🏷️ Basic Information

Make:

Harley-Davidson

Model:

Dyna

Year:

2004

Product Name:

Harley Davidson Dyna 2004 Service Repair Workshop Manual

👋 Introduction

Market Segment:

American V-twin cruiser motorcycles, targeting riders seeking customization and a classic riding experience.

Key Competitors:

Indian Motorcycles, various Japanese cruiser manufacturers (e.g., Yamaha V-Star, Honda Shadow, Kawasaki Vulcan), and custom motorcycle builders.

Distinctive Features:

V-twin engine character, rider-centric ergonomics, extensive customization potential, strong brand heritage, accessible platform for modifications.

Manual Value:

Essential for owners and independent mechanics to perform accurate diagnostics, maintenance, and repairs, thereby saving costs and ensuring optimal performance and longevity of the vehicle.

📋 Manual Details

Primary Coverage:

Service, Repair, Maintenance, Troubleshooting, Diagnostics

Model Variants Covered:

All Harley-Davidson Dyna models for the 2004 model year (e.g., Super Glide, Low Rider, Wide Glide, Street Bob, Fat Bob - exact sub-models depend on specific manual scope, assuming comprehensive coverage)

Estimated Page Count:

700+

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

Print (likely comb-bound or perfect bound)

📖 Manual Coverage

Engine Systems:

Engine disassembly/assembly, top end, bottom end, lubrication system, cooling system (if applicable, though Dyna is air-cooled), fuel system (carburetor/EFI specifics), ignition system, exhaust system.

Drivetrain Systems:

Clutch, primary drive, transmission (5-speed or 6-speed depending on specific Dyna model), final drive (belt drive).

Chassis Systems:

Frame, suspension (front forks, rear shocks), steering, wheels, tires, brakes (front and rear hydraulic disc), brake fluid specifications and bleeding procedures.

Electrical Systems:

Battery, charging system (alternator/stator, regulator/rectifier), starting system (starter motor, solenoid), lighting system (headlight, taillight, turn signals), ignition system components, instrument cluster, wiring diagrams, fuses, relays, EFI control module (ECM/VCM).

Bodywork And Trim:

Fenders, fuel tank, seat, handlebars, controls, fairings (if applicable), saddlebags (if applicable), cosmetic components.

Routine Maintenance:

Oil changes, filter replacement, chain adjustment (if applicable), spark plug replacement, air filter cleaning/replacement, brake pad inspection/replacement, tire pressure checks, lubrication points.

Diagnostic Procedures:

Troubleshooting common problems, fault code retrieval and interpretation (for EFI models), circuit testing, component testing.

Repair Procedures:

Engine rebuild, transmission overhaul, brake system repair, suspension component replacement, electrical component repair/replacement, fuel system service.

Special Tools And Jigs:

Identification and usage instructions for specialized Harley-Davidson tools required for specific procedures.

Depth Of Coverage:

Comprehensive, covering everything from basic scheduled maintenance to full engine and transmission rebuilds. Includes detailed exploded views, torque specifications, and diagnostic flowcharts.

📊 Manual Specifications

File Format Details:

Assumed printed format. If digital, typically PDF. Print quality is typically professional, clear text, and high-resolution diagrams.

Diagram Quality:

High-resolution, clear, and detailed diagrams for easy component identification and assembly/disassembly guidance.

Binding Type:

Likely comb-bound or perfect-bound for ease of use and laying flat on a workbench.

Paper Type:

Durable, often glossy or semi-gloss paper to withstand workshop environments and oil/grease resistance.

⚙️ Engine Specifications

Engine Family:

Harley-Davidson Evolution (Evo) V-Twin

Engine Configuration:

Air-cooled, 45-degree V-twin

Engine Displacement Variants:

Commonly 1450cc (88 cubic inches) for the 2004 Dyna models. Some specialized models or aftermarket configurations might exist.

Bore X Stroke:

Approximately 3.75 in x 4.00 in (95.25 mm x 101.6 mm) for 1450cc.

Compression Ratio:

Typically around 9.0:1 to 9.7:1 depending on specific model and head design.

Horsepower Estimate:

Around 65-70 HP at the crankshaft (actual figures vary by sub-model and tuning).

Torque Estimate:

Around 80-85 lb-ft at the crankshaft (actual figures vary by sub-model and tuning).

Fuel Delivery:

Carbureted (e.g., Keihin CV40) or Electronic Fuel Injection (EFI) depending on the specific Dyna model (e.g., Dyna Super Glide EFI, Low Rider EFI).

Fuel Type:

Unleaded gasoline, octane rating typically 87 or higher.

Fuel Capacity:

Varies by model, typically 4.0 - 5.0 gallons (15.1 - 18.9 liters).

Oil Type Specification:

Harley-Davidson recommends specific motorcycle oil, often SAE 20W50, meeting Harley-Davidson specifications (e.g., HD-360, SYN3). Check manual for exact part numbers and API classifications.

Oil Capacity:

Approximately 3.0 - 3.5 quarts (2.8 - 3.3 liters) with filter change. Consult manual for precise capacity.

Ignition Type:

Electronic Ignition (CDI or solid-state ignition module).

Spark Plugs:

Commonly Harley-Davidson OEM spark plugs or equivalent like Champion or NGK. Specific part numbers will be in the manual (e.g., H-D 32302-00).

