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Harley Davidson FXDX Super Glide Sport 2002 Service Repair Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: FXDX Super Glide Sport Year: 2002 Platform: Dyna Codes Vin Prefix: 1HD1 👋 Introduction Market Position Segment: Performance cruiser / Sport cruiser within...
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🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
FXDX Super Glide Sport
Year:
2002
Platform:
Dyna
Codes
Vin Prefix:
1HD1
👋 Introduction
Market Position
Segment:
Performance cruiser / Sport cruiser within the Harley-Davidson lineup.
Target Audience:
Riders seeking a more performance-oriented Harley-Davidson experience with sportier handling and styling.
Competitive Analysis
Competitors:
Other American V-twins of the era, and performance-oriented Japanese cruisers.
Key Features
Styling:
Aggressive styling with forward controls, dual front disc brakes, and a more raked-out front end compared to standard models.
Performance Orientation:
Tuned for a balance of power and handling, often equipped with better suspension components.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service, Repair, Overhaul
Page Count
Estimated Pages:
Approximately 600-800 (typical for Harley-Davidson service manuals of this era)
Manual Type
Type:
Factory Service Manual / Workshop Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed breakdown and repair procedures for the Harley-Davidson Twin Cam 88 engine.
Transmission:
Service and repair of the 5-speed transmission, including clutch and primary drive.
Electrical:
Comprehensive wiring diagrams, troubleshooting for ignition, lighting, charging system, and accessories.
Chassis:
Frame, suspension (front fork and rear shocks), steering, and wheel bearing maintenance.
Brakes:
Front and rear brake system service, including caliper and master cylinder overhaul, fluid replacement.
Fuel System:
Carburetor (likely Keihin CV) service, fuel pump, and fuel tank maintenance.
Exhaust System:
Exhaust component removal, installation, and gasket replacement.
Bodywork And Fittings:
Body panel removal, installation, fairing, seat, and fuel tank component servicing.
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, spark plug inspection/replacement, chain adjustment (if applicable, though likely belt drive on this model), brake fluid flush, air filter service.
Diagnostic Procedures:
Step-by-step troubleshooting guides for common electrical and mechanical issues, diagnostic codes.
Engine Overhaul:
Piston removal/installation, cylinder head service, valve adjustments, cam bearing replacement.
Transmission Rebuild:
Gearset inspection, bearing replacement, shift drum and fork service.
Electrical Troubleshooting:
Fault finding for starting system, charging system, ignition, lighting, and accessory circuits using wiring diagrams.
Suspension Service:
Fork seal replacement, fork oil change, rear shock absorber service/replacement.
Brake System Repair:
Master cylinder rebuild, caliper service, brake line replacement, bleeding procedures.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics, and chassis overhauls.
📊 Manual Specifications
File Format
Quality:
High-resolution scans, generally searchable text if OCR'd.
Print Quality
Usability:
Designed for printing and use in a workshop environment.
Binding Type
Original Format:
Typically ring-bound for lay-flat use in workshops.
Paper Type
Original Material:
Durable, coated paper stock to withstand workshop conditions.
⚙️ Engine Specifications
Primary Engine
Engine Family:
Harley-Davidson Twin Cam 88
Engine Type:
Air-cooled, 45-degree V-twin
Displacement:
1450 cc (88 cubic inches)
Bore X Stroke:
3.75 in x 4.00 in (95.25 mm x 101.6 mm)
Compression Ratio:
8.5:1 (typical for early Twin Cam 88)
Valve Train:
Overhead valves (OHV), pushrod actuated, 2 valves per cylinder.
Performance
Horsepower:
Approximately 65-70 HP (estimated, varies with tuning)
Torque:
Approximately 85-90 lb-ft (estimated, varies with tuning)
Fuel System
Carburetor:
Keihin CV (Constant Velocity) 40 mm carburetor
Fuel Type:
Unleaded gasoline, minimum 87 octane.
Lubrication
Oil Type:
Harley-Davidson 20W50 motorcycle oil or equivalent.
Oil Capacity:
Approximately 3.0-3.5 quarts (2.8-3.3 liters) with filter change.
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh, sequential manual.
Primary Drive:
Triplex chain, 1.37:1 ratio.
