Harley Davidson Dyna 2005 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: Dyna Year: 2005 Codes Product Code: Not specified in product information 👋 Introduction Market Position Segment: Cruiser motorcycle segment, known for its V-twin engine, rider comfort, and customization potential. Competitive Analysis Competitors: Competed with other American V-twin cruisers and Japanese power cruisers of the era, such as Indian, Victory, and certain models from Yamaha (V-Star) and Honda (Shadow). Key Features Drivetrain: Harley-Davidson Evolution (Big Twin) engine, known for its distinctive torque delivery and sound. Handling Chassis: Robust steel frame, designed for stable highway cruising and responsive handling for its class. Styling: Classic Harley-Davidson styling, with customizable options for handlebars, seats, exhaust, and paint. 📋 Manual Details Coverage Areas Coverage Scope: Complete official factory service and repair information for all 2005 Harley-Davidson Dyna models. Page Count Pages: Hundreds (exact number not specified, but described as 'complete' and 'hundreds of pages') Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, diagnosis, inspection, tuning, lubrication systems, cooling systems (if applicable), fuel systems (carburetor/EFI), ignition systems, exhaust systems, emissions control. Transmission Drivetrain: Clutch operation and adjustment, transmission disassembly and assembly, primary drive, final drive (belt or chain), lubrication, troubleshooting. Electrical Systems: Battery, charging system (alternator/stator, regulator/rectifier), starting system (starter motor, solenoid), ignition system, lighting systems (headlight, taillight, signals), instrument cluster, wiring diagrams, fuses and relays, diagnostics. Chassis Suspension: Frame inspection and repair, front suspension (forks, steering head bearings), rear suspension (shocks, swingarm, bushings), wheel bearings, alignment. Braking Systems: Front and rear brake caliper service, master cylinders, brake lines, pads, rotors, bleeding procedures, hydraulic system diagnosis. Fuel System: Carburetor models: Mikuni HSR42 or equivalent, teardown, cleaning, jetting, adjustments. Fuel injection models (if applicable to specific 2005 Dyna variants): Fuel pump, injectors, sensors, ECU diagnostics, throttle body service. Bodywork Fittings: Fender removal and installation, fuel tank service, seat removal, fairings (if equipped), controls, mirrors, luggage systems. Procedures Included Maintenance: Routine maintenance checks, oil changes, filter replacements, spark plug service, chain/belt adjustment and lubrication, tire pressure, brake inspection. Troubleshooting: Diagnostic flowcharts for common problems, identifying causes of poor performance, starting issues, electrical faults, noise diagnosis. Repair Rebuild: Detailed step-by-step instructions for component removal, overhaul, and reassembly for all major vehicle systems. Diagnostics: On-board diagnostics (if applicable), interpretation of fault codes, electrical system testing using multimeter and specialized tools. Technical Depth Depth: Comprehensive, covering from basic scheduled maintenance to full engine and transmission overhauls, including detailed torque specifications and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for easy information retrieval (standard for professional manuals). Print Quality Printability: Designed for printing, allowing users to print sections or the entire manual for workshop use. Binding Type Binding Recommendation: Users can print and bind in a workshop-friendly format (e.g., binder, coil binding). Paper Type Paper Recommendation: Recommended for printing on durable, oil-resistant paper for workshop durability. ⚙️ Engine Specifications Primary Engine Engine Family: Harley-Davidson Evolution (often referred to as the 'Evo' Big Twin) Engine Configuration: Air-cooled, 45-degree V-twin Displacement: Typically 1450cc (88 cubic inches) for 2005 Dyna models. Specific models might have variants, but this is the common displacement. Bore X Stroke: 3.5625 in x 4.25 in (90.425 mm x 107.95 mm) for 1450cc. Compression Ratio: Approximately 9.0:1 (can vary slightly based on specific model/tuning). Valve Train: Overhead valves (OHV), two valves per cylinder, operated by pushrods and tappets. Power Output: Estimated 65-70 HP (actual figures vary, Harley-Davidson did not always publish precise HP ratings). Torque Output: Estimated 78-85 lb-ft (around 106-115 Nm) at ~3200 RPM (actual figures vary). Performance Top Speed: Governed by gearing and rider, typically capable of 100+ mph. Fuel System Fuel Delivery: Most 2005 Dyna models used a carburetor, typically the Keihin CV (Constant Velocity) carburetor, or the later HSR42 on some performance-oriented models. Some early 2005 models might have had Electronic Fuel Injection (EFI), but carburetor was more common. The manual will cover the specific system fitted. Fuel Type: Unleaded gasoline, 91 octane (Research Octane Number) or higher recommended. Fuel Capacity: Typically 4.9 US gallons (18.5 liters) for standard Dyna tanks. 🔧 Transmission Standard Transmission Type: 5-speed constant mesh, sequential manual gearbox. Primary Drive: Wet, multi-plate clutch, enclosed in a primary drive chain case. Gear ratio typically around 1.43:1. Final Drive: Belt drive. Gear ratio typically around 2.75:1 (32/11 teeth sprockets for belt drive). Features Clutch Type: Hydraulically actuated, multi-plate wet clutch. 📐 Dimensions Exterior Length: Varies by specific Dyna model (e.g., Super Glide, Low Rider, Street Bob), typically around 90-92 inches (2286-2337 mm). Width: Varies, typically around 36-38 inches (914-965 mm) at handlebars. Height: Varies, typically around 47-50 inches (1194-1270 mm) to the top of handlebars. Wheelbase: Varies, typically around 62-64 inches (1575-1626 mm). Weights Dry Weight: Varies by model, typically 580-630 lbs (263-286 kg). Gross...
