Product Category:
Motorcycle Service and Repair Manuals
Target Audience:
Harley-Davidson owners, independent repair shops, motorcycle technicians.
Value Proposition:
Provides comprehensive, factory-authorized repair and maintenance procedures, crucial for proper servicing of the Dyna platform.
Completeness:
This is the complete official factory service manual, covering all aspects of the vehicle's mechanical and electrical systems.
Detail Level:
Features detailed exploded diagrams, step-by-step instructions, and diagnostic troubleshooting charts.
Model Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Chassis Variants Covered:
FXD (Super Glide)
Estimated Page Count:
Approximately 600+
Manual Type:
Factory Service/Workshop Repair Manual
Format:
Downloadable Digital Format (PDF)
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly for Twin Cam 88 engine.
Fuel System:
Carburetor (Keihin CV) disassembly, adjustment, and troubleshooting; fuel tank, lines, and pump maintenance.
Ignition System:
Ignition module, coil, spark plugs, wiring, and troubleshooting.
Transmission Drivetrain:
5-speed constant mesh transmission disassembly, repair, fluid changes, clutch service, belt drive maintenance.
Electrical System:
Complete wiring diagrams, component testing, charging system (stator, regulator, battery), lighting, starting system, and accessories.
Brakes:
Hydraulic brake system servicing, caliper rebuilds, master cylinder maintenance, brake fluid flush, and troubleshooting.
Suspension:
Front fork (39mm Telescopic) disassembly, seal replacement, fluid changes; rear shock absorber inspection and replacement.
Chassis Frame:
Frame inspection, swingarm pivot, steering head bearing service and adjustment.
Bodywork Fittings:
Fender removal/installation, fuel tank mounting, seat service, handlebar and control lever adjustments, exhaust system.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, chain/belt adjustments, tire pressure checks, lubrication points.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common problems, electrical fault finding, engine performance issues.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension upgrades, electrical system repairs.
Component Disassembly Reassembly:
Detailed instructions for removing and installing all major and minor components.
Depth Of Coverage:
Comprehensive factory-level repair information suitable for professional mechanics and experienced DIY enthusiasts.
Diagnostic Procedures:
Includes specific diagnostic flowcharts and resistance/voltage checks for electrical components.
Torque Specifications:
Detailed torque values for all fasteners and critical assembly points.
Engine Type:
Air-cooled, Twin Cam 88 V-Twin
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.75 in x 3.968 in (95.25 mm x 100.6 mm)
Horsepower Approx:
65-70 HP (estimated, varies with tuning)
Torque Approx:
85-90 ft-lbs (estimated, varies with tuning)
Fuel Delivery:
Keihin CV (Constant Velocity) Carburetor, 40mm
Fuel Type:
Unleaded gasoline, 91 octane (or higher)
Oil Type:
Harley-Davidson 20W-50 Motorcycle Oil (or equivalent API SG, SF, SE)
Oil Capacity W Filter:
3.0 US quarts (2.8 liters)
Crash Test Ratings:
N/A (Motorcycles are not subject to the same standardized crash testing as automobiles.)
Braking System:
Hydraulic disc brakes, front and rear. Single front disc (292mm) and single rear disc (292mm).
Lighting:
Halogen headlight, taillight, brake light, turn signals.
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months thereafter.
Transmission Oil Change:
Every 10,000 miles (16,000 km) or 24 months
Primary Chaincase Oil Change:
Every 10,000 miles (16,000 km) or 24 months
Spark Plug Replacement:
Every 10,000 miles (16,000 km)
Engine Oil Grade:
20W-50 API SG or higher
Transmission Primary Oil:
Harley-Davidson Formula+ or Syn-3
Brake Fluid Type:
DOT 4 (for hydraulic systems)
Common Wear Items:
Clutch plates, primary chain tensioner (hydraulic tensioner introduced later), wheel bearings, fork seals.
Engine Characteristics:
Twin Cam 88 engines are known for their character but can be prone to oil leaks if not properly maintained. Early models had a mechanical cam chain tensioner that could wear. Harley-Davidson later introduced an updated hydraulic tensioner system.
Brand History:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its cruiser and touring motorcycles.
Dyna Platform Introduction:
The Dyna platform was introduced in 1991, evolving over the years with key updates like the Twin Cam engine in 1999.
Fxd Super Glide Positioning:
The FXD Super Glide served as a core model in the Dyna line, offering a blend of classic styling and performance.
Production Period:
1999-2005 (for this specific manual coverage)
Manufacturing Location:
United States
Model Recognition:
The Dyna platform, including the Super Glide, has been widely recognized for its versatility and customization potential, making it a favorite among riders.
Customer Satisfaction:
Generally high for the Harley-Davidson brand, with the Dyna platform praised for its ride and handling.
Manual Certification:
This is an official factory service manual, representing the manufacturer's authorized repair documentation.
