Production Years Covered By Manual:
1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998
Target Audience:
Harley-Davidson Dyna Glide owners and independent mechanics seeking detailed service and repair information for specific model years.
Manual Value Proposition:
Provides a cost-effective alternative to dealership service, enabling owners to perform maintenance and repairs with factory-level detail and accuracy.
Key Features:
Comprehensive coverage, detailed illustrations and diagrams, step-by-step procedures, diagnostic information, and torque specifications essential for proper repair.
Engine Systems:
Engine disassembly, assembly, tuning, lubrication, cooling, ignition, fuel delivery (carburetor and early EFI if applicable), exhaust.
Transmission Drivetrain Systems:
Clutch operation and adjustment, transmission disassembly and assembly, final drive system (chain or belt), gearbox oil specifications.
Chassis Suspension Systems:
Frame inspection and repair, front fork service (oil changes, seal replacement), rear shock absorber service and replacement, wheel and tire maintenance, steering head bearing service.
Braking Systems:
Brake caliper service, master cylinder service, brake line replacement, brake fluid specifications and bleeding procedures, rotor and pad wear limits.
Electrical Systems:
Wiring diagrams for all circuits, battery maintenance and testing, charging system (stator, regulator/rectifier), starting system, lighting system, ignition system components, instrument cluster diagnostics.
Bodywork Fittings:
Fairing removal and installation (if applicable), fuel tank maintenance, seat removal, fenders, handlebars, controls and cables adjustment/replacement.
Maintenance Procedures:
Scheduled maintenance, oil and filter changes, spark plug replacement, air filter cleaning/replacement, drive belt/chain adjustment and lubrication, brake fluid flush, fork oil change, battery checks.
Repair Procedures:
Engine rebuilds (top end, bottom end), transmission overhauls, carburetor rebuilds/adjustment, electrical component troubleshooting and replacement, suspension component repair, brake system overhauls.
Troubleshooting Diagnostics:
Step-by-step diagnostic charts for common and uncommon issues, electrical troubleshooting flowcharts, engine performance diagnosis.
Diagnostic Capabilities:
Detailed diagnostic procedures for mechanical and electrical faults, including symptom-based troubleshooting and component testing.
Rebuild Completeness:
Comprehensive instructions for complete engine and transmission rebuilds, including torque specifications, clearances, and assembly sequences.
Engine Family:
Evolution (Evo) V-Twin
Engine Displacement Variants:
Primarily 1340cc (81.6 cubic inches) for most models in this range. Some models may have variations or later carburetor/EFI specific tuning.
Engine Configuration:
Air-cooled, 45-degree V-twin, pushrod actuated overhead valves.
Horsepower Range Estimated:
Typically 55-65 HP (approximate, varies with model and tuning)
Torque Range Estimated:
Typically 70-85 ft-lbs (approximate, varies with model and tuning)
Fuel Delivery Early Years:
Keihin CV (Constant Velocity) Carburetor (e.g., CV40)
Fuel Delivery Later Years:
Electronic Fuel Injection (EFI) began to be introduced in later models within this range, depending on the specific Dyna Glide variant.
Ignition Type:
Electronic Ignition (CDI or similar)
Transmission Type:
5-speed constant mesh manual transmission
Optional Transmissions:
None offered from factory for this period; 5-speed was standard.
Clutch Type:
Wet, multi-plate, cable-actuated
Final Drive:
Primary drive via clutch basket, final drive typically by belt drive (most common) or chain drive on some specific models or aftermarket conversions.
Infotainment Features:
Minimal to none. These models typically featured analog gauges (speedometer, tachometer, odometer, trip meter, oil pressure, voltage meter) and basic lighting controls.
Driver Assistance Features:
None. Focus is on rider control and mechanical feedback.
Connectivity Features:
None.
Engine Oil Change Interval:
Typically every 2,500 - 5,000 miles or 6 months, whichever comes first (refer to specific model year for exact interval).
Primary Chain Case Oil Change:
Every 5,000 - 10,000 miles (refer to manual for specifics).
Transmission Oil Change:
Every 10,000 - 15,000 miles (refer to manual for specifics).
Engine Oil Type:
Harley-Davidson recommends specific V-Twin motorcycle oils, typically 20W-50 or 10W-40 viscosity (API SG or higher), or specific synthetic blends meeting HD standards (e.g., SYN3).
Primary Chain Case Fluid:
Typically Harley-Davidson Primary Fluid or a compatible formula (often a Type 'E' or similar)
Transmission Fluid:
Harley-Davidson Transmission Fluid or a compatible heavy-duty gear oil (e.g., 80W-90 GL-5 if specified).
Brake Fluid Type:
DOT 4 or DOT 5.1, depending on Harley-Davidson's recommendation for that model year and braking system. Some earlier models might have used DOT 5.
Common Issues 1991-1998 Dyna Glide:
Cam chain tensioner wear (especially early Evo), carburetor tuning issues (CV carb), potential for primary chain drive slack, aging electrical connectors, starter solenoid issues, fork seal leaks.
Maintenance Importance:
Regular adherence to maintenance schedules is crucial for longevity and performance, especially for the older Evo engine and its associated components.
Harley Davidson Legacy:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer with a rich history of producing large-displacement V-twin motorcycles known for their distinctive sound, styling, and build quality.
Dyna Glide Introduction:
The Dyna Glide platform was introduced in 1991 as a successor to the Shovelhead-powered FXRs, offering a blend of classic styling with modern chassis design. It aimed to provide a more rigid frame and improved handling compared to earlier models.
Evolution Engine Integration:
This era saw the widespread adoption of the Evolution (Evo) engine, known for its reliability and torquey performance, replacing older engine designs. The manual covers this pivotal transition period.
Manufacturing Location:
United States (primarily York, Pennsylvania and Milwaukee, Wisconsin)
