Target Audience:
Harley-Davidson Dyna owners, independent repair shops, motorcycle technicians
Purpose:
To provide comprehensive guidance for maintaining, diagnosing, and repairing Harley-Davidson Dyna FX Series motorcycles.
Value Proposition:
Offers factory-level repair information, crucial for preserving vehicle integrity and performance, often at a fraction of dealership service costs.
Authenticity:
Complete factory service manual content, ensuring accuracy and completeness of procedures.
Accessibility:
Instant download PDF format for immediate use.
Primary Coverage:
Service, Repair, Workshop
Specific Models Covered:
Dyna Fat Bob (FXDF), Dyna Low Rider (FXDL), Dyna Street Bob (FXDB), Dyna Super Glide (FXDC), Dyna Switchback (FLD), Dyna Wide Glide (FXDWG)
Estimated Page Count:
Likely 700+ pages (typical for factory service manuals of this era and scope)
Type:
Factory Service Manual / Workshop Manual
Powertrain:
Engine (Twin Cam 96 V-Twin), Transmission (6-speed Cruise Drive), Clutch, Final Drive
Chassis:
Frame, Suspension (Front Fork, Rear Shocks), Wheels, Tires, Brakes (Front/Rear Disc), Steering
Electrical:
Ignition System, Charging System (Alternator, Regulator), Starting System, Lighting (Headlight, Taillight, Signals), Gauges, Instruments, Horn, Battery, Wiring Diagrams
Fuel System:
Fuel Injection (Electronic Sequential Port Fuel Injection - ESPFI), Fuel Tank, Fuel Pump, Fuel Filter
Exhaust System:
Exhaust Pipes, Mufflers, Heat Shields
Bodywork:
Fenders, Fuel Tank, Seat, Handlebars, Controls, Footpegs, Floorboards (where applicable), Mirrors
Cooling System:
Oil Cooling (Air-cooled engine with oil cooler)
Maintenance:
Scheduled Maintenance Intervals, Oil Changes, Filter Replacements, Lubrication Points, Battery Maintenance, Tire Pressure Checks, Brake Pad Inspection
Troubleshooting:
Diagnostic Flowcharts, Common Problem Identification, Fault Code Interpretation
Repair:
Component Removal and Installation, Engine Overhaul, Transmission Rebuild, Suspension Servicing, Brake System Overhaul, Electrical Component Diagnosis and Replacement
Diagnostics:
Use of Diagnostic Tools (e.g., Digital Technician), Sensor Testing, Actuator Testing
Specifications And Tolerances:
Torque Values, Clearances, Fluid Capacities, Electrical Specifications
Depth:
Comprehensive Factory Level (from basic maintenance to complete engine and transmission rebuilds)
Detail Level:
Detailed step-by-step instructions with accompanying diagrams, illustrations, and photographs.
Engine Type:
Air-cooled, Twin Cam 96, V-Twin
Displacement:
96 cubic inches (1584 cc)
Bore X Stroke:
3.75 in x 4.38 in (95.25 mm x 111.25 mm)
Compression Ratio:
Typically 9.2:1
Valve Train:
Pushrod actuated, overhead valves with two valves per cylinder
Horsepower:
Approx. 75-80 HP (Varies slightly by model and tune)
Torque:
Approx. 96-98 lb-ft @ 3200 RPM (Varies slightly by model and tune)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane (R+M)/2
Oil Type:
Harley-Davidson Genuine Motor Oil SAE 20W50 or equivalent
Oil Capacity:
Approximately 4 quarts (3.8 liters) with filter change
Type:
6-speed Cruise Drive
Gear Ratios:
1st: 9.312, 2nd: 6.994, 3rd: 4.948, 4th: 3.893, 5th: 3.315, 6th: 2.790 (Approximate, consult manual for exact ratios per model)
Clutch Type:
Hydraulically actuated, multi-plate wet clutch
Optional Transmissions:
None (Standard configuration for this generation)
Features:
Smooth shifting, reduced engine RPM at highway speeds in 6th gear.
