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Harley Davidson FXDX Dyna Super Glide 2002 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley Davidson Model: FXDX Dyna Super Glide Sport Year: 2002 Codes Engine Type Code: Evolution (V-Twin) 👋 Introduction Market Position Market Position: The 2002 Harley...
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类型: Motorcycle
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Harley Davidson FXDX Dyna Super Glide 2002 Service Repair ManualHarley Davidson FXDX Dyna Super Glide 2002 Service Repair ManualHarley Davidson FXDX Dyna Super Glide 2002 Service Repair ManualHarley Davidson FXDX Dyna Super Glide 2002 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Harley Davidson
Model:
FXDX Dyna Super Glide Sport
Year:
2002
Codes
Engine Type Code:
Evolution (V-Twin)
👋 Introduction
Market Position
Market Position:
The 2002 Harley Davidson FXDX Dyna Super Glide Sport was positioned as a performance-oriented cruiser within the Dyna lineup, featuring a more aggressive stance and suspension compared to standard Dyna models. It appealed to riders seeking a blend of classic Harley styling with sportier handling characteristics.
Competitive Analysis
Competitive Analysis:
Competed against other American V-twin cruisers from brands like Indian, as well as Japanese manufacturers offering V-twin models in similar displacement categories, such as Yamaha's V-Star series and Honda's V-twin cruisers.
Key Features
Key Features:
Twin downtube frame, forward-mounted foot controls, dual front disc brakes, performance-tuned suspension, 5-speed transmission, Twin Cam 88 engine (carbureted).
📋 Manual Details
Coverage Areas
Coverage:
Comprehensive repair and service for the 2002 Harley Davidson FXDX Dyna Super Glide Sport.
Page Count
Page Count:
707
Manual Type
Manual Type:
Workshop Service Manual
Manual Purpose:
Designed for mechanics and owners to perform repair, maintenance, and adjustments efficiently and correctly.
Language
Language:
English
Format
File Format:
PDF
Digital Delivery:
Instant download available upon completion of secure payment, eliminating shipping costs and delays.
Compatibility
Operating Systems:
Compatible with Windows, Mac, and Linux operating systems.
Requirement
Software Requirement:
Adobe Reader or compatible PDF viewer.
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine (disassembly, assembly, troubleshooting, performance adjustments), Fuel System (carburetor, fuel lines, tank), Ignition System, Electrical System (wiring diagrams, lighting, charging system, starter), Drivetrain (clutch, transmission, primary drive, final drive), Chassis (frame, suspension, steering, brakes), Wheels and Tires, Bodywork, Emissions Control Systems.
Suspension Systems:
Front telescopic fork (showcases inspection, seal replacement, oil level and type), Rear shock absorbers (discusses adjustment and replacement).
Braking Systems:
Front dual-disc brake system, rear disc brake system. Covers hydraulic system checks, fluid replacement, pad replacement, caliper service, and rotor inspection.
Procedures Included
Procedures Included:
Routine maintenance, scheduled maintenance, troubleshooting guides, diagnostic procedures, component removal and installation, disassembly and assembly, adjustments (idle speed, clutch, brakes, suspension), rebuilding procedures, torque specifications, wear limits, special tool usage, electrical diagnostics, wiring schematics.
Diagnostic Procedures:
The manual provides diagnostic flowcharts and symptom-based troubleshooting for common issues related to engine performance, electrical systems, and braking.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all circuits, including lighting, ignition, starting, charging, and accessories.
Special Tool Identification:
References to specific Harley Davidson or aftermarket special service tools required for various procedures, often accompanied by illustrations of the tool in use.
Technical Depth
Technical Depth:
Detailed step-by-step instructions with comprehensive explanations and pictorial diagrams, suitable for both professional mechanics and experienced DIY enthusiasts. Covers basic adjustments to complete engine rebuilds and electrical system diagnostics.
Detail Level Engine:
Detailed overhaul procedures for the Twin Cam 88 engine, including cylinder head removal/installation, piston and ring replacement, crankshaft and connecting rod checks, camshaft inspection and timing.
Torque Specifications:
Includes specific torque values for a wide range of fasteners throughout the motorcycle, essential for safe and correct assembly.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
Printable from PDF, high resolution for clear viewing and reproduction.
