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Checks to ensure safe operation after storage and between regular service intervals.
Lists periodic maintenance requirements for Dyna models with service intervals and quick reference chart.
Instructions on selecting proper engine oil grade and viscosity based on temperature and avoiding lubricant brand mixing.
Step-by-step instructions for changing engine oil and filter, including torque specifications and oil capacity.
CAUTIONary information regarding brake fluid contact and spills, and procedure for checking fluid levels.
Guidelines on matching tires, tubes, and air valves, using approved tires, and checking tire pressure and tread.
Troubleshooting common engine problems like starting issues, rough running, and overheating.
Specifications for tire sizes, rim contours, and valve hole diameters for Dyna models.
Steps to remove the front wheel, including disconnecting brake caliper and removing axle.
Instructions for removing the rear wheel, including brake pads and caliper.
Checking vehicle alignment using axle plugs and measuring tools for accurate wheel alignment.
Steps for removing and disassembling the front brake master cylinder, including fluid drainage.
Procedure for removing tires from motorcycle wheels, including deflating and loosening beads.
Step-by-step instructions for disassembling the front fork, including removing components and oil.
Procedures for removing steering head bearing races using specialized tools.
Instructions for removing and disassembling the throttle control, including cables and housing.
Instructions for removing rear shock absorbers, emphasizing one-at-a-time removal.
Steps to remove the rear fender, including detaching electrical harness and seat.
Instructions for cleaning the jiffy stand and its mating surfaces, including lubrication.
Procedures for removing front and rear engine isolators, including supporting the engine.
Provides general specifications for the engine, including number of cylinders, type, torque, bore, stroke, and displacement.
Details the flow of oil from the oil pan through the crankcase and into the cam support plate.
Procedures to diagnose and correct noisy hydraulic lifters and valve train components.
Procedure for performing a compression test to determine cylinder leakage.
Steps for top end service with the engine in the chassis.
Procedures for bottom end service with the engine in the chassis.
Step-by-step instructions for removing the engine from the motorcycle chassis.
Instructions for disassembling the breather assembly, including removing fasteners and parts.
Steps for removing cylinder head bolts, rocker housing, and cylinder head.
Procedure for removing piston pin circlips and piston pin.
Instructions for checking piston ring end gap before placing each ring on the piston.
Table of fuel capacity specifications for various Dyna models.
Refers to the Electrical Diagnostic Manual for EFI troubleshooting and diagnostic information.
Steps for removing the air cleaner cover, breather tubes, bracket, and filter element.
Procedure for removing the fuel tank, including purging fuel lines and disconnecting connectors.
Instructions for removing the exhaust system, excluding muffler removal steps.
Steps for performing an intake leak test using propane to detect leaks.
Table of starter specifications including free speed, current, cranking current, and stall torque.
Instructions for removing the starter, including battery and starter cover removal.
Procedures for testing the starter armature, field coil winding, and brush holder insulation.
Disassembly and assembly instructions for the solenoid assembly.
Table of sprocket specifications indicating the number of teeth for DOM/HDI and Japan models.
Instructions for installing the primary chaincase cover, including gasket and fastener torque.
Procedure for removing drive components including primary chain, clutch, and sprockets.
Instructions for removing and installing the clutch assembly, including clutch pack.
Procedure for partial disassembly of the clutch pack for servicing.
Steps for cleaning and inspecting clutch plates and steel plates for wear or damage.
Instructions for installing the drive belt, including handling and tension adjustment.
Table of service wear limits for various transmission components like gears and bearings.
Explanation of power flow through the 6-speed transmission for each gear.
Instructions for adjusting the shift rod if full engagement or lever travel is not achieved.
Steps for removing the transmission assembly, including primary chaincase and clutch.
Detailed instructions for disassembling the transmission, including shifter cam and shifter forks.
Procedure for removing the main drive gear, including bearing and retaining ring.
Instructions for cleaning and inspecting the main drive gear, bearings, and seals.
Steps for removing the transmission case from the motorcycle frame.
Table of electrical specifications including ignition, circuit breakers/fuses, and charging system data.
Instructions for removing the electrical caddy cover, relay/fuse panels, and connectors.
Steps for removing the ignition switch/fork lock, including fuel system purging.
Instructions for removing and installing the battery tray and guiding battery cables.
Instructions for installing new bulbs and assembling headlamp components, with alignment notes.
Procedure for replacing the tail lamp bulb in standard style units.
Steps for installing the TSM/TSSM/HFSM module, including connectors and password learning.
Instructions for installing the CKP sensor, including O-ring lubrication and connector attachment.
Instructions for installing the stator, rotor, and connecting wiring, including torque specifications.
Procedure for removing the console to access the fuel gauge.
Steps for removing the fuel gauge from the top plate, including disconnecting connectors.
Procedure for removing the fuel gauge sender, including disconnecting wiring and hoses.
Instructions for removing and installing the speedometer and its console components.
Steps for installing the neutral switch, including lubricating the O-ring and tightening.
Procedure for installing the active exhaust module, including routing the cable.
Instructions for routing and connecting the main wiring harness, including ground wires.
Instructions for repairing the upper housing, including splicing wires and securing cables.
Steps for removing the left handlebar switch assembly, including housing screws.
Procedure for removing socket terminals from AMP 1-place connectors using a tool.
Instructions for removing socket terminals from Deutsch connectors using a screwdriver or pick.
Procedure for removing socket terminals from Packard 150 Metri-Pack connectors.
Instructions for splicing wire leads using a connector and heat shrink tubing.
General| Engine Type | Air-cooled, Twin Cam 96 |
|---|---|
| Bore x Stroke | 95.3 mm x 111.1 mm |
| Compression Ratio | 9.2:1 |
| Fuel System | Electronic Sequential Port Fuel Injection (ESPFI) |
| Transmission | 6-speed |
| Final Drive | Belt |
| Frame | Mild steel, tubular frame; rectangular section backbone; stamped, cast, and forged junctions; forged fender supports; MIG welded |
| Front Suspension | 49 mm telescopic fork |
| Displacement | 1584 cc |
| Front Brakes | Single disc |
| Rear Brakes | Single disc |
| Seat Height | 710 mm (28 in) |
| Fuel Capacity | 18.9 L (5 US gal) |
| Rear Tire | 160/70-17 |
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