Model Range:
Dyna (Super Glide, Low Rider, Wide Glide, FXRP, FXLR, FXDC, etc.)
Years Covered:
1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998
Vin Code Generation:
N/A for this manual coverage focus
Market Position:
Essential resource for Harley-Davidson owners and independent mechanics seeking to perform maintenance and repairs on the 1991-1998 Dyna platform. Positions itself as the authoritative dealer-equivalent manual.
Competitive Analysis:
Direct competitor to other aftermarket repair manuals, but distinguished by its claimed dealership-level accuracy and comprehensiveness, making it the preferred choice for serious DIYers and professionals.
Key Features:
Detailed step-by-step instructions, extensive illustrations and diagrams, comprehensive troubleshooting guides, factory-approved specifications, and coverage for the entire Dyna model range during the specified production years.
Primary Coverage:
Mechanical, electrical, and bodywork repair and maintenance for Harley-Davidson Dyna models 1991-1998.
Specific Model Coverage:
All variants within the Dyna family for the specified years, including but not limited to FXDC, FXDL, FXDWG, FXDX, FXRS.
Estimated Page Count:
Over 700 pages (typical for comprehensive factory service manuals).
Manual Type:
Factory-authorized Repair Workshop Manual.
Format:
Printed (as implied by dealership usage and typical manual sales).
Engine:
Evo Big Twin (Evolution engine) including assembly, disassembly, tuning, diagnostics, lubrication, cooling (air-cooled), ignition, and carburetor systems.
Transmission:
5-speed constant mesh transmission (4-speed in early models with 5-speed option becoming standard), clutch, primary drive, and drive belts.
Chassis:
Frame, suspension (forks, rear shocks), steering head, swingarm, and wheel bearings.
Brakes:
Front and rear braking systems, including hydraulic lines, master cylinders, calipers, rotors, and bleeding procedures.
Electrical:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, ignition system components, starter, and instrumentation.
Fuel System:
Fuel tanks, petcocks, fuel lines, carburetors (e.g., Keihin CV), and fuel delivery systems.
Exhaust System:
Exhaust pipes, mufflers, mounting hardware, and emissions control (where applicable).
Bodywork:
Fenders, fuel tank, seat, handlebars, controls, fairings (if equipped), and trim.
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, chain/belt adjustments, spark plug replacement, brake pad inspection/replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault codes (where applicable), and symptom-based troubleshooting guides.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation, including engine rebuilds, transmission overhauls, and electrical system repairs.
Assembly Disassembly:
Detailed instructions for complete vehicle disassembly and reassembly.
Specifications:
Torque values, clearances, fluid capacities, and tolerances for all components.
Performance Tuning:
Basic engine tuning, carburetor adjustments, ignition timing checks, and exhaust system upgrades.
Wheel Tire Service:
Wheel bearing replacement, tire mounting/balancing, and brake caliper service.
Frame Suspension Service:
Fork seal replacement, rear shock absorber replacement, steering head bearing adjustment/replacement.
Electrical Diagnostics:
Testing ignition coils, charging system components (stator, regulator), starter, and lighting circuits with troubleshooting flowcharts.
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission overhauls, electrical diagnostics, and chassis component repairs. Equivalent to dealership-level service information.
Engine Family:
Harley-Davidson Evolution (Evo) Big Twin.
Displacement Variants:
Primarily 80 cubic inches (1340cc). Some earlier models may have 74 cubic inches (1200cc) but 80ci became standard for this era.
Configuration:
45-degree V-twin, air-cooled.
Bore X Stroke:
3.500 in x 4.250 in (88.9 mm x 108.0 mm) for 80ci.
Compression Ratio:
Approximately 8.8:1 to 9.2:1 depending on specific model and year.
Horsepower Estimated:
Around 60-65 HP (at crankshaft), varies by tuning and exact model.
Torque Estimated:
Around 70-75 lb-ft (at crankshaft), varies by tuning and exact model.
Carburetor:
Typically Keihin CV (Constant Velocity) carburetor, 40mm.
Fuel Type:
Unleaded gasoline, 91-octane (AKI) or higher recommended.
Oil Type:
Harley-Davidson 20W50 motorcycle oil (or equivalent API SG or higher).
Oil Capacity:
Approximately 3.5 US quarts (3.3 liters) with filter change.
Ignition Type:
Electronic Ignition (single fire or dual fire depending on model/year).
Transmission Type:
5-speed constant mesh manual.
Transmission Variants:
Some early models might have 4-speed, but 5-speed became standard within this range.
Primary Drive:
Enclosed primary chain drive (wet clutch).
Final Drive:
Belt drive (49-tooth rear pulley common).
Transmission Oil Type:
Harley-Davidson Formula + (or equivalent API GL-4, SAE 80W-90 hypoid gear oil).
Transmission Oil Capacity:
Approximately 20-24 US fluid ounces (0.6-0.7 liters).
Initial Service:
First service typically around 1,000 miles (1600 km): oil change, primary chain adjustment, check all fasteners, adjust clutch and throttle cables.
Subsequent Service:
Every 5,000 miles (8,000 km) or annually: oil change, filter replacement, check/adjust belt tension, inspect brakes, check tire pressure, inspect spark plugs.
Major Service:
Refer to manual for specific major service intervals (e.g., valve adjustments, transmission service, engine tune-ups). Typically every 10,000-20,000 miles.
Engine Oil:
Harley-Davidson 20W50 Motorcycle Oil (or API SG/SH/SJ/SL/SM/SN, SAE 20W50).
Transmission Oil:
Harley-Davidson Formula + (or API GL-4, SAE 80W-90).
Primary Chain Case Oil:
Harley-Davidson Formula + (or API GL-4, SAE 80W-90). Note: Some models used engine oil in the primary. Verify with manual.
Brake Fluid:
DOT 4 (for most models, verify specific caliper/master cylinder).
Coolant:
N/A (Air-cooled engine).
Known Issues Common:
Cam bearing wear, rocker box leaks, carburetor tuning issues (stalling, hesitation), primary chain tensioner wear, starter solenoid issues, rear brake pad wear, oil leaks from gaskets/seals.
Maintenance Tips:
Regularly check and adjust primary chain tension, inspect cam bearing for play, ensure proper carburetor idle mixture and adjustment, use high-quality synthetic oil for better protection.
Brand Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer known for its V-twin engines, touring bikes, cruisers, and a strong associated culture.
Model Evolution:
The Dyna line was introduced in 1991 as a successor to the classic Big Twin frames. It combined the Evo engine with a modern chassis that offered improved handling and comfort over previous generations. The Dyna platform evolved through various iterations and sub-models (Super Glide, Low Rider, Wide Glide, etc.) before being phased out in favor of the Softail platform in 2018.
Production Period:
1991-2017 (Dyna platform).
Manufacturing Location:
United States (primarily York, Pennsylvania and Milwaukee, Wisconsin).
