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Harley FXDX Dyna Super Glide Sport 2004 Service Repair Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: FXDX Dyna Super Glide Sport Year: 2004 Family: Dyna Codes Chassis Code: FXDX 👋 Introduction Market Position Vehicle Segment: Cruiser/Performance Cruiser Target Audience:...
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🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FXDX Dyna Super Glide Sport
Year:
2004
Family:
Dyna
Codes
Chassis Code:
FXDX
👋 Introduction
Market Position
Vehicle Segment:
Cruiser/Performance Cruiser
Target Audience:
Enthusiast riders seeking a blend of classic Harley styling with more aggressive performance and handling characteristics.
Competitive Analysis
Competitors 2004:
Other Harley-Davidson Dyna models, some Indian Chief models, and performance-oriented Japanese cruisers.
Key Features
Performance Focus:
The 'Sport' designation highlights its focus on improved handling and performance over more traditional cruisers.
Handling Enhancements:
Often features upgraded suspension components, dual front disc brakes, and a more aggressive riding position compared to other Dyna models.
Manual Value Proposition
Diy Support:
Essential for owners who perform their own maintenance and repairs, saving on dealership labor costs.
Diagnostic Tool:
Empowers riders to understand and diagnose issues, leading to more informed repair decisions.
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Manual
Language:
English
Format:
PDF
Page Count
Estimated Page Count:
Approximately 500-700 pages (typical for Harley service manuals of this era)
📖 Manual Coverage
Systems Covered
Engine Service:
Engine assembly, disassembly, inspection, tuning, lubrication, cooling system, fuel system, exhaust system
Transmission Drivetrain:
Primary drive, transmission assembly, clutch operation, final drive (belt)
Chassis Suspension:
Frame inspection, front fork service (including cartridge type for FXDX), rear shock absorber and swingarm maintenance, wheel bearing service
Electrical System:
Battery maintenance, ignition system, lighting, starter system, charging system, instrument cluster, wiring diagrams, troubleshooting electrical faults
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake line replacement, ABS system (if equipped), brake fluid specifications
Fuel System:
Carburetor (Keihin CV) disassembly, cleaning, and adjustment, fuel pump, fuel lines, fuel tank service
Bodywork Fittings:
Fender removal and installation, fuel tank mounting, seat service, handlebar and control adjustments, fairing and saddlebag (if applicable) service
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, spark plug replacement, air filter service, lubrication points, belt tension adjustment
Troubleshooting Diagnostics:
Systematic diagnosis of common performance issues, electrical faults, and mechanical problems with step-by-step guides
Rebuild Procedures:
Complete engine rebuilds, transmission overhauls, and component-specific repair instructions with torque specifications
Electrical Diagnostics:
Use of multimeters, interpretation of wiring diagrams, fault code identification and resolution (where applicable)
Technical Depth
Diagnostic Level:
Advanced diagnostic procedures, including troubleshooting charts and component testing
Repair Scope:
Comprehensive repair instructions, from minor adjustments to major component overhauls and replacements
Specification Detail:
Detailed torque specifications, clearances, fluid capacities, and component tolerances
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF for easy keyword finding
Printability:
Printable, allowing users to create physical copies of sections or the entire manual
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity (typical for professional service manuals)
Binding Type
Digital Format:
N/A (Digital PDF)
Paper Type
Digital Format:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Family:
Evolution (Big Twin)
Engine Type:
Air-cooled V-twin, 45-degree cylinder angle
Displacement:
1450cc (88 cubic inches)
Bore X Stroke:
3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)
Compression Ratio:
8.8:1
Performance
Horsepower:
Approximately 65-70 HP (estimated, actual may vary based on tuning and emissions)
Torque:
Approximately 70-75 ft-lbs @ 3200 RPM (estimated)
Fuel System
Fuel Delivery:
Carbureted (Harley-Davidson Keihin CV 40mm)
Fuel Type:
Unleaded gasoline, 91 octane (R+M)/2 or higher recommended
Engine Components
Camshafts:
Stock cam specifications will be detailed in the manual for timing and lift
Valve Train:
Pushrod-actuated overhead valves
🔧 Transmission
Standard
Type:
5-speed constant mesh
Clutch:
Wet, multi-plate, diaphragm spring
Optional
Transmission Options:
N/A for stock 2004 FXDX
Features
Primary Drive:
Duplex chain
Final Drive:
Belt drive
Fluid Specifications
Transmission Oil Type:
Harley-Davidson Formula+ Transmission & Primary Chaincase Lubricant or equivalent API GL-4 SAE 80W-90 gear oil
Fluid Capacities
Transmission Oil Capacity:
Approximately 1 quart (0.95 L)
📐 Dimensions
Exterior
Length:
Approximately 90.4 inches (2296 mm)
Width:
Approximately 33.9 inches (861 mm)
Height:
Approximately 49.0 inches (1245 mm)
Wheelbase:
Approximately 63.4 inches (1610 mm)
Weights
Dry Weight:
Approximately 636 lbs (288 kg)
Gross Vehicle Weight Rating:
Approximately 1030 lbs (467 kg)
Cargo
Saddlebags:
Optional, typically rigid or semi-rigid, capacity varies
Wheels Tires
Front Tire Size:
100/90-19 57H
Rear Tire Size:
160/70-17 73V
Front Wheel:
19-inch cast aluminum
Rear Wheel:
17-inch cast aluminum
Bolt Pattern:
5x114.3mm (typically for Harley-Davidson)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycles are not subject to the same crash test ratings as automobiles)
Active Features
Braking System:
Dual front disc brakes with 4-piston calipers, single rear disc brake with 4-piston caliper
ABS:
Anti-lock Braking System (ABS) was an optional feature for some Harley models in this era, check specific VIN.
