Target Audience:
Harley-Davidson FXD Dyna owners, independent repair shops, motorcycle enthusiasts seeking to perform their own maintenance and repairs
Value Proposition:
Provides comprehensive, dealership-level repair information at a fraction of the cost of official service manuals or shop labor, enabling owners to maintain their investment and extend the lifespan of their motorcycle.
Completeness:
Covers virtually every aspect of the motorcycle's mechanical and electrical systems, offering a complete guide for servicing.
Accuracy:
Based on official manufacturer specifications and procedures, ensuring accuracy and reliability of information.
Accessibility:
Digital format allows for easy access on computers, tablets, and smartphones, with search functionality for rapid information lookup.
Model Years Covered:
1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998
Specific Models Covered:
FXD Dyna (all variants within the FXD platform for these years)
Estimated Page Count:
Approximately 600-800 pages (typical for comprehensive workshop manuals of this era)
Type:
Workshop Service Repair Manual
Format:
Downloadable Digital Format (likely PDF)
Engine:
Engine assembly, disassembly, inspection, repair, timing, lubrication, cooling (air-cooled), fuel delivery, ignition system, starting system
Transmission:
5-speed transmission (primary and secondary drive, clutch, gear inspection and repair, shift linkage)
Chassis:
Frame, front suspension (forks), rear suspension (shocks/swingarm), steering system, wheel bearings, axle specifications
Brakes:
Front and rear brake systems (hydraulic, caliper, rotor, master cylinder, brake fluid specifications, bleeding procedures)
Electrical:
Wiring diagrams, battery, charging system (alternator, stator, regulator/rectifier), ignition system components, lighting, instrumentation, starting system, electrical troubleshooting
Fuel System:
Carburetor (Keihin CV) disassembly, cleaning, adjustment, fuel lines, fuel pump (if applicable), fuel tank maintenance
Exhaust System:
Exhaust pipe and muffler inspection, gasket replacement, mounting hardware
Bodywork:
Fenders, fuel tank, seat, handlebars, control levers, fairings/covers (if equipped), mounting hardware, cosmetic care
Wheels And Tires:
Tire types, sizes, pressure specifications, wheel balancing, spoke tension (if applicable), rim types
Maintenance:
Regular service checks, oil changes, filter replacements, spark plug maintenance, drive belt adjustment/replacement, brake pad inspection, lubrication points
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault finding charts, symptoms and causes
Repair:
Detailed step-by-step instructions for component disassembly, reassembly, and repair, including engine rebuilds, transmission overhauls, suspension work, and electrical system repairs
Component Overhaul:
In-depth instructions for complete teardown and rebuilding of major components like engines, transmissions, and carburetors
Wiring Diagrams:
Comprehensive and detailed wiring schematics for all electrical systems
Special Tools:
Identification and usage of specialized tools required for specific repair and maintenance tasks
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics
Diagnostic Capabilities:
Detailed diagnostic procedures, fault code interpretation (if applicable), symptom-based troubleshooting guides
Rebuild Instructions:
Detailed instructions for complete teardown, cleaning, inspection, measurement, and reassembly of all major mechanical components
Engine Type:
V-twin, air-cooled, four-stroke, Evolution engine
Displacement Variants:
Primarily 1338 cc (82 cubic inches) for the specified years, potentially with variations depending on specific sub-models or tuning.
