Harley Davidson Dyna 2002 Service Repair Manual

Regular price: $16.99
Sale price: $16.99
Regular price
Unit price: per

🏷️ Basic Information Identification Make: Harley-Davidson Model: Dyna Year: 2002 Model Variant: FXD, FXDX, FXDXT, FXDL, FXDWG Codes Engine Family Code: Evolution (Big Twin) 👋 Introduction Market Position Target Audience:...

20 people are viewing this right now

Type: Motorcycle

Vendor:

Sku: 485330

Tags: 2002 Dyna Harley Davidson Misc Motorcycle Motorcycles

Product variants

Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Year:

Model Variant:

FXD, FXDX, FXDXT, FXDL, FXDWG

Codes

Engine Family Code:

Evolution (Big Twin)

👋 Introduction

Market Position

Target Audience:

Harley-Davidson Dyna owners, independent motorcycle mechanics, and service technicians.

Competitive Analysis

Advantage Over Physical Manuals:

Easily accessible, searchable, portable, and can be viewed on multiple devices. No wear and tear compared to paper manuals.

Key Features

Accessibility:

Immediate download and access to repair information.

Comprehensiveness:

Covers all major mechanical and electrical systems for the specified model year range.

Visuals:

Includes diagrams, illustrations, and potentially exploded views of components.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Repair, Maintenance, Troubleshooting

Secondary Coverage:

Wiring Diagrams, Technical Specifications, Component Identification

Page Count

Estimated Page Count:

Approximately 600-800 (typical for comprehensive service manuals of this era)

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Service:

Engine disassembly, assembly, overhaul, tuning, lubrication system, cooling system (air-cooled).

Fuel System:

Carburetor (Keihin CV) service, fuel tank, fuel lines, fuel pump operation (if applicable).

Ignition System:

Ignition timing, spark plugs, ignition coils, electronic control module (ECM) diagnostics.

Transmission And Drivetrain:

5-speed gearbox, primary drive, clutch service, final drive belt, chain adjustment (if applicable), transmission oil.

Electrical System:

Battery, charging system (alternator, regulator), starting system (starter motor, solenoid), lighting, instrumentation, fuses, relays, wiring diagrams.

Chassis And Suspension:

Frame inspection, front fork (telescopic), rear shock absorbers, steering head bearings, swingarm, wheel bearings.

Braking System:

Hydraulic brake system, front and rear calipers, master cylinders, brake lines, brake fluid specifications, pad replacement, bleeding procedures.

Wheels And Tires:

Wheel removal and installation, tire inspection and replacement, tire pressures, wheel balancing.

Bodywork And Fittings:

Fender removal, fuel tank mounting, seat installation, exhaust system service, handlebar replacement.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, spark plug checks, brake fluid checks, air filter cleaning/replacement.

Troubleshooting Guides:

Diagnostic procedures for common starting, running, and electrical issues.

Component Overhaul:

Detailed step-by-step instructions for engine, transmission, and brake component rebuilds.

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams and diagnostic flowcharts.

Special Tool Requirements:

Identification and usage of specialized tools required for specific repair procedures.

Technical Depth

Depth Of Information:

Comprehensive (covers everything from basic maintenance to complete engine and transmission rebuilds).

Diagnostic Level:

Advanced diagnostics, including troubleshooting charts and component testing procedures.

Repair Procedures:

Detailed, step-by-step repair instructions with torque specifications, clearances, and assembly sequences.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable, allowing users to quickly find specific terms or procedures.

Print Quality

Printability:

Designed to be printable for workshop use, with clear diagrams and text.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Quality:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 45-degree V-twin, Evolution Engine

Displacement:

88 cubic inches (1442cc)

Bore X Stroke:

3.500 in x 4.429 in (88.9 mm x 112.5 mm)

Compression Ratio:

8.8:1 (typical for 2002 models)

Valve Train:

OHV, 2 valves per cylinder, pushrod actuated

Performance

Horsepower Estimated:

~65-70 HP (at crankshaft, depending on model variant and tuning)

Torque Estimated:

~75-80 ft-lbs (at crankshaft, depending on model variant and tuning)

Fuel System

Fuel Delivery:

Carbureted (Keihin 40mm CV - Constant Velocity)

Fuel Type:

Unleaded gasoline, minimum 87 octane

Engine Oil

Oil Type:

Harley-Davidson Genuine V-Twin 20W-50, or equivalent API SG certified oil

Oil Capacity:

3.0 US quarts (2.8 liters) with filter change

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh, helical gear

Gear Ratios Estimate:

1st: 9.315, 2nd: 6.432, 3rd: 4.743, 4th: 3.805, 5th: 3.104 (values are approximate and can vary slightly)

Primary Drive:

Duplex chain, 1.370:1 ratio

Final Drive:

Belt drive, 32/66 tooth sprockets, 3.15:1 ratio

Optional

Optional Gear Sets:

None from factory for this year; aftermarket options available.