Final Drive:
Belt drive, 32 tooth front pulley, 65 tooth rear pulley (3.15:1 final ratio).
Features
Clutch:
Wet, multi-plate, diaphragm spring.
Transmission Fluid:
Harley-Davidson Primary Chain Lubricant or equivalent. Capacity approx. 1 quart (0.95 L).
📐 Dimensions
Exterior
Wheelbase:
Approximately 63.5 inches (1613 mm)
Length:
Approximately 90.0 inches (2286 mm)
Seat Height:
Approximately 26.7 inches (678 mm) unladen
Weights
Dry Weight:
Approximately 615 lbs (279 kg)
Gross Vehicle Weight Rating:
Approximately 1040 lbs (472 kg)
Tires
Front Tire:
100/90-19
Rear Tire:
160/70-17
Wheels
Wheel Type:
Cast aluminum, 19-inch front, 17-inch rear.
🛡️ Safety Features
Ratings
Certification:
Meets FMVSS standards applicable to motorcycles.
Active Features
Brakes:
Dual 292 mm (11.5 inch) floating front disc brakes with 4-piston calipers, Single 292 mm (11.5 inch) rear disc brake with 2-piston caliper.
Passive Features
Lighting:
Halogen headlight, tail light, brake light, front and rear turn signals.
💡 Technology Features
Infotainment
Audio:
Optional factory or aftermarket radio/audio systems may be installed.
Driver Assistance
ABS:
ABS was not a standard feature on the 2002 FXDX.
Connectivity
Gauge Cluster:
Analog speedometer, tachometer, fuel gauge, oil pressure light, and indicator lights.
🔧 Maintenance
Service Intervals
Oil Change:
Every 2,500-5,000 miles (4,000-8,000 km) or annually, whichever comes first.
Primary Fluid Change:
Every 5,000-10,000 miles (8,000-16,000 km) or annually.
Transmission Fluid Change:
Every 10,000-20,000 miles (16,000-32,000 km) or every two years.
Spark Plugs:
Inspection every 5,000 miles (8,000 km), replacement as needed or every 10,000-15,000 miles (16,000-24,000 km).
Brake Fluid Flush:
Every 1-2 years or as recommended by fluid condition.
Fluid Specifications
Engine Oil:
Harley-Davidson Genuine V-Twin 20W50 Synthetic Motorcycle Oil, or equivalent SAE 20W50 motorcycle oil meeting Harley-Davidson specifications (e.g., API SG or higher).
Primary Chain Lubricant:
Harley-Davidson Genuine Formula + Transmission/Primary Chaincase Lubricant, or equivalent.
Brake Fluid:
DOT 4 brake fluid.
Known Issues
Cam Chain Tensioner:
Early Twin Cam 88s (pre-2007) are known for potential wear on the cam chain tensioners, which can lead to engine noise or failure if not replaced with upgraded components (hydraulic tensioners).
Crankshaft Runout:
Some early Twin Cam engines exhibited excessive crankshaft runout, though less common on factory bikes than on modified engines.
Oil Leaks:
Potential for leaks from rocker boxes, primary cover, or transmission seals due to age and material degradation.
Electrical Connectors:
Corrosion or loosening of electrical connectors, particularly in high-moisture areas, can cause intermittent issues.
📚 Vehicle History
Brand Heritage
Foundation:
Harley-Davidson Motor Company founded in 1903, iconic American motorcycle manufacturer.
Model Evolution
Dyna Introduction:
The Dyna platform was introduced in 1991 as a successor to the FXR platform, offering a more relaxed rider triangle and often a larger engine.
Fxdx Introduction:
The FXDX model was introduced in 1999 as a sportier variant of the Dyna line, featuring dual front disc brakes, a more robust front suspension, and often a lower profile.
Twin Cam Introduction:
The Twin Cam 88 engine was introduced in 1999, replacing the Evolution Big Twin engine.
Production
Production Period:
The Twin Cam 88 engine was produced from 1999 through 2006. The FXDX model ran from 1999 to 2005.
🏆 Awards & Recognition
Recognitions
Motorcycle Press:
Generally well-received by the motorcycle press for its blend of Harley-Davidson heritage and sporty handling.