Bore X Stroke:
Typical 3.496 in x 4.25 in (88.8 mm x 108 mm) for 1338cc
Compression Ratio:
Approximately 8.3:1 to 9.0:1 depending on model year and specific tuning
Horsepower:
Typically around 55-65 HP (at crank, dependent on specific tuning and model year)
Torque:
Typically around 70-80 lb-ft (at crank, dependent on specific tuning and model year)
Carburetor:
Keihin CV (Constant Velocity) carburetor (e.g., CV40 on many models)
Fuel Type:
Unleaded Gasoline, minimum octane rating typically 87 or higher (check specific manual for exact recommendation)
Ignition Type:
Electronic Ignition (CDI or similar Harley-Davidson specific system)
Oil Type:
Harley-Davidson recommends specific motorcycle oils, typically 20W50 or 10W40 (check manual for exact specification)
Oil Capacity:
Approximately 3.0-3.5 US quarts (2.8-3.3 liters) including oil filter (check manual for exact capacity)
Cooling Method:
Air-cooled
Gearbox:
5-speed constant mesh, manual transmission
Transmission Options:
N/A (Standard 5-speed manual)
Primary Drive:
Clutch, chain-driven primary drive to transmission
Secondary Drive:
Belt drive (typically 25mm or 32mm wide belt)
Transmission Oil Type:
Harley-Davidson primary chaincase lubricant or equivalent (check manual for exact specification)
Primary Chaincase Capacity:
Approximately 1.0-1.2 US quarts (0.9-1.1 liters) (check manual for exact capacity)
Wheelbase:
Approximately 62.5 inches (1587.5 mm) (typical for FXD models)
Length:
Varies by model year and specific configuration, typically around 90-92 inches (2286-2337 mm)
Dry Weight:
Approximately 570-600 lbs (259-272 kg) (varies by specific FXD model)
Gross Vehicle Weight Rating Gvwr:
Typically around 950-1000 lbs (431-454 kg)
Front Tire Size:
Commonly 100/90-19 or similar
Rear Tire Size:
Commonly 130/90-16 or similar
Wheel Type:
Typically steel or alloy spoke wheels or solid cast wheels depending on trim
Wheel Bolt Pattern:
N/A (Harley-Davidson wheels use hub mounting, not bolt patterns)
Fuel Tank Capacity:
Approximately 3.7 US gallons (14 liters) for standard tanks
Infotainment System:
Limited to basic instrumentation: speedometer, tachometer (optional), odometer, trip meter, indicator lights (oil pressure, turn signals, neutral, high beam).
Driver Assistance Features:
None (This era of motorcycle predates modern electronic rider aids).
Connectivity Features:
None (No Bluetooth, Wi-Fi, or smartphone integration).
First Service:
Typically at 1,000 miles (1,600 km) or 6 months, whichever comes first.
Subsequent Oil Change:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first.
Belt Inspection Replacement:
Inspect belt for wear and damage at every service; replacement intervals vary based on riding conditions and wear.
Spark Plug Replacement:
Typically every 10,000-15,000 miles (16,000-24,000 km)
Engine Oil Specification:
Consult manual for specific Harley-Davidson recommended oil viscosity (e.g., SAE 20W50, SAE 10W40) and API classification.
Primary Chaincase Fluid Specification:
Consult manual for Harley-Davidson primary chaincase lubricant or equivalent specification.
Brake Fluid Specification:
DOT 4 or DOT 5.1 hydraulic brake fluid (confirm exact specification for the model year in the manual).
Transmission Fluid Specification:
N/A (Transmission shares oil with primary chaincase).
Evolution Engine Wear:
Potential for oil leaks from pushrod tubes or rocker boxes due to aging seals.
Cam Chain Tensioners:
Early Evolution engines used spring-loaded cam chain tensioners that could wear prematurely, leading to noise or potential engine damage; later models and aftermarket upgrades address this.
Carburetor Issues:
Keihin CV carburetor can be sensitive to altitude and require fine-tuning for optimal performance. Diaphragm can degrade over time.
Belt Drive Wear:
Rear drive belt can be susceptible to damage from road debris or improper tensioning.
Brand Origin:
Harley-Davidson Motor Company, established in Milwaukee, Wisconsin, USA, in 1903.
Dyna Introduction:
The Dyna platform was introduced in 1991, evolving from earlier Big Twin models with a focus on a more modern ride and handling while retaining the classic Harley-Davidson character.
Evolution Engine:
The Evolution engine (also known as the 'Evo') was introduced in 1984 and became the primary powerplant for Harley-Davidson's Big Twin models, including the Dyna series, known for its improved reliability and performance over previous Shovelhead and Evolution predecessors.
Manufacturing Location:
Primarily manufactured at Harley-Davidson's facilities in the United States.
