Dynaglide 99-05 Repair Manual.pdf

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CHAPTER ONE

GENERAL INFORMATION

This detailed and comprehensive manual covers

the Harley-Davidson Dyna Glide Twin Cam 88

model from 1999-on. Procedures and specifications

unique to 2002-2005 models are covered in the

Supplement at the end of the manual. The text pro-

vides complete information on maintenance,

tune-up, repair and overhaul. Hundreds of photos

and drawings guide the reader through every job.

A shop manual is a reference tool and as in all

service manuals, the chapters are thumb tabbed for

easy reference. Important items are indexed at the

end of the book. All procedures, tables and figures

are designed for the reader who may be working on

the vehicle for the first time. Frequently used speci-

fications and capacities from individual chapters

are summarized in the Quick Reference Data at the

front of the book.

Tables 1-9 are at the end of this chapter.

Table 1 lists model designation.

Table 2 lists general vehicle dimensions.

Table 3 lists vehicle weight.

Table 4 lists decimal and metric equivalents.

Table 5 lists conversion tables.

Table 6 lists general torque specifications.

Table 7 lists technical abbreviations.

Table 8 lists American tap and drill sizes.

Table 9 lists special tools.

MANUAL ORGANIZATION

All dimensions and capacities are expressed in

metric and U.S. standard units of measurement.

This chapter provides general information on

shop safety, tool use, service fundamentals and shop

supplies. The tables at the end of the chapter include

general vehicle information.

Chapter Two provides methods for quick and ac-

curate diagnosis of problems. Troubleshooting pro-

cedures present typical symptoms and logical

methods to pinpoint and repair the problem.

CHAPTER ONE

Chapter Three explains all routine maintenance

necessary to keep the vehicle running well. Chapter

Three also includes recommended tune-up proce-

dures, eliminating the need to constantly consult the

chapters on the various assemblies.

Subsequent chapters describe specific systems

such as engine, transmission, clutch, drive system,

fuel and exhaust systems, suspension and brakes.

Each disassembly, repair and assembly procedure is

discussed in step-by-step form.

Some of the procedures in this manual specify

special tools. In most cases, the tool is illustrated in

use. Well-equipped mechanics may be able to sub-

stitute similar tools or fabricate a suitable replace-

ment. However, in some cases, the specialized

equipment or expertise needed may make it imprac-

tical for the home mechanic to attempt the proce-

dure. When necessary, such operations are

identified in the text with the recommendation to

have a dealership or specialist perform the task. It

may be less expensive to have a professional per-

form these jobs, especially when considering the

cost of the equipment.

Carbon monoxide levels build quickly in small en-

closed areas and can cause unconsciousness and

death in a short time. Make sure the work area is

properly ventilated or operate the vehicle outside.

2. Never use gasoline or any extremely flammable

liquid to clean parts. Refer to Cleaning Parts and

Handling Gasoline Safely in this chapter.

3. Never smoke or use a torch in the vicinity of

flammable liquids, such as gasoline or cleaning sol-

vent.

4. If welding or brazing on the vehicle, remove the

fuel tank, carburetor and shocks to a safe distance at

least 50 ft. (15 m) away.

5. Use the correct type and size of tools to avoid

damaging fasteners.

6. Keep tools clean and in good condition. Replace

or repair worn or damaged equipment.

7. When loosening a tight fastener, be guided by

what would happen if the tool slips.

8. When replacing fasteners, make sure the new

fasteners are of the same size and strength as the

original ones.

9. Keep the work area clean and organized.

10. Wear eye protection anytime the safety of the

eyes is in question. This includes procedures in-

volving drilling, grinding, hammering, compressed

air and chemicals.

11. Wear the correct clothing for the job. Tie up or

cover long hair so it can not get caught in moving

equipment.

12. Do not carry sharp tools in clothing pockets.

13. Always have an approved fire extinguisher

available. Make sure it is rated for gasoline (Class

B) and electrical (Class C) fires.

