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Harley Davidson FXDLI Dyna Low Rider EFI 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: FXDLI Dyna Low Rider Year: 2004 Sub Model: EFI Codes Engine Code: TBD (typically 88 cu in Twin Cam 88B) Vin Code Year:...
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类型: Motorcycle
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Harley Davidson FXDLI Dyna Low Rider EFI 2004 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FXDLI Dyna Low Rider
Year:
2004
Sub Model:
EFI
Codes
Engine Code:
TBD (typically 88 cu in Twin Cam 88B)
Vin Code Year:
4
👋 Introduction
Market Position
Positioning:
The Harley-Davidson Dyna Low Rider (FXDLI) for 2004 represented a significant model in the burgeoning cruiser market, offering a blend of classic Harley-Davidson styling with modern fuel injection for improved performance and rideability. It targeted riders seeking a comfortable, iconic V-twin cruiser experience with the reliability and ease of use afforded by EFI.
Competitive Analysis
Competitors:
Competed with models from Indian, custom builders, and other large-displacement cruisers from Japanese manufacturers that were entering the V-twin segment.
Key Features
Performance Enhancement:
The 'I' in FXDLI signifies Electronic Fuel Injection, a key upgrade over carbureted models for this year, offering better throttle response and cold-weather starting.
Styling:
Distinctive Low Rider styling with pullback handlebars, a low seat height, and custom details, embodying the classic American motorcycle aesthetic.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics, Overhaul
Page Count
Estimated Pages:
Approximately 300-500 (typical for this era's service manuals)
Manual Type
Type:
Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Twin Cam 88B (1450cc), carburetor vs. EFI system specifics, ignition, lubrication, cooling
Transmission:
5-speed Cruise Drive transmission, clutch, primary drive, final drive (belt)
Electrical System:
Battery, charging system (stator, regulator/rectifier), starting system, ignition system, lighting, instrumentation, EFI control module (ECM), fuel pump, sensors
Chassis And Suspension:
Frame, front fork (2004 model specific: possibly 49mm Dyna forks), rear shock absorbers, steering, swingarm
Braking System:
Front and rear hydraulic disc brakes, master cylinders, calipers, brake lines, brake fluid
Fuel System:
Fuel tank, fuel lines, fuel pump, fuel filter, EFI throttle body, injectors, pressure regulator
Exhaust System:
Exhaust pipes, mufflers, catalytic converter (if applicable)
Wheels And Tires:
Wheel bearings, tire inspection and replacement, wheel balancing
Bodywork And Trim:
Fenders, tank, seat, handlebars, controls, mirrors, side covers
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plug service, brake fluid flush, battery maintenance, drive belt inspection and adjustment
Troubleshooting:
Diagnostic flowcharts, common problem diagnosis (e.g., starting issues, poor performance, electrical faults)
Repair:
Engine disassembly and reassembly, transmission overhaul, electrical component replacement, brake caliper rebuild, fork service
Diagnostics:
EFI system diagnostics, fault code retrieval (if applicable via diagnostic port), sensor testing
Tune Up:
Ignition timing (if adjustable), fuel mixture adjustment (EFI specific), idle speed setting
Wiring Diagrams:
Comprehensive electrical schematics for all systems
Technical Depth
Depth:
Comprehensive. Covers from basic maintenance to complete engine and transmission rebuilds, advanced EFI diagnostics, and electrical system troubleshooting.
📊 Manual Specifications
File Format
Quality:
High-resolution, searchable PDF with clear text and imagery.
Printable:
Yes, designed for printing individual pages or the entire manual.
Print Quality
Imaging:
Sharp and clear diagrams, illustrations, and photographs.
Binding Type
Digital Binding:
N/A (Digital PDF)
Paper Type
Digital Paper Simulation:
Simulated high-quality, durable paper suitable for a workshop environment.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 45-degree V-twin, Twin Cam 88B
Displacement:
1449 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 Est:
Approx. 65-70 HP (at crank)
Torque Est:
Approx. 75-80 ft-lbs (at crank)
Fuel System
Induction:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Capacity:
4.8 US gallons (18.2 L)
Ignition
Ignition System:
Electronic ignition with knock control
Lubrication
Oil Capacity:
3.0 US quarts (2.8 L)
Oil Type Spec:
Harley-Davidson Genuine Formula Plus or equivalent SAE 20W-50 motorcycle oil (check manual for precise spec)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh, Cruise Drive
Primary Drive:
Plated, heavy-duty, 1.625 in (41.3 mm) chain
Final Drive:
Carbon fiber reinforced belt, 32 mm width
Features
Clutch:
Hydraulic actuation, multi-plate wet clutch
Transmission Oil Capacity:
Approx. 2.7 US quarts (2.5 L)
Transmission Oil Type Spec:
Harley-Davidson Genuine Formula Plus or equivalent SAE 50 motorcycle oil (check manual for precise spec)
📐 Dimensions
Exterior
Length:
Approx. 91.5 in (2324 mm)
Seat Height Laden:
Approx. 26.3 in (668 mm)
Ground Clearance:
Approx. 4.5 in (114 mm)
Weights
Dry Weight Est:
Approx. 625 lbs (283 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 1070 lbs (485 kg)
Payload Capacity Est:
Approx. 445 lbs (202 kg)
Wheels Tires
Front Tire Size:
100/90-19 57H
Rear Tire Size:
160/70-17 73V
Front Wheel Type:
Cast aluminum, 19 x 2.50 in
Rear Wheel Type:
Cast aluminum, 17 x 4.50 in
Wheel Bolt Pattern:
N/A (Harley-Davidson proprietary hub)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Motorcycles of this era were not subject to standardized crash testing like automobiles. Safety is determined by design and rider control.