Passive Features
Lighting:
Halogen headlight, LED taillight and brake light, amber turn signals
Frame Construction:
Steel tube frame for rigidity and handling
💡 Technology Features
Infotainment
Audio System:
Base models typically did not feature integrated audio. Optional accessory radios and speakers were available.
Navigation:
N/A (No factory integrated navigation system)
Driver Assistance
ABS Availability:
Optional on this model. Manual will cover diagnostic and operational aspects if equipped.
Connectivity
Smart Phone Integration:
N/A (No factory smartphone integration)
🔧 Maintenance
Service Intervals
First Service:
Typically at 1,000 miles (1,600 km) for initial break-in service (oil change, filter, primary check, belt check)
Subsequent Oil Changes:
Every 5,000 miles (8,000 km) or annually, whichever comes first
Belt Tension Check:
Every 5,000 miles (8,000 km) or as per manual recommendation
Spark Plug Replacement:
Refer to manual, often around 10,000 - 15,000 miles (16,000 - 24,000 km)
Fluid Specifications
Engine Oil Type:
Harley-Davidson SYN3 Synthetic Motorcycle Oil or equivalent SAE 20W-50 motorcycle specific engine oil.
Engine Oil Capacity:
Approximately 3 quarts (2.8 L) with filter change
Brake Fluid Type:
DOT 4 recommended for hydraulic brake systems.
Fork Oil Type:
Refer to manual for specific weight (e.g., 10W or 15W) and type (e.g., Showa SS-8 or equivalent)
Known Issues
Cam Chain Tensioners:
Hydraulic cam chain tensioners in earlier Twin Cam models (prior to 2007) could wear prematurely. The manual will detail inspection and replacement procedures.
Carburetor Tuning:
CV carburetors may require periodic adjustment for optimal performance due to altitude, fuel variations, or wear.
Charging System Issues:
Rotor and stator failures can occur, leading to charging problems. The manual provides diagnostic steps.
Maintenance Parts
Oil Filter Part Number:
Commonly 63796-77A or equivalent aftermarket (refer to manual for exact fitment)
Air Filter Part Number:
Varies by filter type; manual will specify OE numbers or recommend types.
📚 Vehicle History
Brand Heritage
Harley Davidson Legacy:
Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer known for its V-twin engines and distinctive styling.
Model Evolution
Dyna Platform Introduction:
The Dyna platform was introduced in 1991, evolving from the earlier FXR models, offering a balance of handling and comfort.
Fxdx Positioning:
The FXDX Super Glide Sport was positioned as a more performance-oriented variant within the Dyna line, featuring upgraded suspension and brakes.
Production
Production Period Fxdx:
The FXDX model was produced from 1999 to 2005.
Manufacturer Location:
USA (assembly typically in York, Pennsylvania or Milwaukee, Wisconsin)
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
The FXDX was generally well-received for its performance and handling capabilities relative to other Harley models of its time.
Ratings
Performance Metrics:
Praised for its ability to handle corners better than many traditional cruisers, making it more engaging for spirited riding.
Certifications
Epa Certification:
The manual will contain information related to emissions compliance for the 2004 model year as per EPA regulations.