Model Variants:
Various (e.g., Super Glide, Low Rider, Wide Glide, Fat Bob, Street Bob - specific variants covered depend on internal manual sections not fully detailed in product info, but these are common Dyna models within the era).
Generation Name:
Second Generation Dyna (pre-Twin Cam 96 development, primarily Evolution Big Twin variants)
Vin Decoder Primary Engine Code:
Primarily 'G' for Evolution Big Twin 80 cubic inch (1340cc) engine.
Target Audience:
Harley-Davidson Dyna owners and independent repair shops seeking detailed, authoritative repair and maintenance information for models from 1999-2005.
Value Proposition:
Provides a cost-effective alternative to dealership service or expensive physical manuals, offering the same depth of information needed for DIY repairs and maintenance.
Digital Access:
Instant PDF download eliminates shipping costs and waiting times, providing immediate access to critical repair data.
Comprehensiveness:
596 pages of detailed diagrams, instructions, specifications, and troubleshooting guides, covering nearly every aspect of vehicle service.
Covered Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Type:
Workshop Service Repair Manual
Format:
PDF (Digital Download)
Powertrain:
Engine disassembly, inspection, assembly, tuning, troubleshooting; Carburetor (likely Keihin CV) overhaul and adjustment; Ignition system diagnostics; Exhaust system maintenance.
Drivetrain:
Transmission (5-speed, likely Cruise Drive) removal, installation, internal inspection, repair, clutch operation and adjustment, final drive belt maintenance.
Chassis And Suspension:
Front fork (telescopic) service, fork seal replacement, oil levels; Rear shock absorber inspection and replacement; Swingarm bearing service; Wheel bearing replacement; Steering head bearing adjustment.
Brakes:
Front and rear brake caliper overhaul, pad replacement, fluid bleeding, master cylinder service, rotor inspection.
Electrical:
Wiring diagrams, starter system, charging system (stator, regulator/rectifier), battery maintenance, lighting system, horn, ignition switch, diagnostic codes (if applicable).
Fuel System:
Fuel tank removal/installation, fuel lines, fuel filter replacement, fuel petcock service, carburetor function.
Bodywork And Trim:
Fender removal/installation, fuel tank graphics and emblems, seat removal, handlebar maintenance, control cable routing and adjustment.
Maintenance:
Scheduled maintenance tasks, oil and filter changes, spark plug replacement, air filter cleaning/replacement, drive belt tensioning and alignment.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides.
Repair:
Step-by-step repair instructions for all major components and systems, including complete engine and transmission rebuilds.
Diagnostics:
Fault code retrieval (if applicable for the era), testing of electrical components, engine performance testing.
Depth:
Comprehensive, from basic fluid changes to complete engine teardowns and rebuilds, including specifications for clearances, torque values, and wear limits.
Quality:
Likely high-resolution PDF, suitable for digital viewing and printing. Text should be searchable for efficient information retrieval.
Suitability:
Designed for printing individual pages or sections as needed by technicians and owners.
Format Consideration:
As a PDF, no physical binding. Users can print and bind as desired.
Format Consideration:
As a PDF, no physical paper type. Digital format offers flexibility.
Engine Type:
Evolution Big Twin (known as the 'Evo' Big Twin)
Engine Displacement:
80 cubic inches (1340cc)
Engine Configuration:
Air-cooled, 45-degree V-twin
Bore X Stroke:
3.4375 in x 4.25 in (87.3 mm x 108 mm)
Horsepower Estimated:
Approx. 65-70 HP (varies slightly by specific model and tuning)
Torque Estimated:
Approx. 80-85 lb-ft @ 3200 RPM (varies slightly by specific model and tuning)
Carburetor Model:
Keihin CV (Constant Velocity) 40mm carburetor (standard)
Fuel Type:
Unleaded gasoline, 91 octane (AKI) or higher recommended.
Ignition Type:
Electronic Ignition (e.g., Harley-Davidson Electronic Spark Control - ESC)
Transmission Type:
5-speed Manual Transmission
Transmission Gear Ratios:
Specific ratios will be detailed in the manual, typically ranging from ~2.94:1 in 1st to 0.87:1 in 5th.
Clutch Type:
Wet, multi-plate, cable-actuated clutch
Final Drive:
Belt drive (32mm wide, 14mm pitch)
Transmission Fluid Type:
Harley-Davidson Transmission Fluid (or equivalent API GL-5, SAE 80W-90 gear oil). Manual will specify approved types.
Crash Test Ratings:
Not applicable in the same manner as automobiles; focus is on rider safety features and handling stability.
Braking System:
Dual disc front brakes, single disc rear brake. Likely fixed caliper designs. Anti-lock Braking System (ABS) was generally optional or not available on many Dyna models during this period.
Lighting:
Halogen headlight, tail light, brake light, turn signals.
Features:
Basic audio systems (radio/cassette/CD) were optional or available on higher trim levels. Many bikes from this era did not have integrated infotainment as we know it today.
Features:
Limited to rider-controlled systems. ABS was an option on some models, but not standard.
Features:
None in the modern sense. Connectivity would be limited to aftermarket accessories.
Engine Oil Change:
Typically every 5,000 miles (8,000 km) or annually, whichever comes first. Manual will detail exact mileage and time intervals.
Transmission Oil Change:
Typically every 10,000 miles (16,000 km) or annually. Manual will specify.
Primary Chain Tensioner Check:
Crucial check at intervals specified in the manual (e.g., 1000, 5000 miles), as failure can lead to significant damage. Auto-tensioners were introduced later, but early models may have manual or less robust auto-tensioners.
Spark Plug Replacement:
Recommended every 10,000-15,000 miles (16,000-24,000 km).
Engine Oil Type:
Viscosity: 20W-50 is common for Harley-Davidson Evolution Big Twins in warmer climates. Harley-Davidson 20W-50 SYN3 (Synthetic) or H-D Classic 20W-50 motorcycle oil. Manual will list specific approved oils and grades based on temperature.
Primary Drive Fluid Type:
Harley-Davidson Primary Chaincase Lubricant (or equivalent SAE 75W-90 Synthetic Transmission Fluid). Manual will specify.
Brake Fluid Type:
DOT 4 (or DOT 5.1 depending on specific components, but DOT 4 is most common for this era). Manual will confirm.
Primary Chain Tensioner:
The original spring-loaded tensioner shoe on many Evo Big Twins (including early Dynas) was prone to wear, leading to rattling noises and potential failure. Upgraded hydraulic or automatic tensioners are common aftermarket fixes.
Cam Chain Tensioner:
Similar to the primary tensioner, the cam chain tensioner can wear. Manual will provide inspection procedures.
Carburetor Tuning:
Keihin CV carbs can sometimes require fine-tuning, especially with exhaust or intake modifications. Proper adjustment is key to performance and fuel economy.
Oil Leaks:
Common on older air-cooled V-twins, particularly around pushrod tubes, rocker boxes, and primary/transmission seals. Manual will guide on identifying and fixing leaks.
Legacy:
Harley-Davidson, founded in 1903, has a long-standing heritage in motorcycle manufacturing, synonymous with American motorcycle culture.
Dyna Lineage:
The Dyna platform, introduced in 1991, offered a more modern chassis compared to the Big Twin FXR while retaining the classic Harley-Davidson Big Twin engine. It served as a versatile platform for various styling cues and rider preferences.
Manufacturing Location:
Primarily assembled in Milwaukee, Wisconsin, USA.
