|
Introduction
|
|
Market Position
|
|
Vehicle Segment:
|
American V-twin cruiser/performance motorcycle segment
|
|
Target Audience:
|
Harley-Davidson owners and independent service technicians
|
|
Competitive Analysis
|
|
Key Competitors 2003:
|
Indian Chief, Victory Cruiser models, custom choppers, other V-twin manufacturers
|
|
Key Features
|
|
Manual Value Proposition:
|
Empowers owners for DIY maintenance and repairs, reduces dealership reliance, provides expert-level technical data.
|
|
Vehicle Appeal:
|
Customizable platform, iconic V-twin engine, strong brand loyalty, diverse model range within Dyna family.
|
|
Manual Coverage
|
|
Systems Covered
|
|
Powertrain:
|
Engine, transmission, clutch, final drive
|
|
Chassis:
|
Frame, suspension (front and rear), steering, wheels, tires
|
|
Brakes:
|
Front and rear brake system components, hydraulic lines, master cylinders, calipers, rotors
|
|
Electrical:
|
Ignition system, lighting, starting system, charging system, battery, instrumentation, wiring diagrams, accessories
|
|
Fuel System:
|
Carburetor (or early fuel injection systems for specific models), fuel pump, fuel tank, fuel lines
|
|
Exhaust System:
|
Exhaust pipes, mufflers, heat shields
|
|
Bodywork And Trim:
|
Fenders, fuel tank, seat, handlebars, controls, fairings (if applicable, e.g., FXDXT T-Sport)
|
|
Procedures Included
|
|
Routine Maintenance:
|
Oil changes, filter replacements, chain/belt adjustment, spark plug replacement, air filter service
|
|
Troubleshooting:
|
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides
|
|
Major Repairs:
|
Engine overhaul, transmission rebuild, fork seal replacement, brake caliper overhaul, electrical component replacement
|
|
Disassembly Reassembly:
|
Step-by-step instructions for complete vehicle tear-down and reassembly
|
|
Technical Specifications:
|
Torque specifications for all fasteners, fluid capacities, electrical specifications, measurements
|
|
Technical Depth
|
|
Diagnostics Level:
|
Advanced, including electrical system diagnostics and component testing
|
|
Rebuild Scope:
|
Complete engine, transmission, and suspension rebuilds
|
|
Detail Level:
|
Detailed, with exploded views, part diagrams, and step-by-step instructions
|
|
Engine Specifications
|
|
Primary Engine
|
|
Engine Family:
|
Harley-Davidson Evolution (Evo) V-twin
|
|
Engine Displacement:
|
88 cubic inches (1449cc)
|
|
Engine Configuration:
|
Air-cooled, 45-degree V-twin
|
|
Bore X Stroke:
|
3.50 in x 4.47 in (88.9 mm x 113.5 mm)
|
|
Compression Ratio:
|
8.8:1 (typical for 88ci Evo)
|
|
Performance
|
|
Horsepower Rating:
|
Approximately 60-65 HP (estimated, varies slightly by model and tuning)
|
|
Torque Rating:
|
Approximately 70-75 ft-lbs (estimated, varies slightly by model and tuning)
|
|
Fuel System
|
|
Fuel Delivery Method:
|
Keihin CV 40mm Carburetor (standard for most Dyna models in 2003)
|
|
Ignition Type:
|
Electronic Ignition with Single Fire Coil
|
|
Safety Features
|
|
Ratings
|
|
Crash Test Ratings:
|
Motorcycles are not typically rated by agencies like NHTSA in the same way as cars.
|
|
Active Features
|
|
Braking System Type:
|
Hydraulic disc brakes, front and rear
|
|
Front Brake Specifications:
|
Single 292 mm (11.5 in) floating disc, 4-piston caliper
|
|
Rear Brake Specifications:
|
Single 292 mm (11.5 in) disc, 2-piston caliper
|
|
Passive Features
|
|
Lighting System:
|
Halogen headlamp, LED tail/stop lamp, amber incandescent turn signals
|
|
Maintenance
|
|
Service Intervals
|
|
Engine Oil Change Interval:
|
Every 2,500 - 5,000 miles or annually, whichever comes first (consult manual for specifics)
|
|
Transmission Oil Change Interval:
|
Every 10,000 miles (consult manual)
|
|
Primary Chain Case Oil Change Interval:
|
Every 5,000 miles (consult manual)
|
|
Spark Plug Replacement Interval:
|
Typically every 10,000 - 15,000 miles
|
|
Fluid Specifications
|
|
Engine Oil Type:
|
Harley-Davidson Genuine V-Twin Motor Oil SAE 20W50 or equivalent API SG, SH, SJ rated
|
|
Engine Oil Capacity:
|
3.0 US quarts (2.8 Liters) with filter change
|
|
Transmission Oil Type:
|
Harley-Davidson Genuine Formula + Transmission Oil or equivalent SAE 80W-90 GL-5
|
|
Transmission Oil Capacity:
|
1 US quart (0.95 Liters)
|
|
Primary Chain Case Oil Type:
|
Harley-Davidson Genuine Formula + Transmission Oil or equivalent SAE 80W-90 GL-5
|
|
Primary Chain Case Oil Capacity:
|
26 US fluid ounces (0.77 Liters)
|
|
Brake Fluid Type:
|
DOT 4 hydraulic fluid
|
|
Known Issues
|
|
Common Wear Items:
|
Clutch plates, wheel bearings, steering head bearings, belt tensioner
|
|
Potential Engine Issues:
|
Oil leaks (especially from crankcase seals), cam bearing wear, tappet adjustment issues, carburetor tuning.
|
|
Potential Electrical Issues:
|
Voltage regulator failure, stator failure, wiring harness degradation over time.
|