Features

Clutch Type:

Wet, multi-plate

Transmission Oil Type:

Harley-Davidson Genuine Formula +, or equivalent SAE 50 transmission oil

Transmission Oil Capacity:

2.5 US quarts (2.4 liters)

📐 Dimensions

Exterior

Wheelbase:

Approximately 62.5 inches (1588 mm)

Length:

Approximately 89.7 inches (2278 mm)

Weights

Dry Weight:

Approximately 630-660 lbs (286-299 kg), varies by model variant

Gross Vehicle Weight Rating Gvwr:

Approximately 1000-1050 lbs (454-476 kg)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Motorcycles are not typically rated by government agencies like NHTSA for crash safety in the same manner as cars.

Active Features

Braking System:

Dual disc front brakes, single disc rear brake (standard on most models), hydraulic actuation.

Passive Features

Frame Construction:

Steel tubing frame designed for stability and rider feedback.

Lighting System:

Halogen headlamp, LED tail lamp, turn signals, brake light.

💡 Technology Features

Infotainment

Audio System:

Optional factory or dealer-installed accessory audio systems were available, typically featuring AM/FM radio and cassette players, but not standard on all models.

Driver Assistance

Anti-lock Braking System (ABS) was not a standard or widely available option on Dyna models in 2002. It became more common in later years.

Connectivity

Usb Ports:

Not applicable for this model year.

Instrumentation

Dashboard Layout:

Analog speedometer on the handlebar-mounted dash, tachometer (on some models), odometer, trip meter, fuel gauge (often dash-mounted), indicator lights for turn signals, oil pressure, and neutral.

🔧 Maintenance

Service Intervals

Initial Service:

1,000 miles (1600 km) - Oil change, primary chain tension adjustment, inspection of all major components.

Subsequent Oil Changes:

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

Primary Chain Tension Adjustment:

Every 5,000 miles (8,000 km)

Brake Fluid Flush Replacement:

Every 2 years, or as recommended by the manual, due to hygroscopic nature of DOT 4 fluid.

Fluid Specifications

Engine Oil Spec:

Harley-Davidson Genuine V-Twin 20W-50 (or equivalent API SG/SH/SJ or higher)

Transmission Oil Spec:

Harley-Davidson Genuine Formula + (or equivalent SAE 50)

Primary Chain Case Oil Spec:

Harley-Davidson Genuine Formula + (or equivalent SAE 50)

Brake Fluid Spec:

DOT 4

Known Issues

Cam Chain Tensioners:

Early Evolution engines (pre-2007) are known for wear on the cam chain tensioner pads, which can lead to engine damage if not replaced proactively with improved designs.

Carburetor Tuning:

The Keihin CV carburetor can sometimes require fine-tuning or adjustment, especially with aftermarket exhaust or air cleaner modifications.

Primary Drive Chain Stretch:

Regular inspection and adjustment of the primary drive chain are crucial to prevent excessive wear and potential damage.

📚 Vehicle History

Brand Heritage

Founding:

Founded in 1903 in Milwaukee, Wisconsin, USA. Pioneered motorcycle manufacturing.

Model Evolution

Dyna Line Introduction:

The Dyna family was introduced in 1991, featuring a new frame and rubber isolation for the powertrain, offering a smoother ride compared to earlier rigid-mount V-twins.

2002 Updates:

The 2002 models continued to utilize the 88 cubic inch Evolution engine and the robust frame design. Minor styling and component updates occurred across the model range.

Production

Manufacturing Location:

USA (Milwaukee, Wisconsin; York, Pennsylvania)

🏆 Awards & Recognition

Recognitions

Brand Awards:

Harley-Davidson has a long history of awards and recognition for its motorcycles, often lauded for their iconic styling, rider experience, and build quality.

Ratings

Customer Satisfaction:

Generally high for the Harley-Davidson brand, particularly among dedicated enthusiasts, though specific model year ratings fluctuate.

Certifications

Emissions Standards:

Certified to meet US EPA and California Air Resources Board (CARB) emissions standards for the model year.