Cruiser motorcycle segment, known for its V-twin engine, rider comfort, and customization potential.
Competitive Analysis
Competitors:
Competed with other American V-twin cruisers and Japanese power cruisers of the era, such as Indian, Victory, and certain models from Yamaha (V-Star) and Honda (Shadow).
Key Features
Drivetrain:
Harley-Davidson Evolution (Big Twin) engine, known for its distinctive torque delivery and sound.
Handling Chassis:
Robust steel frame, designed for stable highway cruising and responsive handling for its class.
Styling:
Classic Harley-Davidson styling, with customizable options for handlebars, seats, exhaust, and paint.
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete official factory service and repair information for all 2005 Harley-Davidson Dyna models.
Page Count
Pages:
Hundreds (exact number not specified, but described as 'complete' and 'hundreds of pages')
Diagnostic flowcharts for common problems, identifying causes of poor performance, starting issues, electrical faults, noise diagnosis.
Repair Rebuild:
Detailed step-by-step instructions for component removal, overhaul, and reassembly for all major vehicle systems.
Diagnostics:
On-board diagnostics (if applicable), interpretation of fault codes, electrical system testing using multimeter and specialized tools.
Technical Depth
Depth:
Comprehensive, covering from basic scheduled maintenance to full engine and transmission overhauls, including detailed torque specifications and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF for easy information retrieval (standard for professional manuals).
Print Quality
Printability:
Designed for printing, allowing users to print sections or the entire manual for workshop use.
Binding Type
Binding Recommendation:
Users can print and bind in a workshop-friendly format (e.g., binder, coil binding).
Paper Type
Paper Recommendation:
Recommended for printing on durable, oil-resistant paper for workshop durability.
⚙️ Engine Specifications
Primary Engine
Engine Family:
Harley-Davidson Evolution (often referred to as the 'Evo' Big Twin)
Engine Configuration:
Air-cooled, 45-degree V-twin
Displacement:
Typically 1450cc (88 cubic inches) for 2005 Dyna models. Specific models might have variants, but this is the common displacement.
Bore X Stroke:
3.5625 in x 4.25 in (90.425 mm x 107.95 mm) for 1450cc.
Compression Ratio:
Approximately 9.0:1 (can vary slightly based on specific model/tuning).
Valve Train:
Overhead valves (OHV), two valves per cylinder, operated by pushrods and tappets.
Power Output:
Estimated 65-70 HP (actual figures vary, Harley-Davidson did not always publish precise HP ratings).
Governed by gearing and rider, typically capable of 100+ mph.
Fuel System
Fuel Delivery:
Most 2005 Dyna models used a carburetor, typically the Keihin CV (Constant Velocity) carburetor, or the later HSR42 on some performance-oriented models. Some early 2005 models might have had Electronic Fuel Injection (EFI), but carburetor was more common. The manual will cover the specific system fitted.
Fuel Type:
Unleaded gasoline, 91 octane (Research Octane Number) or higher recommended.
Fuel Capacity:
Typically 4.9 US gallons (18.5 liters) for standard Dyna tanks.
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh, sequential manual gearbox.
Primary Drive:
Wet, multi-plate clutch, enclosed in a primary drive chain case. Gear ratio typically around 1.43:1.
Final Drive:
Belt drive. Gear ratio typically around 2.75:1 (32/11 teeth sprockets for belt drive).
Features
Clutch Type:
Hydraulically actuated, multi-plate wet clutch.
