Target Audience:
Harley-Davidson Dyna owners and independent repair shops seeking detailed, professional repair and maintenance information.
Value Proposition:
Provides factory-level technical data and procedures, enabling accurate repairs and maintenance, potentially saving significant costs compared to dealership servicing.
Manual Value:
Authored and used by mechanics worldwide, ensuring practical and reliable repair guidance.
Primary Coverage:
Service, Repair, Maintenance, Troubleshooting, Diagnostics
Estimated Page Count:
Likely 500-800+ pages (typical for comprehensive service manuals)
Manual Type:
Service Repair Workshop Manual
Format:
Likely printed manual, potentially available as a digital PDF
Engine Systems:
Twin Cam 88 Engine, Fuel System (Carbureted), Ignition System, Lubrication System, Cooling System (Air-Cooled), Exhaust System
Transmission Systems:
5-Speed Manual Transmission, Clutch System, Primary Drive System
Electrical Systems:
Wiring Diagrams, Lighting System, Ignition System, Charging System (Alternator/Stator), Battery, Starter System, Instruments and Gauges, Security System (if equipped)
Chassis Systems:
Frame and Bodywork, Suspension (Front Fork, Rear Shocks), Brakes (Front & Rear), Wheels and Tires, Steering System, Swingarm
Bodywork And Trim:
Fenders, Fuel Tank, Seat, Handlebars, Fairings/Batwing (if applicable), Passenger Footboards, Mirrors
Maintenance Procedures:
Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug Replacement, Chain/Belt Adjustment, Brake Pad Replacement, Tire Rotation/Replacement
Repair Procedures:
Engine Rebuilds (Top-End and Bottom-End), Transmission Overhaul, Clutch Replacement, Fork Seal Replacement, Shock Absorber Replacement, Brake System Service, Electrical Component Diagnosis and Replacement, Bodywork Repair
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common and uncommon issues, Fault code interpretation (if applicable), Electrical system troubleshooting using wiring diagrams
Depth Of Information:
Comprehensive, covering everything from routine maintenance to complete engine and transmission overhauls. Suitable for professional mechanics and experienced DIY enthusiasts.
Digital Format Characteristics:
Searchable text, high-resolution diagrams, often bookmarkable for easy navigation (if PDF)
Printed Format Characteristics:
High-quality paper, clear and legible text, detailed exploded views and schematics, durable binding
Binding Type:
Likely Spiral-bound or perfect-bound for workshop use, allowing pages to lay flat
Paper Type:
Durable, often coated or heavy-weight paper to withstand workshop environments
Engine Type:
Harley-Davidson Twin Cam 88
Displacement:
1449.55 cc (88 cubic inches)
Configuration:
Air-cooled, 45-degree V-twin
Bore X Stroke:
3.75 in x 4.00 in (95.25 mm x 101.60 mm)
Compression Ratio:
8.8:1 (typical)
Horsepower:
Approx. 65-70 HP (at crank, dependent on specific model and tuning)
Torque:
Approx. 75-80 lb-ft (at crank, dependent on specific model and tuning)
Fuel Delivery:
Keihin CV 40mm Carburetor (most common for 2002 models)
Fuel Type:
Unleaded Gasoline, Octane Rating 87 or higher
Ignition Type:
Electronic Ignition, Single Fire (typical)
Oil Type:
Harley-Davidson SYN3 (or equivalent premium motorcycle oil meeting Harley-Davidson specifications, e.g., SAE 20W-50)
Oil Capacity:
Approximately 3.5 US quarts (3.3 liters) with filter change
Cooling Method:
Air-Cooled
Transmission Type:
5-Speed Manual
Primary Drive:
Multi-plate Wet Clutch, Enclosed Primary Chain Drive
Final Drive:
Belt Drive (2002 models typically feature a 1-inch belt drive)
Gear Ratios:
Specific gear ratios will be detailed in the manual (e.g., 1st: 9.332, 2nd: 6.421, 3rd: 4.746, 4th: 3.894, 5th: 3.209)
Transmission Fluid Type:
Harley-Davidson transmission lubricant (or equivalent, e.g., SAE 80W-90 hypoid gear oil)
Transmission Fluid Capacity:
Approximately 1.0 US quart (0.95 liters)
Wheelbase:
Varies by specific Dyna model (e.g., FXD, FXDL, FXDWG), typically around 62.8 - 64.8 inches (1595 - 1646 mm)
Dry Weight:
Varies by specific Dyna model, generally in the range of 570 - 620 lbs (258 - 281 kg)
Gross Vehicle Weight Rating:
Typically around 900-1000 lbs (408-454 kg)
Safety Standards:
Complies with relevant US federal motor vehicle safety standards (FMVSS) for motorcycles.
Braking System:
Hydraulic disc brakes, front and rear. Specific brake caliper configurations and disc sizes will be detailed.
Lighting:
Headlight, Taillight, Brake Lights, Turn Signals
Audio System:
Optional factory-installed or aftermarket audio systems may be present. Manual will cover basic electrical connections and fuse locations.
ABS:
Anti-lock Braking System (ABS) was not standard on most 2002 Dyna models; optional depending on specific trim and market.
Security System:
Many Harley-Davidson motorcycles of this era were equipped with an optional factory alarm/security system, which the manual will detail.
Initial Service:
1,000 miles (1,600 km) - typically includes oil change, filter check/replacement, primary chain adjustment, and general inspection.
Subsequent Services:
Every 5,000 miles (8,000 km) or annually, whichever comes first. Intervals for specific components like spark plugs, brake fluid, and drive belt are detailed in the manual.
Engine Oil Specification:
Harley-Davidson SYN3 (SAE 20W-50) or equivalent meeting H-D specifications.
Primary Chain Case Oil:
Harley-Davidson Primary Chain Lubricant or equivalent (often a dedicated primary fluid or heavy-duty engine oil).
Transmission Oil Specification:
Harley-Davidson transmission lubricant (SAE 80W-90) or equivalent.
Brake Fluid Specification:
DOT 4 Hydraulic Brake Fluid (Harley-Davidson recommends their own brand or an equivalent)
Common Wear Items:
Clutch friction plates, brake pads, fork seals, drive belt (wear and tension), wheel bearings.
Potential Twin Cam 88 Considerations:
While generally robust, early Twin Cam 88 engines could experience issues related to cam chain tensioners (requiring upgrade to hydraulic tensioners), oil pump drive, or exhaust header leaks. Manual will detail inspection and correction.
Oil Filter Part Number:
Harley-Davidson part number 63796-77B (or equivalent aftermarket filter for Twin Cam 88)
Air Filter Part Number:
Varies by specific air cleaner assembly, consult manual for exact fitment.
Harley Davidson Legacy:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its cruiser, touring, and custom style motorcycles.
Dyna Series Introduction:
The Dyna line was introduced in 1991, characterized by its distinctly American styling, comfortable riding position, and the integration of the engine and transmission into the frame as stressed members.
Twin Cam 88 Era:
The 2002 model year falls within the early era of the Twin Cam 88 engine, which replaced the Evolution engine, offering improved performance and reliability.
Manufacturing Location:
Harley-Davidson motorcycles are predominantly manufactured in the United States.
