Positioning:
The Harley-Davidson Dyna series for 2002 represented a significant evolution in the company's cruiser lineup, offering a blend of traditional styling with modern performance and handling characteristics. This manual serves the enthusiast and professional mechanic who maintains these iconic machines.
Competitors:
The Dyna models competed primarily with other American V-twin cruisers from brands like Indian, and to some extent, custom motorcycle builders and other manufacturers offering large-displacement V-twin platforms.
Vehicle Features:
Key features of the 2002 Dyna models included the Twin Cam 88 engine, a robust 5-speed transmission, distinctive styling, and a rider-focused platform that emphasized torque and a visceral riding experience.
Engine:
Detailed coverage of Twin Cam 88 engine disassembly, assembly, tuning, and troubleshooting. Includes ignition system, fuel system (carburetion and early EFI), lubrication, cooling (air-cooled), and exhaust systems.
Transmission Drivetrain:
Complete coverage of the 5-speed transmission, including clutch operation, gear inspection, bearing replacement, and final drive belt maintenance and adjustment.
Chassis Suspension:
In-depth information on frame inspection, front fork disassembly and rebuild (including Dyna Wide Glide and Super Glide specific fork types), rear shock absorber service, and wheel bearing maintenance.
Brakes:
Detailed procedures for front and rear brake caliper service, master cylinder overhaul, brake line bleeding, and inspection of brake pads and rotors.
Electrical System:
Comprehensive wiring diagrams, troubleshooting guides for lighting, ignition, starter, charging system (alternator, regulator), instrumentation, and accessory circuits.
Bodywork Fittings:
Procedures for removal and installation of fuel tanks, fenders, seat assembly, handlebars, mirrors, and other cosmetic and functional body components.
Diagnostics Troubleshooting:
Extensive troubleshooting sections organized by symptom, including diagnostic charts, common failure modes, and repair strategies for electrical and mechanical issues.
Maintenance:
Regular service intervals, oil changes, filter replacements, lubrication points, chain/belt adjustments, brake inspections, tire pressure checks, and battery maintenance.
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly, including engine overhauls, transmission rebuilds, suspension repairs, and electrical system fixes.
Troubleshooting:
Methodical approaches to diagnosing and resolving common and complex problems using electrical schematics and mechanical diagnostic procedures.
Depth:
Expert level, covering everything from basic preventive maintenance to full engine and transmission rebuilds. Includes detailed torque specifications, clearances, and alignment procedures.
Engine Family:
Harley-Davidson Twin Cam 88
Engine Type:
Air-cooled, 45-degree 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)
Compression Ratio:
8.8:1 (typical)
Horsepower:
Approx. 65-70 HP (at crank, depending on specific tuning and model variant)
Torque:
Approx. 75-80 lb-ft (at crank, depending on specific tuning and model variant)
Fuel Delivery:
Carburetor (Keihin CV 40 mm) or early Electronic Fuel Injection (EFI) depending on specific sub-model.
Fuel Type:
Unleaded gasoline, minimum 87 octane recommended.
Transmission Type:
5-speed constant mesh, left-foot shift
Clutch:
Wet, multi-plate, diaphragm spring
Optional Transmission:
N/A for 2002 Dyna models
Drive Type:
Belt drive, 1.25-inch wide final drive belt
Transmission Fluid Type:
Harley-Davidson Genuine Formula Plus or equivalent SAE 80W-90 Hypoid Gear Oil (check manual for exact specification).
Wheelbase:
Approx. 63.5 inches (1613 mm) - Varies slightly by Dyna model (e.g., Super Glide, Low Rider, Wide Glide)
Length:
Approx. 90 inches (2286 mm) - Varies slightly by Dyna model
Dry Weight:
Approx. 600-630 lbs (272-286 kg) - Varies by model
Gvwr:
Not explicitly stated for motorcycles, but payload capacity is relevant.
Fuel Capacity:
4.2 gallons (15.9 liters) for most Dyna models.
Safety Ratings:
Motorcycles are not typically rated by agencies like NHTSA or IIHS. Safety relies on rider skill and machine design features.
Braking System:
Dual-piston caliper front, single-piston caliper rear brakes. Disc brakes front and rear.
Suspension Tuning:
Adjustable rear shocks (pre-load) on many models for tuning ride height and damping.
Lighting:
Halogen headlight, taillight, brake light, front and rear turn signals.
Infotainment System:
Basic instrumentation typical for the era: speedometer, tachometer (optional on some models), odometer, trip meter, oil pressure light, neutral indicator, high beam indicator, turn signal indicators. No integrated infotainment systems like modern motorcycles.
Assistance Features:
No electronic driver assistance features like ABS or traction control were standard on 2002 Dyna models.
Initial Service:
First service typically at 1,000 miles (1600 km) for engine oil and filter change, primary chain adjustment, and inspection of all major components.
Routine Maintenance:
Subsequent oil and filter changes recommended every 5,000 miles (8000 km) or annually. Primary fluid change every 10,000 miles (16000 km). Spark plug replacement typically at 10,000-20,000 miles. Belt check and adjustment every 10,000 miles.
Engine Oil Type:
Harley-Davidson Genuine V-Twin 20W-50 (or equivalent API CG-4 rated synthetic or mineral oil).
Engine Oil Capacity:
Approximately 4 quarts (3.8 liters) with filter change.
Primary Chain Case Fluid:
Harley-Davidson Genuine Primary Chain Case Lubricant or Formula + (or equivalent SAE 85W-140).
Primary Chain Case Capacity:
Approximately 1 quart (0.95 liters).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Issues:
Potential issues include oil leaks from crankcase seals, transmission seal leaks, starter solenoid failures, ignition module issues (especially with early ignition systems), and exhaust header pipe leaks at the cylinder head. Some models may experience clutch drag. The Twin Cam 88 can be susceptible to cam chain tensioner wear, although this is more prevalent in later models.
Oil Filter Oem:
63731-98 (for certain Twin Cam models of this era, verify with specific VIN)
Heritage:
Harley-Davidson has a rich history dating back to 1903, renowned for its V-twin motorcycles, iconic styling, and a strong cultural identity.
Dyna Lineage:
The Dyna platform was introduced in 1991, evolving from the earlier FXR chassis, and became a distinct line within Harley-Davidson's offerings. The 2002 models were part of the evolution towards the Twin Cam engine, replacing older Evolution Big Twin engines in many applications.
Manufacturing Location:
Primarily manufactured in the United States by Harley-Davidson Motor Company.