📐 Dimensions
Exterior
Length:
Varies by specific Dyna model (e.g., Super Glide, Low Rider, Street Bob), typically around 90-92 inches (2286-2337 mm).
Width:
Varies, typically around 36-38 inches (914-965 mm) at handlebars.
Height:
Varies, typically around 47-50 inches (1194-1270 mm) to the top of handlebars.
Wheelbase:
Varies, typically around 62-64 inches (1575-1626 mm).
Weights
Dry Weight:
Varies by model, typically 580-630 lbs (263-286 kg).
Gross Vehicle Weight Rating Gvwr:
Typically around 950-1000 lbs (431-454 kg).
Payload Capacity:
Approximately 350-400 lbs (159-181 kg).
🛡️ Safety Features
Ratings
Safety Standards:
Manufactured to meet US DOT and EPA standards for motorcycles. Specific crash test ratings are not typically provided for motorcycles in the same way as cars.
Active Features
Braking:
Dual disc front brakes with dual-piston calipers, single disc rear brake with dual-piston caliper. ABS was not standard or widely available on Dyna models in 2005.
Lighting:
Halogen headlight, taillight, brake light, turn signals, and marker lights.
Passive Features
Frame Construction:
Steel tube frame provides a robust structure.
Ergonomics:
Rider-focused ergonomics with various handlebar and seating options available for customization to improve control.
💡 Technology Features
Infotainment
Audio System:
Base 2005 Dyna models generally did not come with factory installed audio systems. Aftermarket audio systems and CB radios were common additions.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was not typically standard or available on the 2005 Dyna models. The manual would therefore not cover ABS diagnostics or repair.
Connectivity
Smart Features:
No advanced connectivity features like Bluetooth, GPS, or smartphone integration were standard on 2005 Harley-Davidson models.
Instrumentation
Gauge Cluster:
Analog speedometer, tachometer (on some models), fuel gauge, odometer, trip meter, and indicator lights for turn signals, oil pressure, neutral, and high beam.
🔧 Maintenance
Service Intervals
Initial Service:
First service typically at 1,000 miles (1,600 km), involving oil change, filter change, inspection of primary drive, chain/belt, brakes, and fasteners.
Subsequent Service:
Subsequent services typically every 5,000 miles (8,000 km) or annually, including oil changes, filter replacements, spark plug checks, and lubrication.
Major Service Intervals:
Valve lash adjustments, primary drive inspection, and other component checks are recommended at specific higher mileage intervals (e.g., 10,000-20,000 miles).
Fluid Specifications
Engine Oil:
Harley-Davidson recommends 20W50 motorcycle oil. Synthetic options are available and often preferred for better protection. Capacity: Approx. 4 US quarts (3.8 liters) for 1450cc Evolution engine.
Primary Chain Case Oil:
Harley-Davidson primary lubricant or compatible heavy-duty chaincase lubricant. Capacity: Approx. 1 US quart (0.95 liters).
Transmission Oil:
Harley-Davidson transmission oil or compatible 75W90 or 80W90 gear lubricant. Capacity: Approx. 24 US fluid ounces (0.71 liters).
Brake Fluid:
DOT 4 or DOT 5.1 brake fluid (check specific recommendation for 2005, usually DOT 4 for ABS-free models). Always use fresh, sealed fluid.
Fork Oil:
Specific weight of fork oil recommended by Harley-Davidson, often around 10W or 15W. Capacity varies by fork model, check manual.
Known Issues
Cam Chain Tensioners:
Early Evolution engines (prior to 2006) had hydraulic cam chain tensioners that could wear and require replacement. The manual will detail inspection and replacement procedures.
Carburetor Performance:
CV carburetors can require tuning for altitude changes or aftermarket exhaust/intake modifications. The manual provides jetting and adjustment guidance.
Electrical Connectors:
As with many older vehicles, electrical connectors can corrode or loosen over time, leading to intermittent issues. The manual's wiring diagrams and diagnostic sections are crucial.
Regulator Rectifier:
The charging system's regulator/rectifier can be a failure point. The manual outlines testing procedures.
📚 Vehicle History
Brand Heritage
Manufacturer History:
Harley-Davidson is an iconic American motorcycle manufacturer founded in 1903, renowned for its V-twin engines, cruiser styling, and a rich history in motorcycling and popular culture.
Model Evolution
Dyna Lineage:
The Dyna line, introduced in 1991, was characterized by its frame-mounted engine (unlike the rubber-mounted engines of the FL models) and a more traditional, rigid look. The 2005 models represent a mature iteration of this platform, built upon the Evolution engine.
Production
Production Years:
The Dyna line was produced from 1991 to 2017, before being replaced by the Softail platform.