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Introduction
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Market Position
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Segment:
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Cruiser motorcycle segment, known for its V-twin engine, rider comfort, and customization potential.
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Competitive Analysis
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Competitors:
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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).
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Key Features
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Drivetrain:
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Harley-Davidson Evolution (Big Twin) engine, known for its distinctive torque delivery and sound.
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Handling Chassis:
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Robust steel frame, designed for stable highway cruising and responsive handling for its class.
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Styling:
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Classic Harley-Davidson styling, with customizable options for handlebars, seats, exhaust, and paint.
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Manual Coverage
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Systems Covered
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Engine Systems:
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Engine disassembly, assembly, diagnosis, inspection, tuning, lubrication systems, cooling systems (if applicable), fuel systems (carburetor/EFI), ignition systems, exhaust systems, emissions control.
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Transmission Drivetrain:
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Clutch operation and adjustment, transmission disassembly and assembly, primary drive, final drive (belt or chain), lubrication, troubleshooting.
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Electrical Systems:
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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.
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Chassis Suspension:
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Frame inspection and repair, front suspension (forks, steering head bearings), rear suspension (shocks, swingarm, bushings), wheel bearings, alignment.
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Braking Systems:
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Front and rear brake caliper service, master cylinders, brake lines, pads, rotors, bleeding procedures, hydraulic system diagnosis.
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Fuel System:
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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.
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Bodywork Fittings:
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Fender removal and installation, fuel tank service, seat removal, fairings (if equipped), controls, mirrors, luggage systems.
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Procedures Included
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Maintenance:
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Routine maintenance checks, oil changes, filter replacements, spark plug service, chain/belt adjustment and lubrication, tire pressure, brake inspection.
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Troubleshooting:
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Diagnostic flowcharts for common problems, identifying causes of poor performance, starting issues, electrical faults, noise diagnosis.
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Repair Rebuild:
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Detailed step-by-step instructions for component removal, overhaul, and reassembly for all major vehicle systems.
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Diagnostics:
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On-board diagnostics (if applicable), interpretation of fault codes, electrical system testing using multimeter and specialized tools.
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Technical Depth
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Depth:
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Comprehensive, covering from basic scheduled maintenance to full engine and transmission overhauls, including detailed torque specifications and diagnostic procedures.
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Engine Specifications
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Primary Engine
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Engine Family:
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Harley-Davidson Evolution (often referred to as the 'Evo' Big Twin)
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Engine Configuration:
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Air-cooled, 45-degree V-twin
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Displacement:
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Typically 1450cc (88 cubic inches) for 2005 Dyna models. Specific models might have variants, but this is the common displacement.
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Bore X Stroke:
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3.5625 in x 4.25 in (90.425 mm x 107.95 mm) for 1450cc.
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Compression Ratio:
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Approximately 9.0:1 (can vary slightly based on specific model/tuning).
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Valve Train:
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Overhead valves (OHV), two valves per cylinder, operated by pushrods and tappets.
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Power Output:
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Estimated 65-70 HP (actual figures vary, Harley-Davidson did not always publish precise HP ratings).
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Torque Output:
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Estimated 78-85 lb-ft (around 106-115 Nm) at ~3200 RPM (actual figures vary).
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Performance
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Top Speed:
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Governed by gearing and rider, typically capable of 100+ mph.
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Fuel System
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Fuel Delivery:
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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.
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Fuel Type:
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Unleaded gasoline, 91 octane (Research Octane Number) or higher recommended.
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Fuel Capacity:
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Typically 4.9 US gallons (18.5 liters) for standard Dyna tanks.
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Dimensions
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Exterior
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Length:
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Varies by specific Dyna model (e.g., Super Glide, Low Rider, Street Bob), typically around 90-92 inches (2286-2337 mm).
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Width:
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Varies, typically around 36-38 inches (914-965 mm) at handlebars.
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Height:
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Varies, typically around 47-50 inches (1194-1270 mm) to the top of handlebars.
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Wheelbase:
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Varies, typically around 62-64 inches (1575-1626 mm).
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Weights
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Dry Weight:
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Varies by model, typically 580-630 lbs (263-286 kg).
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Gross Vehicle Weight Rating Gvwr:
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Typically around 950-1000 lbs (431-454 kg).
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Payload Capacity:
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Approximately 350-400 lbs (159-181 kg).
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Technology Features
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Infotainment
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Audio System:
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Base 2005 Dyna models generally did not come with factory installed audio systems. Aftermarket audio systems and CB radios were common additions.
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Driver Assistance
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ABS:
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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.
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Connectivity
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Smart Features:
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No advanced connectivity features like Bluetooth, GPS, or smartphone integration were standard on 2005 Harley-Davidson models.
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Instrumentation
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Gauge Cluster:
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Analog speedometer, tachometer (on some models), fuel gauge, odometer, trip meter, and indicator lights for turn signals, oil pressure, neutral, and high beam.
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Maintenance
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Service Intervals
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Initial Service:
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First service typically at 1,000 miles (1,600 km), involving oil change, filter change, inspection of primary drive, chain/belt, brakes, and fasteners.
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Subsequent Service:
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Subsequent services typically every 5,000 miles (8,000 km) or annually, including oil changes, filter replacements, spark plug checks, and lubrication.
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Major Service Intervals:
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Valve lash adjustments, primary drive inspection, and other component checks are recommended at specific higher mileage intervals (e.g., 10,000-20,000 miles).
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Fluid Specifications
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Engine Oil:
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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.
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Primary Chain Case Oil:
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Harley-Davidson primary lubricant or compatible heavy-duty chaincase lubricant. Capacity: Approx. 1 US quart (0.95 liters).
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Transmission Oil:
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Harley-Davidson transmission oil or compatible 75W90 or 80W90 gear lubricant. Capacity: Approx. 24 US fluid ounces (0.71 liters).
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Brake Fluid:
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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.
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Fork Oil:
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Specific weight of fork oil recommended by Harley-Davidson, often around 10W or 15W. Capacity varies by fork model, check manual.
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Known Issues
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Cam Chain Tensioners:
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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.
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Carburetor Performance:
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CV carburetors can require tuning for altitude changes or aftermarket exhaust/intake modifications. The manual provides jetting and adjustment guidance.
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Electrical Connectors:
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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.
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Regulator Rectifier:
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The charging system's regulator/rectifier can be a failure point. The manual outlines testing procedures.
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