Harley FXDX Dyna Super Glide Sport 1999-2005 Service Repair Manual
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🏷️ Basic Information Identification Make: Harley-Davidson Model: FXDX Dyna Super Glide Sport Model Code: FXDX Generation Start Year: 1999 End Year: 2005 👋 Introduction Market Position Target Audience: DIY enthusiasts and experienced mechanics seeking detailed repair and maintenance information for the Harley-Davidson FXDX Dyna Super Glide Sport. Key Features Convenience: Digital PDF format offers cost savings and easy access compared to traditional paper manuals. Cost Effectiveness: Inexpensive way to keep the vehicle in proper working order, saving money on labor costs. Instructional Quality: Hundreds of pages with step-by-step instructions, photos, and illustrations for detailed guidance. Competitive Analysis Market Segment: Cruiser/Performance Cruiser segment. 📋 Manual Details Coverage Applicable Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005 Coverage Areas: General Information, Maintenance, Chassis, Fuel System, Cooling System, Engine, Clutch, Engine Lubrication System, Engine Removal/Installation, Drive, Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Wiring Diagram, All Styles Format Format: PDF File Type: Digital Download Accessibility: Can be accessed on PC, laptop, smartphone, and tablet. Pages Page Count: Hundreds Language Language: English Type Manual Type: Complete Factory Service Repair Manual Content Level: Full Factory Service 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly/assembly, lubrication, cooling, fuel delivery, ignition, exhaust, engine tuning Drivetrain Systems: Clutch operation and service, transmission overhaul, final drive maintenance, belt drive inspection and adjustment Chassis Systems: Suspension (forks, shocks), steering, wheels, tires, brakes (hydraulic systems, pad replacement), frame inspection Electrical Systems: Complete electrical troubleshooting, wiring diagrams, battery, charging system, lighting, ignition system, starter, instrumentation Bodywork: Fenders, fuel tank, seat, fairings (if equipped), body panels, controls. Procedures Included Maintenance Procedures: Scheduled maintenance, fluid changes, filter replacements, chain/belt adjustments, tire pressure checks Repair Procedures: Step-by-step instructions for component repair and replacement, including engine rebuilds, transmission servicing, brake system repairs, electrical component replacement Troubleshooting: Diagnostic procedures for common problems, fault code interpretation (if applicable), systematic problem-solving guides Diagnostic Procedures: Detailed diagnostic steps for identifying and resolving mechanical and electrical faults. Wiring Diagrams: Detailed electrical system wiring diagrams for troubleshooting and repairs. Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostics and specifications. Illustrations Photos: Hundreds of photos and illustrations to guide users through service and repair procedures. 📊 Manual Specifications File Characteristics Searchable Text: Yes (implied by PDF format) Printable: Yes, individual pages or entire manual Print Quality: High quality, suitable for printing. Compatibility Operating Systems: All Versions of Windows, Mac, Web Browser Access Requirements Software Requirements: Adobe PDF Reader, Winzip (free) Delivery Download Speed: Fast Download ⚙️ Engine Specifications Primary Engine Engine Family: Evolution (Big Twin) Engine Type: Air-cooled V-twin Displacement Cc: 1449 Displacement Ci: 88 Bore X Stroke In: 3.75 in x 4.00 in Bore X Stroke Mm: 95.25 mm x 101.6 mm Compression Ratio: 9.0:1 (typical) Performance Horsepower Approx: 60-70 HP (estimated, varies with tuning) Torque Approx: 70-80 lb-ft (estimated, varies with tuning) Fuel System Fuel Delivery: Carburetor (e.g., Keihin CV 40) or Fuel Injection (later models within the range, specific to sub-model variations not detailed here) Carburetor Model: Keihin CV 40 (typical for this era) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Gear Ratios: Refer to manual for specific gear ratios. Features Drive Type: Belt Drive Clutch Type: Wet, multi-plate 📐 Dimensions Weights Dry Weight Lbs: Approximately 614 lbs (278.5 kg) Wet Weight Lbs: Approximately 648 lbs (294 kg) Gvwr Lbs: Not typically specified for motorcycles in the same way as cars; consult vehicle VIN for specific load limits. Fuel Capacity Gal: Approximately 4.2 gallons Exterior Wheelbase In: Approximately 64.2 inches 🛡️ Safety Features Ratings Crash Test Results: Motorcycle safety is primarily assessed through rider skill, maintenance, and accident avoidance rather than standardized crash tests. Active Features Braking System: Dual front disc brakes with hydraulic actuation, single rear disc brake. FXDX often featured improved braking over standard models. Passive Features Frame Construction: Steel cradle frame designed for stability and handling. 💡 Technology Features Infotainment Audio System: Optional accessory radios were available; factory integration minimal on base models. Instrumentation Gauge Cluster: Analog speedometer, tachometer, odometer, trip meter, indicator lights for turn signals, oil pressure, neutral, high beam, and engine diagnostics. Driver Assistance ABS: Anti-lock Braking System (ABS) was an optional feature on some models within this range; consult specific vehicle VIN. 🔧 Maintenance Service Intervals Oil Change Miles: Refer to manual (typically 2,500-5,000 miles or annually) Primary Chain Tension Inspection: Refer to manual (often every 5,000 miles) Fluid Specifications Engine Oil Type: Refer to manual (e.g., Harley-Davidson Genuine V-Twin Oil 20W50 or equivalent) Transmission Oil Type: Refer to manual (e.g., Harley-Davidson Genuine Formula + Transmission/Primary Chaincase Lubricant or equivalent) Primary Chaincase Oil Type: Refer to manual (same as transmission oil for many models) Brake Fluid Type: Refer to manual (DOT 4 recommended for most Harley-Davidsons of this era) Fork Oil Type: Refer to manual (specific viscosity, e.g., Harley-Davidson Fork...