14. Do not use compressed air to clean clothes, the

vehicle or the work area. Debris may be blown into

the eyes or skin. Never direct compressed air at any-

one. Do not allow children to use or play with any

compressed air equipment.

15. When using compressed air to dry rotating

parts, hold the part so it can not rotate. Do not allow

the force of the air to spin the part. The air jet is ca-

pable of rotating parts at extreme speed. The part

may be damaged or disintegrate, causing serious in-

jury.

16. Do not inhale the dust created by brake pad and

clutch wear. These particles may contain asbestos.

In addition, some types of insulating materials and

gaskets may contain asbestos. Inhaling asbestos

particles is hazardous to health.

WARNINGS, CAUTIONS AND NOTES

The terms, WARNING, CAUTION and NOTE

have specific meanings in this manual.

A WARNING emphasizes areas where injury or

even death could result from negligence. Mechani-

cal damage may also occur. WARNINGS are to be

taken seriously .

ACAUTION emphasizes areas where equipment

damage could result. Disregarding a CAUTION

could cause permanent mechanical damage, though

injury is unlikely.

ANOTE provides additional information to make

a step or procedure easier or clearer. Disregarding a

NOTE could cause inconvenience, but would not

cause equipment damage or personal injury.

SAFETY

Professional mechanics can work for years and

never sustain a serious injury or mishap. Follow

these guidelines and practice common sense to

safely service the vehicle.

1. Do not operate the vehicle in an enclosed area.

The exhaust gasses contain carbon monoxide, an

odorless, colorless, and tasteless poisonous gas.

GENERAL INFORMATION

17. Never work on the vehicle while someone is

working under it.

18. When placing the vehicle on a stand, make sure

it is secure before walking away.

Cleaning Parts

Cleaning parts is one of the more tedious and dif-

ficult service jobs performed in the home garage.

There are many types of chemical cleaners and sol-

vents available for shop use. Most are poisonous

and extremely flammable. To prevent chemical ex-

posure, vapor buildup, fire and serious injury, ob-

serve each product warning label and note the

following:

1. Read and observe the entire product label before

using any chemical. Always know what type of

chemical is being used and whether it is poisonous

and/or flammable.

2. Do not use more than one type of cleaning sol-

vent at a time. If mixing chemicals is called for,

measure the proper amounts according to the manu-

facturer.

3. Work in a well-ventilated area.

4. Wear chemical-resistant gloves.

5. Wear safety glasses.

6. Wear a vapor respirator if the instructions call

for it.

7. Wash hands and arms thoroughly after cleaning

parts.

8. Keep chemical products away from children and

pets.

9. Thoroughly clean all oil, grease and cleaner resi-

due from any part that must be heated.

10. Use a nylon brush when cleaning parts. Metal

brushes may cause a spark.

11. When using a parts washer, only use the solvent

recommended by the manufacturer. Make sure the

parts washer is equipped with a metal lid that will

lower in case of fire.

Handling Gasoline Safely

Gasoline is a volatile flammable liquid and is one

of the most dangerous items in the shop. Because

gasoline is used so often, many people forget that it

is hazardous. Only use gasoline as fuel for gasoline

internal combustion engines. Keep in mind, when

working on a vehicle, gasoline is always present in

the fuel tank, fuel line and carburetor. To avoid a di-

sastrous accident when working around the fuel

system, carefully observe the following precau-

tions:

1. Never use gasoline to clean parts. See Cleaning

Parts in this chapter.

2. When working on the fuel system, work outside

or in a well-ventilated area.

3. Do not add fuel to the fuel tank or service the fuel

systemwhile the vehicle is near open flames, sparks

or where someone is smoking. Gasoline vapor is

heavier than air, it collects in low areas and is more

easily ignited than liquid gasoline.

4. Allow the engine to cool completely before

working on any fuel system component.

5. When draining the carburetor, catch the fuel in a

plastic container and then pour it into an approved

gasoline storage device.

6. Do not store gasoline in glass containers. If the

glass breaks, a serious explosion or fire may oc-

cur.

