower Approximate:
Approximately 65-70 HP (varies by source and dyno testing)
Torque Approximate:
Approximately 85-90 ft-lbs @ 3500 RPM (varies by source and dyno testing)
Fuel System
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Oil System
Oil Capacity:
3.0 US quarts (2.8 L)
Oil Type:
Harley-Davidson Genuine SYN3 (synthetic blend) or equivalent API SG, Jaso MA certified motorcycle oil.
Ignition System
Ignition Type:
Electronic ignition, controlled by ECM
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Primary Drive:
Patented enclosed primary drive with chain; wet multi-plate clutch
Final Drive:
Carbon-fiber belt drive, 32/66 ratio
Features
Clutch Type:
Hydraulic actuated, wet multi-plate
Fluid Specifications
Transmission Oil Type:
Harley-Davidson Formula+ (or equivalent API GL-4, SAE 80W-90 gear oil)
Fluid Capacities
Transmission Oil Capacity:
2.4 US quarts (2.3 L)
📐 Dimensions
Exterior
Length:
90.5 in. (2299 mm)
Width:
35.9 in. (912 mm)
Height:
49.6 in. (1260 mm)
Wheelbase:
63.5 in. (1613 mm)
Ground Clearance:
4.8 in. (122 mm)
Weights
Dry Weight:
Approximately 648 lbs (294 kg)
Gvwr:
Not specified in general product info, but typically around 1000 lbs (454 kg).
Payload Capacity:
Not specified in general product info, typically rider and passenger plus luggage.
Wheels Tires
Front Tire:
100/90-19 57H
Rear Tire:
160/70B17 73V
Front Wheel:
Cast aluminum, 19 x 3.00 in.
Rear Wheel:
Cast aluminum, 17 x 4.50 in.
Fuel Capacity
Fuel Tank Capacity:
4.8 US gallons (18.2 L)
Reserve Fuel Capacity:
Approximately 0.5-1.0 US gallons (1.9-3.8 L)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycles are not typically rated by organizations like NHTSA or IIHS in the same way as cars.)
Active Features
Braking System:
Dual 300mm front discs with 4-piston calipers, Single 292mm rear disc with 2-piston caliper.
Passive Features
Lighting:
Halogen headlight, LED taillight/brake light, amber incandescent turn signals.
Ergonomics:
Sport-oriented riding position designed for rider control.
💡 Technology Features
Infotainment
Infotainment System:
Base model, typically no integrated infotainment system beyond basic gauges and indicator lights. Optional accessory radios/audio systems were available.
Gauges:
Analog speedometer, tachometer, fuel gauge, voltmeter, oil pressure light, engine diagnostic light, turn signal indicators, high beam indicator.
Driver Assistance
Assistance Features:
N/A (No electronic rider aids like ABS or traction control were standard on this model.)
Connectivity
Connectivity Features:
N/A (No Bluetooth or smartphone integration.)
Electronics
ECM Functionality:
Engine Control Module (ECM) manages fuel injection, ignition timing, and other engine parameters based on sensor input.
🔧 Maintenance
Service Intervals
Initial Service:
Typically 1,000 miles (1,600 km) for the first service, including oil change, primary chain adjustment, and general inspection.
Regular Oil Change:
Every 5,000 miles (8,000 km) or annually, whichever comes first.
Primary Oil Change:
Every 10,000 miles (16,000 km) or annually.
Transmission Oil Change:
Every 10,000 miles (16,000 km) or annually.
Air Filter Service:
Inspect every 5,000 miles (8,000 km), clean or replace as needed based on conditions.
Spark Plug Replacement:
Typically every 10,000 miles (16,000 km), but check manual for specific type and interval.
Drive Belt Adjustment:
Inspect every 5,000 miles (8,000 km), adjust as needed per specifications in manual.
Fluid Specifications
Engine Oil Spec:
Harley-Davidson Genuine SYN3 (20W-50 synthetic blend) or equivalent API SG, Jaso MA certified motorcycle oil.
Primary Chain Case Oil Spec:
Harley-Davidson Formula+ (or equivalent API GL-4, SAE 80W-90 gear oil)
Transmission Oil Spec:
Harley-Davidson Formula+ (or equivalent API GL-4, SAE 80W-90 gear oil)
Brake Fluid Spec:
DOT 4 brake fluid (refer to manual for specific Harley-Davidson part number)
Fork Oil Spec:
Harley-Davidson Type 'E' (or equivalent SAE 10W fork oil) - check manual for exact type and quantity
Known Issues
Cam Chain Tensioner:
Early Twin Cam engines (pre-2007) used cam chain tensioners that could wear out, leading to noise and potential damage. Upgraded hydraulic tensioners are recommended.
Crank Position Sensor:
Failure of the crank position sensor can cause stalling or no-start conditions.
Idle Control Module:
Some EFI models can experience issues with the idle air control (IAC) motor, leading to rough or unstable idle.
Primary Drive Belt:
While robust, the primary drive belt requires proper tensioning. Overtightening can lead to premature bearing wear.
Rear Wheel Bearings:
Some owners report premature wear of rear wheel bearings, especially with heavy loads or aggressive riding.
📚 Vehicle History
Brand Heritage
Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines, distinctive styling, and rich racing history. The brand has a massive global following and a strong association with freedom and the open road.
Model Evolution
Evolution Of Dyna:
The Dyna platform, introduced in 1991, was designed to offer a more modern ride compared to the older FXR and Big Twin models, featuring a more rigid frame and improved handling. The FXDXI Super Glide Sport represented an evolution within the Dyna line, specifically targeting riders who desired a more performance-oriented and agile motorcycle.
Production
Production Period:
The FXDXI Dyna Super Glide Sport was produced from 2004 to 2005, before being replaced by the FXDCI Super Glide Custom in some aspects, with the FXDXI nameplate being retired.
Engine Progression:
The Twin Cam 88 engine was a significant departure from Harley's Shovelhead and Evolution engines, offering increased displacement and a more refined, yet still characterful, V-twin experience. The 1450cc displacement was the standard for most Harley models in this era.
🏆 Awards & Recognition
Recognitions
Awards:
Harley-Davidson motorcycles, particularly within the Dyna family, have consistently received praise for their styling, sound, and riding experience from motorcycle enthusiasts and publications. Specific awards for the 2005 FXDXI are not widely documented as it was part of a broad model lineup, but the Dyna platform itself is highly regarded.
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