Category:
Custom Cruiser / Classic American Motorcycle
Target Audience:
Harley-Davidson owners and independent repair shops specializing in vintage Harley-Davidsons.
Competitors:
Other American V-twin motorcycles of the era (e.g., Indian, custom choppers), Japanese cruisers seeking a different aesthetic.
Design:
Iconic Wide Glide front end with extended forks and a raked-out appearance, classic Harley-Davidson styling.
Riding Experience:
Characteristic V-twin rumble, comfortable cruiser ergonomics, strong aftermarket support.
Manual Value:
Essential for maintaining the longevity and performance of these classic machines, particularly for owners performing their own maintenance.
Applicable Years:
1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998
Estimated Pages:
Approximately 500-800 pages (typical for comprehensive service manuals)
Type:
Service Repair Manual / Workshop Manual
Powertrain:
Engine, Transmission, Primary Drive, Final Drive
Chassis:
Frame, Suspension (Front Fork, Rear Shocks), Steering, Wheels, Tires, Brakes (Front and Rear)
Electrical:
Ignition System, Lighting System, Charging System (Alternator, Regulator), Battery, Wiring Diagrams, Instruments, Gauges, Switches, Relays, Horn
Bodywork:
Fuel Tank, Fenders, Seat, Handlebars, Controls, Mirrors, Exhaust System
Miscellaneous:
Component identification, specifications, troubleshooting guides
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication, adjustments
Repair Overhaul:
Engine disassembly/assembly, transmission overhaul, brake system repair, suspension servicing, electrical component replacement
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts
Diagnostics:
Component testing, electrical system diagnostics, ignition timing procedures
Depth:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
Engine Type:
Air-cooled, Evolution (V-Twin)
Displacement:
80 cubic inches (1339 cc)
Bore X Stroke:
3.50 in x 4.25 in (88.9 mm x 108 mm)
Compression Ratio:
8.5:1 (typical for Evolution 80ci)
Valvetrain:
OHV, 2 valves per cylinder
Firing Order:
0, 3, 6, 2, 1, 5, 4, 7 (for 45° V-twin)
Oil Capacity:
Approximately 4 quarts (3.8 liters) with filter change.
Horsepower:
Approx. 58-65 hp (at crankshaft, estimates vary)
Torque:
Approx. 65-70 ft-lbs (at crankshaft, estimates vary)
Carburetor:
Keihin CV (Constant Velocity) 40mm
Fuel Type:
Unleaded gasoline, 89 octane minimum (91 octane recommended)
Fuel Tank Capacity:
4.2 US gallons (15.9 liters)
Type:
5-speed Manual Constant Mesh
Gear Ratios:
1st: 3.05, 2nd: 2.14, 3rd: 1.63, 4th: 1.32, 5th: 1.00 (typical for 5-speed) - specific ratios can be found in the manual.
Clutch Type:
Wet, multi-plate, diaphragm spring
Primary Drive:
Chain, 34/46 teeth (1.353:1)
Final Drive:
Belt drive, 32/65 teeth (2.031:1)
Type:
Harley-Davidson Syn3 (synthetic blend) or equivalent 20W-50 motorcycle oil.
Capacity:
24 US fluid ounces (0.71 liters) for gearbox.
Wheelbase:
Approx. 65.0 inches (1651 mm)
Length:
Approx. 93.0 inches (2362 mm)
Overall Width:
Approx. 35.0 inches (889 mm)
Overall Height:
Approx. 52.0 inches (1321 mm)
Ground Clearance:
Approx. 4.5 inches (114 mm)
Seat Height:
Approx. 26.7 inches (678 mm)
Dry Weight:
Approx. 565 lbs (256 kg)
Gross Vehicle Weight Rating:
Approx. 940 lbs (426 kg)
Payload Capacity:
Approx. 375 lbs (170 kg)
Crash Testing:
Motorcycles of this era were not subject to standardized crash testing like automobiles. Safety is inherent in design and rider skill.
Braking:
Hydraulic disc brakes front and rear. Single disc front, single disc rear.
Suspension:
Telescopic front fork with 39mm stanchions, dual rear shock absorbers with adjustable preload.
Lighting:
Halogen headlight, taillight, brake light, turn signals.
Frame:
Steel tube cradle frame, designed for stability.
System:
Basic instrumentation: speedometer, odometer, tachometer (optional), neutral indicator, oil pressure light, high beam indicator. No integrated infotainment or advanced electronics.
Features:
N/A. This era of Harley-Davidson focused on mechanical simplicity and rider feedback rather than electronic aids.
Features:
N/A. No Bluetooth, USB ports, or smartphone integration.
Oil Change:
Every 2,500-5,000 miles or annually, whichever comes first (refer to specific manual for exact interval).
Primary Chain Tension:
Check and adjust every 5,000-10,000 miles (or as per manual, may be automatic tensioner depending on exact build).
Spark Plugs:
Inspect/replace every 10,000-15,000 miles.
Drive Belt:
Inspect for wear and tension every 5,000 miles. Replace as needed (typically 30,000-60,000 miles).
Engine Oil:
API CG-4 or better, SAE 20W-50 motorcycle specific (e.g., Harley-Davidson 20W-50 Syn3).
Transmission Fluid:
Harley-Davidson Heavy Duty ShockProof Gear Oil (preferred by many) or SAE 80W-90 gear oil.
Primary Chain Case Oil:
Harley-Davidson Primary Fluid or SAE 20W-50 motorcycle oil.
Brake Fluid:
DOT 4 hydraulic fluid.
Oil Leaks:
Common with older Evolution engines, particularly around base gaskets, rocker boxes, and pushrod tubes. Proper torque and new seals are critical.
Cam Chain Tensioner:
Early Evolution engines (pre-2000) used spring-loaded tensioners which could wear out, leading to noise and potential damage. Upgraded hydraulic tensioners are recommended.
Carburetor Performance:
Keihin CV carburetors can require tuning adjustments (e.g., jetting, needle) for optimal performance, especially with aftermarket exhaust or engine modifications.
Electrical Connections:
Corrosion or loose connections in the wiring harness can cause intermittent issues or component failures.
Suspension Wear:
Front fork seals and rear shock absorbers can wear over time, leading to a less comfortable ride and reduced handling.
Legacy:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer with a long history of producing V-twin motorcycles known for their distinctive sound, styling, and customization potential.
Dyna Platform:
The Dyna platform was introduced in 1991 and served as a core platform for Harley-Davidson's cruiser line. The FXDWG Wide Glide variant was a key model within this platform, emphasizing retro styling and a chopper-inspired profile.
Evolution Engine:
The Evolution engine (often referred to as 'Evo') replaced the Shovelhead engine in 1984 for big twins and became the standard powerplant, known for its reliability and improved performance over its predecessors.
Manufacturing Location:
United States (Various Harley-Davidson assembly plants)
Model Run:
The FXDWG Wide Glide was produced in this form from 1991 through the 1998 model year, before undergoing updates and platform changes.