Active Features
Braking:
Dual disc front braking, single disc rear braking. ABS was not standard or commonly available in 2004 on this model.
Lighting:
Halogen headlight, LED tail light, incandescent turn signals.
Passive Features
Frame Construction:
Steel frame designed for stability and rider confidence.
Suspension Design:
Dyna chassis with telescopic front forks and dual rear shock absorbers for predictable handling.
💡 Technology Features
Infotainment
Infotainment System:
Basic instrumentation: speedometer, tachometer (if equipped), odometer, trip meter, fuel gauge, oil pressure light, neutral indicator, turn signal indicators, high beam indicator. No advanced infotainment systems like audio or navigation were standard.
Driver Assistance
Driver Assistance Features:
None standard. Focus on rider control and mechanical feedback.
Connectivity
Connectivity Features:
None. Vehicle systems are self-contained.
Efi System
Efi Components:
Engine Control Module (ECM), throttle position sensor (TPS), manifold absolute pressure (MAP) sensor, intake air temperature (IAT) sensor, exhaust gas oxygen sensors (if equipped), fuel injectors, fuel pump, ignition module.
🔧 Maintenance
Service Intervals
Initial Service Mileage:
1000 miles (1600 km) - includes engine oil change, filter change, primary chain adjustment, and inspection of all systems.
Subsequent Oil Change Interval:
Every 5000 miles (8000 km) or annually, whichever comes first. Check manual for exact specification.
Drive Belt Tension Check Interval:
Every 2500 miles (4000 km) or annually.
Brake Fluid Flush Interval:
Every 2 years, or as recommended based on inspection.
Spark Plug Replacement Interval:
Refer to manual, typically 10,000-15,000 miles for original equipment.
Fluid Specifications
Engine Oil Grade Spec:
SAE 20W-50 (Harley-Davidson Genuine Formula Plus or equivalent, consult manual for exact spec).
Transmission Oil Grade Spec:
SAE 50 (Harley-Davidson Genuine Formula Plus or equivalent, consult manual for exact spec).
Primary Chain Case Oil Grade Spec:
Harley-Davidson Genuine Formula Plus or equivalent (often the same as transmission oil, verify with manual).
Brake Fluid Type:
DOT 4 hydraulic brake fluid (check manual for specific type and brand recommendations).
Fork Oil Grade Spec:
Check manual; typically 10W or 15W fork oil.
Known Issues
Common Issues:
Potential for oil leaks (gaskets, seals), starter issues, voltage regulator failure, timing chain tensioner wear (pre-Twin Cam '07 models sometimes had issues, though Twin Cam 88B generally improved), minor EFI glitches that the manual helps diagnose.
📚 Vehicle History
Brand Heritage
Heritage:
Harley-Davidson, founded in 1903, possesses one of the richest histories in motorcycling, synonymous with American freedom, individuality, and the V-twin engine. The Dyna platform, introduced in 1991, evolved from earlier Big Twin models, offering a more modern chassis while retaining classic styling.
Model Evolution
Dyna Platform Introduction:
The Dyna chassis debuted in 1991, featuring rubber engine isolation for reduced vibration, a feature carried through to the 2004 FXDLI.
Low Rider Concept:
The Low Rider designation historically refers to models with a lowered seat height and often altered handlebar positions for a relaxed riding posture, a concept Harley-Davidson has applied across various platforms.
Production
Production Location:
United States (various Harley-Davidson assembly plants)
Production Years Fxdi Series:
The 'I' designation for EFI models was introduced incrementally. 2004 was a key year for widespread EFI adoption across the Harley-Davidson lineup, including the Dyna series.
🏆 Awards & Recognition
Recognitions
Model Specific Awards:
The 2004 Dyna Low Rider would have been evaluated by motorcycle publications for its ride quality, handling, and performance. While specific awards for this exact model are rare to pinpoint historically, it contributed to the overall success and positive reception of the Dyna platform.
Ratings
Industry Ratings:
Generally well-regarded by riders and critics for its blend of classic styling and modern (for the time) technology.
Certifications
Emission Standards:
Designed to meet U.S. EPA emissions standards for the model year.
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