7. Immediately wipe up spilled gasoline with rags.

Store the rags in a metal container with a lid until

they can be properly disposed of, or place them out-

side in a safe place for the fuel to evaporate.

8. Do not pour water onto a gasoline fire. Water

spreads the fire and makes it more difficult to put

out. Use a class B, BC or ABC fire extinguisher to

extinguish the fire.

9. Always turn off the engine before refueling. Do

not spill fuel onto the engine or exhaust system. Do

not overfill the fuel tank. Leave an air space at the

top of the tank to allow room for the fuel to expand

due to temperature fluctuations.

Warning Labels

Most manufacturers attach information and

warning labels to the vehicle. These labels contain

instructions that are important to personal safety

when operating, servicing, transporting and storing

the vehicle. Refer to the owner’s manual for the de-

scription and location of labels. Order replacement

labels from the manufacturer if they are missing or

damaged.

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CHAPTER ONE

SERIAL NUMBERS

Serial numbers are stamped on various locations

on the frame, engine, transmission and carburetor.

Record these numbers in the Quick Reference Data

section in the front of the book. Have these numbers

available when ordering parts.

The frame serial number ( Figure 1 ) is stamped on

the right side of the frame down tube.

The VIN number label ( Figure 2 ) is located just

below the frame number on the right side frame

down tube.

Engine serial number is stamped on a pad on the

left side of the crankcase ( Figure 3 ), as well as the

right side of the crankcase ( Figure 4 ).

The transmission serial number ( Figure 5 ) is

stamped on a pad on the right side of the transmis-

sion case next to the side door.

The carburetor serial number ( Figure 6 ) is lo-

cated on the side of the carburetor body next to the

accelerator pump linkage.

Table 1 lists model designation.

FASTENERS

Proper fastener selection and installati on is im-

portant to ensure that the vehicle operates as de-

signed and can be serviced efficiently. The choice of

original equipment fasteners is not arrived at by

chance. Make sure that replacement fasteners meet

all the same requirements as the originals.

Threaded Fasteners

Threaded fasteners secure most of the compo-

nents on the vehicle. Most are tightened by turning

them clockwise (right-hand threads). If the normal

rotation of the component being tightened would

loosen the fastener, it may have left-hand threads. If

a left-hand threaded fastener is used, it is noted in

the text.

Two dimensions are required to match the threads

of the fastener: the number of threads in a given dis-

tance and the outside diameter of the threads.

Two systems are currently used to specify

threaded fastener dimensions: the U.S. Standard

system and the metric system ( Figure 7 ). Pay par-

ticular attention when working with unidentified

fasteners; mismatching thread types can damage

threads.

GENERAL INFORMATION

-9.8

Grade marking

NOTE

To ensure that the fastener threads are

not mismatched or cross-threaded,

start all fasteners by hand. If a fas-

tener is hard to start or turn, deter-

mine the cause before tightening with

a wrench.

The length (L, Figure 8 ), diameter (D) and dis-

tance between thread crests (pitch) (T) classify met-

ric screws and bolts. A typical bolt may be

identified by the numbers, 8—1.25 130. This indi-

cates the bolt has diameter of 8 mm, the distance be-

tween thread crests is 1.25 mm and the length is 130

mm. Always measure bolt length as shown in Fig-

ure 8 to avoid purchasing replacements of the

wrong length.

The numbers located on the top of the fastener

( Figure 8 ) indicate the strength of metric screws

and bolts. The higher the number, the stronger the

fastener is. Unnumbered fasteners are the weakest.

Many screws, bolts and studs are combined with

nuts to secure particular components. To indicate

the size of a nut, manufacturers specify the internal

diameter and the thread pitch.

The measurement across two flats on a nut or bolt

indicates the wrench size.

American

Metric

60°

WARNING

Do not install fasteners with a

strength classification lower than

what was originally installed by the

manufacturer. Doing so may cause

equipment failure and/or damage.

Torque Specifications

The materials used in the manufacture of the ve-

hicle may be subjected to uneven stresses if the fas-

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