Step-by-step instructions for component repair and replacement, including engine rebuilds, transmission servicing, brake system repairs, electrical component replacement
Troubleshooting:
Diagnostic procedures for common problems, fault code interpretation (if applicable), systematic problem-solving guides
Diagnostic Procedures:
Detailed diagnostic steps for identifying and resolving mechanical and electrical faults.
Wiring Diagrams:
Detailed electrical system wiring diagrams for troubleshooting and repairs.
Technical Depth
Depth:
Comprehensive from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostics and specifications.
Illustrations Photos:
Hundreds of photos and illustrations to guide users through service and repair procedures.
📊 Manual Specifications
File Characteristics
Searchable Text:
Yes (implied by PDF format)
Printable:
Yes, individual pages or entire manual
Print Quality:
High quality, suitable for printing.
Compatibility
Operating Systems:
All Versions of Windows, Mac, Web Browser Access
Requirements
Software Requirements:
Adobe PDF Reader, Winzip (free)
Delivery
Download Speed:
Fast Download
⚙️ Engine Specifications
Primary Engine
Engine Family:
Evolution (Big Twin)
Engine Type:
Air-cooled V-twin
Displacement Cc:
1449
Displacement Ci:
88
Bore X Stroke In:
3.75 in x 4.00 in
Bore X Stroke Mm:
95.25 mm x 101.6 mm
Compression Ratio:
9.0:1 (typical)
Performance
Horsepower Approx:
60-70 HP (estimated, varies with tuning)
Torque Approx:
70-80 lb-ft (estimated, varies with tuning)
Fuel System
Fuel Delivery:
Carburetor (e.g., Keihin CV 40) or Fuel Injection (later models within the range, specific to sub-model variations not detailed here)
Carburetor Model:
Keihin CV 40 (typical for this era)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Gear Ratios:
Refer to manual for specific gear ratios.
Features
Drive Type:
Belt Drive
Clutch Type:
Wet, multi-plate
📐 Dimensions
Weights
Dry Weight Lbs:
Approximately 614 lbs (278.5 kg)
Wet Weight Lbs:
Approximately 648 lbs (294 kg)
Gvwr Lbs:
Not typically specified for motorcycles in the same way as cars; consult vehicle VIN for specific load limits.
Fuel Capacity Gal:
Approximately 4.2 gallons
Exterior
Wheelbase In:
Approximately 64.2 inches
🛡️ Safety Features
Ratings
Crash Test Results:
Motorcycle safety is primarily assessed through rider skill, maintenance, and accident avoidance rather than standardized crash tests.
Active Features
Braking System:
Dual front disc brakes with hydraulic actuation, single rear disc brake. FXDX often featured improved braking over standard models.
Passive Features
Frame Construction:
Steel cradle frame designed for stability and handling.
💡 Technology Features
Infotainment
Audio System:
Optional accessory radios were available; factory integration minimal on base models.
Instrumentation
Gauge Cluster:
Analog speedometer, tachometer, odometer, trip meter, indicator lights for turn signals, oil pressure, neutral, high beam, and engine diagnostics.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an optional feature on some models within this range; consult specific vehicle VIN.
🔧 Maintenance
Service Intervals
Oil Change Miles:
Refer to manual (typically 2,500-5,000 miles or annually)
Primary Chain Tension Inspection:
Refer to manual (often every 5,000 miles)
Fluid Specifications
Engine Oil Type:
Refer to manual (e.g., Harley-Davidson Genuine V-Twin Oil 20W50 or equivalent)
Transmission Oil Type:
Refer to manual (e.g., Harley-Davidson Genuine Formula + Transmission/Primary Chaincase Lubricant or equivalent)
Primary Chaincase Oil Type:
Refer to manual (same as transmission oil for many models)
Brake Fluid Type:
Refer to manual (DOT 4 recommended for most Harley-Davidsons of this era)
Fork Oil Type:
Refer to manual (specific viscosity, e.g., Harley-Davidson Fork Oil or equivalent)
Final Drive Oil Type:
Refer to manual (often the same as transmission/primary oil)
Known Issues
Primary Chain Tensioner Wear:
Hydraulic tensioner can wear over time, leading to noise and potential chain damage. Manual or upgraded aftermarket tensioners are common solutions.
Carburetor Issues:
CV carburetor can sometimes require adjustment or cleaning due to age or fuel quality.
Electrical Connectors:
Corrosion or loose connections in electrical harnesses can cause intermittent issues.
Belt Tension:
Improper belt tension can lead to premature wear of the belt and pulleys.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
United States
Brand Philosophy:
Harley-Davidson is renowned for its iconic American V-twin motorcycles, emphasis on rider experience, and strong brand loyalty.
Model Evolution
Dynaglide Platform:
Introduced in 1991, the Dyna platform was known for its distinctive frame styling and rider-focused ergonomics, evolving through various iterations.
Fxdx Specialization:
The FXDX 'Sport' variant typically featured upgraded suspension components, dual front disc brakes, and a more aggressive riding position compared to standard Dyna models.
Chassis Design:
Dyna chassis featured isolated powertrain for reduced vibration and a characteristic rubber-mounted engine.
Production
Manufacturing Location:
United States (York, Pennsylvania and Milwaukee, Wisconsin plants)
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