Motorcycle Segment:
Cruiser
Target Audience:
Harley-Davidson owners and independent mechanics specializing in vintage Harley-Davidson motorcycles.
Manual Value Proposition:
Provides essential technical data and procedures to maintain, repair, and restore the FXDL Dyna Low Rider, offering significant cost savings compared to dealership service.
Core Competency:
Empowers owners to perform complex maintenance and repairs with confidence through detailed, accurate, and visual instructions.
Covered Years:
1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998
Specific Models Covered:
FXDL Dyna Low Rider
Estimated Page Count:
350+
Type:
Complete Workshop Service Repair Manual
File Format:
PDF (Portable Document Format)
Searchability:
Searchable text for quick information retrieval.
Printable:
Printable pages for hands-on workshop use.
Quality:
High-resolution scans, clear diagrams and illustrations.
Engine Mechanical:
Detailed disassembly, inspection, assembly, and troubleshooting of the Evolution V-twin engine.
Fuel System:
Carburetor (Keihin CV40) tuning, servicing, and overhaul; fuel pump and fuel line maintenance.
Ignition System:
Ignition timing, coil testing, spark plug selection and maintenance, module diagnostics.
Transmission Drivetrain:
5-speed gearbox service, clutch adjustment and replacement, primary drive chain maintenance, final drive belt inspection and adjustment.
Suspension And Steering:
Front fork (Showa conventional) overhaul, rear shock absorber inspection and replacement, steering head bearing adjustment and service.
Brakes:
Front and rear brake caliper service, master cylinder overhaul, brake fluid replacement, rotor and pad inspection.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier) testing, lighting circuits, starter motor service.
Frame And Bodywork:
Frame inspection, body panel removal and installation, fender mounting, seat assembly.
Wheels And Tires:
Wheel bearing service, tire selection and pressure recommendations, spoke tensioning (if applicable).
Scheduled Maintenance:
Detailed service intervals for oil changes, filter replacements, spark plugs, drive belt checks, and more.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon problems with detailed symptom analysis.
Engine Rebuilding:
Step-by-step instructions for complete engine teardown, piston and cylinder inspection, valve service, and reassembly.
Transmission Overhaul:
Complete gearbox disassembly, gear inspection, bearing replacement, and reassembly procedures.
Electrical Diagnostics:
Procedures for testing all electrical components, including using multimeters and interpreting wiring diagrams.
Carburetor Tuning:
Comprehensive guide to adjusting the CV40 carburetor for optimal performance and fuel economy.
Brake System Service:
Detailed steps for bleeding the brake system, replacing pads and rotors, and servicing calipers and master cylinders.
Depth:
Comprehensive: Covers everything from basic maintenance and adjustments to complete engine and transmission rebuilds and advanced diagnostics.
Diagnostic Level:
Advanced diagnostic procedures, including troubleshooting electrical faults and engine performance issues.
Rebuild Level:
Full component-level rebuild instructions for major mechanical and electrical systems.
Engine Type:
Air-cooled, 45-degree V-twin, pushrod valve actuation
Displacement:
1339.8 cc (81.8 cubic inches)
Bore X Stroke:
3.496 in x 4.25 in (88.8 mm x 107.95 mm)
Compression Ratio:
9.0:1 (typical)
Valve Train:
Overhead valves (OHV), 2 valves per cylinder
Camshaft:
Single camshaft located in the crankcase
Horsepower Est:
~50-60 HP (at rear wheel, estimated)
Torque Est:
~65-75 lb-ft (at rear wheel, estimated)
Carburetor Model:
Keihin CV40 (Constant Velocity)
Fuel Type:
Unleaded gasoline, 87-91 octane recommended
Fuel Tank Capacity:
4.0 US gallons (15.1 L)
Engine Oil Change:
Every 2,500 - 5,000 miles (3,000 - 7,500 km) or 6 months, whichever comes first.
Transmission Oil Change:
Every 10,000 miles (16,000 km) or 12 months.
Primary Chain Tension:
Check and adjust every 5,000 miles (7,500 km).
Spark Plug Replacement:
Every 10,000 miles (16,000 km).
Engine Oil Type:
Harley-Davidson 20W-50 motorcycle oil or equivalent API SG or higher rated oil.
Engine Oil Capacity:
3.5 US quarts (3.3 L) with filter change.
Brake Fluid Type:
DOT 4 recommended.
Crankcase Breather System:
Potential for oil blow-by; proper breather setup is crucial.
Carburetor Idle Stability:
CV40 carburetor may require periodic adjustment for stable idle.
Electrical Connections:
Corrosion or looseness in electrical connectors can lead to intermittent issues.
Manufacturer Origin:
United States
Dyna Platform Introduction:
The Dyna platform was introduced in 1991 as a new generation of Harley-Davidson motorcycles, featuring a separate transmission from the engine crankcase and a rubber-isolated powertrain for reduced vibration.
Low Rider Concept:
The Low Rider model has historically emphasized rider comfort with a low seat height and forward-mounted controls.
Manufacturing Era:
1991-1998 model years covered by this manual.
