Covered Years:
1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998
Models Covered:
FXD, FXDC, FXDL, FXDWG (Dyna Wide Glide may have some variations covered, but primary focus is FXD models)
Estimated Page Count:
Approximately 500-700 pages (typical for comprehensive service manuals of this era)
Manual Type:
Service Repair Workshop Manual
Format:
Digital (likely PDF, potentially with searchable text)
Engine Mechanical:
Disassembly, inspection, assembly, overhaul of Evolution V-Twin engine (1340cc/80ci), cylinder heads, cylinders, pistons, crankshaft, connecting rods, camshafts, valve train.
Fuel System:
Carburetor service (e.g., Keihin CV carburetors), fuel tank, fuel lines, fuel pump (if applicable to specific models), fuel petcock operation and maintenance.
Ignition System:
Ignition module, spark plugs, ignition coils, wiring, timing adjustments (if applicable).
Electrical System:
Starter motor, battery, charging system (alternator, regulator), lighting (headlight, taillight, turn signals), wiring diagrams, fuse box, accessory circuits, battery maintenance.
Transmission:
5-speed constant mesh gearbox, clutch operation and adjustment, gearbox disassembly, inspection, assembly, lubrication, gear inspection.
Drivetrain:
Primary drive system (clutch, chain, compensator), final drive belt system (inspection, tensioning, replacement), wheel bearings, swingarm.
Brakes:
Front and rear brake systems (hydraulic disc brakes), caliper service, master cylinder service, brake pad replacement, brake fluid bleeding and replacement, rotor inspection.
Suspension:
Front fork (telescopic) overhaul, seal replacement, oil levels and specifications. Rear shock absorber inspection and replacement, mounting hardware.
Frame And Body:
Frame inspection, steering head bearing service, body panel removal and installation, fenders, fuel tank mounting, seat mounting, fairings (if applicable).
Controls:
Handlebar, throttle controls, brake levers, clutch lever, footpegs, shifter linkage, cable adjustments.
Wheels And Tires:
Wheel removal and installation, tire inspection and replacement, balancing, spoke tensioning (if applicable), wheel bearing service.
Routine Maintenance:
Oil and filter changes, primary chain adjustment, final drive belt tensioning, spark plug replacement, air filter cleaning/replacement, brake system checks, tire pressure checks.
Troubleshooting:
Diagnostic charts for common problems (e.g., starting issues, electrical faults, engine performance problems), symptom-based troubleshooting guides.
Major Repairs:
Complete engine rebuild, transmission overhaul, carburetor rebuild, front fork rebuild, brake caliper rebuild, electrical system diagnostics and repair.
Wiring Diagrams:
Detailed electrical system schematics for all factory electrical components.
Depth Of Information:
Comprehensive. Covers from basic maintenance to complete engine and drivetrain overhauls, including detailed torque specifications and clearances.
Diagnostic Capabilities:
Advanced diagnostic procedures for mechanical and electrical systems.
Rebuild Procedures:
Step-by-step instructions for complete component rebuilds.
Engine Type:
Air-cooled, 45-degree V-twin, OHV (Overhead Valve)
Displacement:
1339.8 cc (81.9 cubic inches)
Bore X Stroke:
3.496 in x 4.25 in (88.8 mm x 108.0 mm)
Compression Ratio:
8.5:1 (typical for this era Evolution engine)
Horsepower:
Approximately 60-65 HP @ 5000 RPM (Varies slightly by year and tuning)
Torque:
Approximately 70-75 lb-ft @ 3000 RPM (Varies slightly by year and tuning)
Carburetor:
Keihin CV (Constant Velocity) 40mm carburetor
Fuel Type:
Unleaded gasoline, minimum 87 octane
Initial Service:
500 miles (800 km) - First scheduled service, including oil change, filter change, primary chain adjustment, and inspection.
Regular Service:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first. Includes oil and filter change, primary chain adjustment, inspection of all systems.
Major Service:
Typically at higher mileage intervals (e.g., 20,000-30,000 miles), involving more in-depth inspection and potential replacement of wear items like wheel bearings, steering head bearings, and brake components.
Engine Oil:
Harley-Davidson 20W-50 V-Twin Motorcycle Oil (or equivalent spec API SG, JASO MA rated)
Engine Oil Capacity:
3.0 US quarts (2.8 Liters) with filter change.
Primary Transmission Fluid:
Harley-Davidson Formula + Transmission/Primary Chaincase Lubricant (or SAE 50 gear oil)
Primary Transmission Capacity:
26-30 fl. oz. (770-890 ml)
Brake Fluid:
DOT 5 Silicone Brake Fluid (Harley-Davidson specifies DOT 5 for this era, NOT DOT 3 or 4)
Fork Oil:
Harley-Davidson Type 'E' or 'G' fork oil (equivalent to SAE 10W or 15W respectively, check manual for specific model year application and quantity).
Cam Chain Tensioner:
Early Evolution engines (pre-2000) had plastic cam chain tensioners that could wear out, leading to noise or catastrophic failure. Upgrade to hydraulic tensioners is a common modification.
Starter Clutch:
Can wear out, leading to a grinding noise when starting the engine.
Carburetor Tuning:
The Keihin CV carburetor can require periodic adjustment for optimal performance and idle.
Crankshaft Runout:
Excessive crankshaft runout can lead to premature engine wear. The manual would detail procedures for checking this.
Oil Leaks:
Common points for leaks can include primary and engine case seals, pushrod tube seals, and rocker box gaskets. Regular inspection and gasket replacement are key.
Brand Legacy:
Harley-Davidson, established in 1903, is an iconic American motorcycle manufacturer known for its V-twin engines, cruiser motorcycles, and rich racing heritage.
Dyna Introduction:
The Dyna platform was introduced by Harley-Davidson in 1991, offering a modern take on the classic cruiser with a more rigid frame and larger displacement Evolution engine than previous models.
Fxdfactories:
The FXD model was the base model in the Dyna line, often featuring a slightly simpler design and fewer chrome accents compared to higher-spec models like the FXDC (Custom) or FXDL (Low Rider).
Production Period:
1991-2017 (Dyna platform), with specific FXD models produced within this manual's range of 1991-1998.
