Positioning:
Essential tool for owners and technicians maintaining and repairing Harley-Davidson Dyna models of the 2007 model year. Positioned as a professional-grade resource.
Competitors:
While unofficial manuals exist, factory service manuals or high-quality aftermarket equivalents (like Haynes or Clymer, though this description implies a factory-level manual) are the benchmark. This PDF download offers convenience and accessibility.
Features:
Comprehensive repair instructions, detailed diagrams, troubleshooting guides, torque specifications, and maintenance schedules for Harley-Davidson Dyna motorcycles.
Engine Mechanical:
Engine disassembly, assembly, inspection, torque specifications, valve adjustments, piston and cylinder work, crankshaft and camshaft service, cylinder head service, oil pump and lubrication system.
Fuel System:
Fuel injection system (EFI) diagnostics and repair, fuel pump, fuel injectors, fuel pressure regulator, throttle body service, fuel tank maintenance.
Transmission And Drivetrain:
Clutch operation and service, transmission disassembly and assembly, gear inspection and replacement, primary drive system, final drive belt maintenance and adjustment, wheel bearing service.
Brakes:
Hydraulic brake system diagnosis and repair, front and rear brake calipers, brake pads, brake lines, master cylinders, brake fluid specifications and bleeding procedures, ABS system (if equipped).
Suspension:
Front fork service (disassembly, seal replacement, oil changes, spring rates), rear shock absorber service and adjustment, swingarm and linkage inspection.
Electrical System:
Wiring diagrams, battery maintenance and testing, charging system (stator, regulator/rectifier), lighting system (headlight, taillight, turn signals), starter motor and solenoid, horn, instrument cluster, accessory wiring.
Cooling System:
Engine oil cooling system components and maintenance (oil cooler, oil lines).
Exhaust System:
Exhaust pipe and muffler inspection, mounting and replacement, gasket replacement.
Ignition Components:
Ignition coils, spark plugs, ignition module, crankshaft position sensor, camshaft position sensor, troubleshooting ignition faults.
Scheduled Maintenance:
Recommended service intervals for oil changes, filter replacements, drive belt inspection/tensioning, brake fluid checks, fork oil changes, spark plug replacement, and overall system checks.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting guides for common issues related to engine performance, electrical systems, and starting problems.
Repair And Overhaul:
Step-by-step repair procedures for all major and minor components, including complete engine rebuilds, transmission overhauls, and suspension repairs.
Diagnosis:
ECM diagnostic codes, sensor testing procedures, fuel system pressure testing, ignition timing verification.
Component Replacement:
Detailed instructions for replacing parts such as brake pads, clutch plates, wheel bearings, fork seals, and various electrical components.
Depth:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic adjustments to complete engine and transmission rebuilds.
Engine Family:
Harley-Davidson Twin Cam 96 (1584cc)
Engine Type:
Air-cooled, V-twin, pushrod actuated, overhead valves
Bore X Stroke:
3.75 in. x 4.38 in. (95.3 mm x 111.3 mm)
Displacement:
96 cu in (1584 cc)
Compression Ratio:
9.2:1 (Typical for Twin Cam 96)
Horsepower:
Estimated 65-70 HP (stock, varies by model and tuning)
Torque:
Estimated 85-90 ft-lbs @ 3,500 RPM (stock, varies by model and tuning)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended
Oil Capacity:
Approximately 3.0 US quarts (2.8 L) with filter change (verify with manual)
Oil Type:
Harley-Davidson proprietary V-Twin Oil or equivalent SAE 20W50 motorcycle oil meeting Harley-Davidson specifications.
Engine Oil Change:
Every 5,000 miles or 6 months, whichever comes first. (Refer to manual for exact interval and conditions).
Primary Chain Tension:
Check and adjust every 10,000 miles or as needed.
Drive Belt Tension:
Check and adjust every 5,000 miles.
Spark Plugs:
Replace every 10,000 miles (or as per manual, check condition).
Brake Fluid:
Inspect and potentially flush/replace every 2 years or 10,000 miles.
Engine Oil:
SAE 20W50 motorcycle oil meeting Harley-Davidson specifications (e.g., Harley-Davidson Genuine V-Twin 20W50). Check manual for specific HD part numbers if available.
Transmission Oil:
Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant (P/N 94615-04 or equivalent).
Primary Chaincase Oil:
Harley-Davidson Formula + Transmission & Primary Chaincase Lubricant (P/N 94615-04 or equivalent).
Brake Fluid:
DOT 4 (for ABS models) or DOT 5.1 (for non-ABS, though DOT 4 is often recommended as a higher-performing alternative to DOT 5.1 if compatible).
Fork Oil:
Specific weight and type depends on the fork (e.g., Harley-Davidson Type 'E' or 'H' Fork Oil, or equivalents like Bel-Ray SAE 10W or 15W).
Common Problems:
Issues can include transmission shifting difficulties, primary chain tensioner wear (especially on earlier models, though improved by 2007), potential oil leaks from seals, and electrical gremlins if not properly maintained. Fueling and ignition system tuning can also be a factor for performance.
Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer known for its V-twin engines and cruiser/touring motorcycles.
Dynafamily:
The Dyna platform, introduced in 1991, featured a frame and suspension design that bridged the gap between the rigid Sportster and the larger, touring-oriented Big Twin frames. It was known for its rubber-mounted engine for reduced vibration.
Manufacturing Location:
Primarily manufactured at Harley-Davidson's York, Pennsylvania, and Milwaukee, Wisconsin facilities.