Binding Type
Binding Type:
Digital Download (PDF)
Paper Type
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Harley Davidson Twin Cam 88
Engine Configuration:
Air-cooled, 45-degree V-twin
Displacement:
1450 cc (88 cubic inches)
Bore X Stroke:
3.75 in x 4.00 in (95.25 mm x 101.6 mm)
Compression Ratio:
8.8:1
Performance
Horsepower Approximate:
60-65 HP (at rear wheel, estimated)
Torque Approximate:
70-75 ft-lbs (at rear wheel, estimated)
Engine Cooling:
Air-cooled
Fuel System
Fuel Delivery:
Keihin CV (Constant Velocity) carburetor, 40mm
Fuel Type:
Unleaded gasoline, minimum 87 octane
Fuel Tank Capacity:
4.5 US gallons (17 liters)
Ignition System Type:
Electronic ignition system
🔧 Transmission
Standard
Transmission Type:
5-speed, constant mesh
Primary Drive:
Chain, 34/46 ratio
Final Drive:
Belt, 32/65 ratio
Features
Clutch Type:
Wet, multi-plate
📐 Dimensions
Exterior
Length:
Approximately 91.5 inches (2324 mm)
Width:
Approximately 34 inches (864 mm) (at handlebars)
Height:
Approximately 49.5 inches (1257 mm)
Weights
Dry Weight:
Approximately 635 lbs (288 kg)
Gross Vehicle Weight Rating:
Approximately 1000 lbs (454 kg)
Load Capacity:
Approximately 365 lbs (166 kg)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycles are not rated by traditional crash test agencies like NHTSA or IIHS for passenger vehicles.)
Active Features
Active Features:
Dual front disc brakes with 4-piston calipers, single rear disc brake with 2-piston caliper, responsive steering geometry.
Passive Features
Passive Features:
Heavy-duty frame construction, integrated rider controls, ergonomic seating position.
💡 Technology Features
Infotainment
Infotainment System:
N/A (This era of motorcycle typically did not feature integrated infotainment systems. Rider typically added aftermarket audio or communication devices.)
Driver Assistance
Driver Assistance Features:
N/A (No electronic driver assistance features like ABS or traction control were standard on this model.)
🔧 Maintenance
Service Intervals
First Service:
1,000 miles (1600 km) or 6 months
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months
Fluid Specifications
Engine Oil Type:
Harley Davidson 20W-50 Synthetic Motorcycle Oil or equivalent meeting Harley Davidson specification (e.g., HD-360).
Engine Oil Capacity:
3.2 US quarts (3.0 liters) with filter change
Primary Chain Case Oil Type:
Harley Davidson Formula + Transmission and Primary Chain Case Lubricant, or Syn3.
Primary Chain Case Oil Capacity:
2.4 US quarts (2.3 liters)
Transmission Oil Type:
Harley Davidson Formula + Transmission and Primary Chain Case Lubricant, or Syn3.
Transmission Oil Capacity:
0.95 US quarts (0.9 liters)
Brake Fluid Type:
DOT 4 (refer to manual for specific front/rear system differences)
Fork Oil Type:
Harley Davidson type E or equivalent, or Harley Davidson Type B for heavier damping (refer to manual for specific recommendation for FXDX).
Fork Oil Level:
Specific levels provided for front fork oil, critical for proper damping.
Known Issues
Known Issues:
Cam chain tensioner wear (especially on early Twin Cam models, though the manual should address checks and replacements), carburetor performance tuning, exhaust leaks, electrical connectors corrosion.
Maintenance Notes:
Regular cleaning of the air filter and checking tire pressure are crucial for optimal performance and longevity. Adherence to the torque specifications is critical for engine and chassis components.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Harley Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines, distinctive styling, and a strong rider community. The brand is synonymous with freedom, rebellion, and a uniquely American riding experience.
Model Evolution
Model Evolution:
The Dyna line, introduced in 1991, was designed to offer a more modern and performance-oriented platform compared to the traditional Big Twin models. The FXDX designation specifically indicated the 'Sport' version, emphasizing enhanced suspension, brakes, and a more aggressive riding posture.
Production
Production Years For Model:
The Dyna Super Glide Sport (FXDX) was produced from 1999 to 2005.
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