🔧 Transmission

Transmission Type:

5-speed constant mesh manual transmission.

Optional Transmission:

While 5-speed was standard for Dyna in 2004, some very late 2004 models might have seen early 6-speed introductions on specific platforms, but 5-speed is most common. Manual will cover the standard 5-speed.

Clutch Type:

Wet multi-plate clutch.

Final Drive:

Enclosed belt drive.

Transmission Fluid Type:

Harley-Davidson recommends specific transmission lubricant. Consult manual for exact specifications and part numbers, often a dedicated gear oil.

📐 Dimensions

Wheelbase:

Varies by model (e.g., Low Rider approx. 64.0 in, Wide Glide approx. 66.0 in).

Seat Height Laden:

Varies by model, typically around 26-28 inches.

Ground Clearance:

Varies by model, typically around 4.5-5.5 inches.

Dry Weight:

Varies by model, typically around 570-620 lbs (258-281 kg).

Gross Vehicle Weight Rating:

Consult individual model specifications, typically around 950-1000 lbs (431-454 kg).

🛡️ Safety Features

Crash Test Ratings:

Motorcycles are not typically subjected to standardized crash test ratings like automobiles. Safety is judged by design and rider aids.

Braking System:

Hydraulic disc brakes front and rear. Dual discs on some front ends, single on others. ABS was not standard in 2004 on Dyna models.

Tire Specifications:

Tire sizes vary by model and front/rear. Front typically 19-inch or 21-inch, rear 16-inch. Consult manual for specific tire size recommendations and pressure.

Lighting:

Halogen headlamp, taillight, brake light, and amber turn signals.

Instrumentation:

Speedometer, tachometer (on some models), odometer, trip meter, fuel gauge, indicator lights for oil, neutral, turn signals, high beam.

💡 Technology Features

Infotainment System:

Basic analog instrumentation. No integrated infotainment systems like modern motorcycles. Aftermarket audio systems were common upgrades.

Driver Assistance Features:

None typically fitted as standard. Rider relies on mechanical feedback and basic lighting indicators.

Connectivity Features:

No factory Bluetooth or smartphone connectivity. Aftermarket solutions are available.

Efi Components:

For EFI models: Engine Control Module (ECM) or V-Twin Control Module (VCM), fuel injectors, throttle body, various sensors (e.g., O2, MAP, IAT, TPS).

🔧 Maintenance

Initial Service:

Typically at 1,000 miles (1,600 km) for break-in service: oil change, filter replacement, primary chain adjustment, spark plug inspection, and general inspection.

Regular Maintenance Intervals:

Oil changes and filter replacement every 5,000 miles (8,000 km) or annually. Other services like spark plugs, air filter, brake fluid, and belt inspection at intervals specified in the manual (e.g., 10,000-20,000 miles).

Engine Oil Viscosity:

SAE 20W50 is common for Harley-Davidson air-cooled V-twins. Specific Harley-Davidson branded oil or equivalent meeting Harley-Davidson performance requirements is recommended.

Primary Chain Case Oil:

Specialized Harley-Davidson primary chain case lubricant or equivalent. Capacity around 20-24 oz (0.6-0.7 L).

Transmission Oil:

Specific Harley-Davidson transmission lubricant or equivalent. Capacity around 24-32 oz (0.7-0.95 L).

Brake Fluid:

DOT 4 or DOT 5.1 hydraulic brake fluid, depending on OEM specification for that year/model. Manual will specify.

Common Wear Items:

Clutch plates, brake pads, tires, wheel bearings, fork seals, drive belt wear.

Potential Electrical Issues:

Regulator/rectifier failures, stator issues, starter solenoid issues can occur over time, especially with age and mileage. Loose connections or corrosion in wiring harnesses.

Engine Specific Notes:

Evolution engine is generally robust but can develop oil leaks from pushrod tubes or base gaskets. Cam bearing wear is a possibility on higher mileage engines.

Fuel System Notes:

Carburetor jets can clog if fuel sits for extended periods. EFI sensors (throttle position, manifold absolute pressure) can affect performance if faulty. Fuel pump issues on EFI models.

📚 Vehicle History

Brand Establishment:

Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer with a rich history of innovation and cultural impact.

Dyna Line Introduction:

The Dyna line was introduced in 1991 as a successor to the popular Sportster FL chassis, featuring a rubber-mounted engine for reduced vibration compared to earlier rigid-mounts. It offered a blend of classic styling and modern comfort.

2004 Model Year Significance:

The 2004 model year saw the continued refinement of the Dyna platform, often featuring the larger 1450cc Evolution engine and continued emphasis on rider comfort and customization. It was a year of robust sales and continued popularity.

Manufacturing Location:

Primarily manufactured at Harley-Davidson's facilities in Milwaukee, Wisconsin, and York, Pennsylvania, USA.

🏆 Awards & Recognition

Brand Recognition:

Harley-Davidson consistently ranks as one of the most recognized and iconic motorcycle brands globally.

Model Recognition:

The Dyna line is well-regarded for its balance of customization, performance, and the characteristic Harley-Davidson riding experience.

Manufacturing Standards:

Adheres to all relevant automotive and motorcycle manufacturing standards for safety and emissions.