1991-2009 Harley Davidson DYNA Repair & Service Manual (315 MB, Searchable & Printable PDF)
Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Harley Davidson DYNA 1991-2009 Motorcycle. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your vehicle like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.
This manual for 1991-2009 Harley Davidson DYNA bike is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.
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MAKE: Harley Davidson
YEAR: 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
MODEL:
“’08 DYNA models.pdf”
2008 Dyna Models Service Manual
99481-08
1,032 pages
“’09 DYNA models.pdf”
2009 Dyna Models Service Manual
99481-09
576 pages
“’91-’98 DYNA Glide.pdf”
1991-1998 DYNA EVOLUTION Service Manual
545 pages
“’99-’05 DYNA Glide.pdf”
1991-1998 FXD DYNA Service Manual
596 pages
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EXCERPT:
1 Chapter One General Information
2 Chapter Two Troubleshooting
3 Chapter Three Periodic Lubrication, Maintenance & Tune-up
4 Chapter Four Engine
5 Chapter Five Clutch and Primary Drive
6 Chapter Six Transmission
7 Chapter Seven Fuel, Exhaust & Emission Control Systems
8 Chapter Eight Electrical System
9 Chapter Nine Wheels, Hubs & Tires
10 Chapter Ten Front Suspension & Steering
11 Chapter Eleven Rear Suspension
12 Chapter Twelve Brakes
13 Chapter Thirteen Body
14 Chapter Fourteen Supplement 2002-2005 Models Service Information
15 Chapter Fifteen Index
16 Chapter Sixteen Wiring Diagrams
CHAPTER FIVE
CLUTCH AND PRIMARY DRIVE
This chapter describes service procedures for the clutch and primary drive assemblies.
Tables 1-3 are at the end of the chapter.
Table 1 lists the clutch general specifications and sprocket sizes
Table 2 lists clutch torque specifications.
Table 3 lists sprocket alignment spacers.
PRIMARY CHAINCASE OUTER COVER
Removal
Refer to Figure 1.
NOTE
On models so equipped, always disarm the optional TSSM security system prior to disconnecting the battery or the siren will sound.
1. Disconnect the negative battery cable as described in Chapter Eight.
WARNING
Disconnect the negative battery cable before working on the clutch or any primary drive component to avoid accidentally activating the starter motor.
2. Remove the bolts securing the left side footpeg assembly (Figure 2) and remove the assembly.
3. Drain the primary chain oil as described in Chapter Three.
NOTE
Note the location of the inspection cover bolts. There are two different
length bolts and they must be reinstalled in the correct location.
4A. On all models except FXDWG, perform the following:
a. Make an alignment mark (A, Figure 3) on the outer shift lever and the end of the inner shift lever shaft.