Transmission Oil Type:
Harley-Davidson Formula+ Transmission and Primary Chain Case Oil (or equivalent API GL-4, SAE 80W-90 gear oil)
Transmission Fluid Capacity:
Approximately 24 US fl oz (0.71 L)
Wheelbase:
Varies by model (e.g., FXDL approx. 64.0 in, FXDF approx. 63.2 in)
Seat Height:
Varies by model (e.g., FXDL approx. 27.4 in, FXDF approx. 26.7 in)
Dry Weight:
Varies by model (e.g., FXDL approx. 632 lbs, FXDF approx. 636 lbs)
Gross Vehicle Weight Rating Gvwr:
Typically around 1050 lbs
Fuel Capacity:
Typically 5.0 US gallons (18.9 L)
Oil Capacity:
See engine_specs
Safety Certifications:
DOT compliant lighting, meets EPA noise emission standards.
Braking System:
Dual disc front, single disc rear with hydraulic actuation. ABS (Anti-lock Braking System) was an option on some models during this period.
Tire Specifications:
Tubeless tires, radial construction. Specific sizes vary by model (e.g., front 100/90-19, rear 160/70B17 are common).
Lighting:
Halogen headlamp, LED taillight, amber incandescent turn signals (typically).
Features:
Base models typically feature analog gauges (speedometer, tachometer, fuel gauge, oil pressure indicator). Some models offered or could be optioned with a radio/audio system.
ABS:
Anti-lock Braking System (ABS) was an optional feature on many Dyna models during these years.
Diagnostic Ports:
Diagnostic connectors (e.g., J1850, CAN bus) for interfacing with diagnostic tools.
Ignition System:
Electronic ignition with knock sensors for optimal performance and emissions.
First Service:
Typically at 1,000 miles (1,600 km) or 6 months, whichever comes first. Includes oil change, filter replacement, primary chain adjustment, inspection of critical fasteners and components.
Subsequent Service:
Typically every 5,000 miles (8,000 km) or 12 months for routine inspections and fluid changes. More frequent checks for tires, brakes, and chain (if applicable) are recommended.
Engine Oil:
Harley-Davidson Genuine Motor Oil SAE 20W50 or equivalent.
Transmission Primary Chain Case Oil:
Harley-Davidson Formula+ Transmission and Primary Chain Case Oil or equivalent API GL-4, SAE 80W-90 gear oil.
Brake Fluid:
DOT 4 (for hydraulic clutch and brake systems).
Primary Clutch Inspection Interval:
Inspect primary chain tension at 1,000 miles and every 10,000 miles thereafter.
Cam Chain Tensioners:
Early Twin Cam models (prior to 2007) had known issues with plastic hydraulic cam chain tensioners. While 2007+ models use improved spring-loaded tensioners, monitoring is still advisable.
Crankcase Bearings:
Some Twin Cam engines can experience issues with crankcase bearings over time, though less common in this specific year range.
Exhaust Leaks:
Potential for exhaust header leaks at the cylinder head due to heat cycling and vibration; torque checks and seal replacement may be required.
Regulator Rectifier:
The regulator/rectifier assembly is a common failure point on many Harley-Davidson models, leading to charging system issues.
Manufacturer:
Harley-Davidson Motor Company, founded in 1903.
Dyna Series Introduction:
The Dyna platform was introduced in 1991, featuring a rubber-isolated powertrain for improved comfort and handling.
Twin Cam Introduction:
The Twin Cam engine series debuted in 1999, replacing the Evolution engine, and became the standard for Harley-Davidson Big Twins.
2007 Updates:
The 2007 model year saw the introduction of the new 6-speed Cruise Drive transmission across the Dyna line, replacing the 5-speed unit, and the mandatory adoption of Electronic Sequential Port Fuel Injection (ESPFI).
Manufacturing Location:
United States (Various Harley-Davidson facilities)
Production Period For Manual:
Covering the 2007-2011 model years, a period of refinement for the Twin Cam 96 powered Dyna platform.
