Harley Davidson Dyna Models (2013) - Workshop Manual / Repair Manual

HARLEY DAVIDSON DYNA MODELS (2013) - WORKSHOP, SERVICE, REPAIR MANUAL

- English Workshop Manual, to motorcycles Harley Davidson Dyna Models (2013).

MODELS COVERED:

- Harley-Davidson FXDL Dyna Low Rider (Japan only)
- Harley-Davidson FXDWG Dyna Wide Glide
- Harley-Davidson FXDB Dyna Street Bob
- Harley-Davidson FXDC Dyna Super Glide Custom
- Harley-Davidson FXDC ANV Dyna Super Glide Custom 110th Anniversary Edition
- Harley-Davidson FXDF Dyna Fat Bob
- Harley-Davidson FLD Dyna Switchback
- Harley-Davidson FXDBP Dyna Street Bob (factory custom)
- Harley-Davidson FXDBA Dyna Street Bob (factory custom)
 

INDEX:

FOREWORD
TABLE OF CONTENTS
1. MAINTENANCE
-1.1 FASTENER TORQUE VALUES
-  Fastener Torque Values in this Chapter
-1.2 GENERAL
-  Servicing a New Motorcycle
-  Safe Operating Maintenance
-  Disposal and Recycling
-  Shop Practices
-  Repair and Replacement Procedures
-  Cleaning
-  Tool Safety
-1.3 FUEL AND OIL
-  Fuel
-  Gasoline Blends
-  Engine Lubrication
-  Winter Lubrication
-1.4 BULB REQUIREMENTS
-  General
-1.5 MAINTENANCE SCHEDULE
-  General
-1.6 ENGINE OIL AND FILTER
-  Checking and Adding Oil
-  Changing Oil and Filter
-1.7 AIR CLEANER AND EXHAUST SYSTEM
-  Removal
-  Installation
-  Exhaust System Leak Check
-1.8 TIRES AND WHEELS
-  Tires
-  Tire Replacement
-  Wheel Bearings
-  Wheel Spokes
-1.9 PRIMARY CHAINCASE LUBRICANT
-  General
-  Changing Primary Chaincase Lubricant
-1.10 TRANSMISSION LUBRICANT
-  Checking Transmission Lubricant
-  Changing Transmission Lubricant
-1.11 CLUTCH
-  Adjustment
-1.12 DRIVE BELT AND SPROCKETS
-  General
-  Cleaning
-  Inspection
-  Checking Belt Deflection
-  Adjusting Belt Deflection
-1.13 THROTTLE CABLES
-  Cable Inspection, Lubrication and Adjustment
-1.14 CABLE AND CHASSIS LUBRICATION
-  General
-  Cables and Hand Levers
-  Jiffy Stand
-1.15 BRAKES
-  Fluid Inspection
-  Rear Pedal Height
-  Brake Lines Inspection
-1.16 BRAKE PADS AND DISCS
-  Inspection
-  Brake Pad Replacement
-1.17 SPARK PLUGS
-  Inspection
-  Spark Plug Cable Inspection
-1.18 STEERING HEAD BEARINGS
-  Adjustment
-  Lubrication
-1.19 CRITICAL FASTENERS
-  Inspection
-1.20 BATTERY MAINTENANCE
-  General
-  Cleaning and Inspection
-  Voltmeter Test
-  Charging Battery
-  Disconnection and Removal
-  Storage
-  Installation and Connection
-1.21 ENGINE MOUNTS
-  Inspection
-1.22 HEADLAMP ALIGNMENT
-  Headlamp Alignment
-  Adjustment: All Models Except FLD
-  Adjustment: FLD Models
-1.23 SUSPENSION ADJUSTMENTS
-  Shock Absorber Preload Adjustment
-1.24 STORAGE
-  General
-  Placing in Storage
-  Removal from Storage
-1.25 TROUBLESHOOTING
-  General
-  Engine
-  Lubrication System
-  Electrical System
-  Transmission
-  Handling
-  Brakes
2. CHASSIS
-2.1 FASTENER TORQUE VALUES
-  Fastener Torque Values in this Chapter
-2.2 SPECIFICATIONS
-  Specifications
-2.3 VEHICLE IDENTIFICATION NUMBER (VIN)
-  Vehicle Identification Number
-2.4 FRONT WHEEL
-  Removal
-  Disassembly
-  Cleaning and Inspection
-  Assembly
-  Installation
-2.5 REAR WHEEL
-  Removal
-  Disassembly
-  Cleaning and Inspection
-  Assembly
-  Installation
-2.6 SEALED WHEEL BEARINGS
-  Inspection
-  Removal
-  Installation
-2.7 WHEEL LACING
-  Wheel Lacing: Angle Flange Hub
-  Wheel Lacing: Straight Flange Hub, Single Hole Circle
-  Wheel Lacing: Straight Flange Hub, Dual Hole Circle
-2.8 CHECKING AND TRUING WHEELS
-  General
-  Checking Wheel Runout
-  Laced Wheel Rim Offset
-  Truing Laced Wheels
-2.9 VEHICLE ALIGNMENT
-  Inspection
-2.10 FRONT BRAKE MASTER CYLINDER
-  General
-  Removal and Disassembly
-  Cleaning and Inspection
-  Assembly and Installation
-2.11 FRONT BRAKE CALIPER
-  Removal
-  Disassembly
-  Cleaning, Inspection and Repair
-  Assembly
-  Installation
-2.12 REAR BRAKE MASTER CYLINDER
-  General
-  Removal
-  Disassembly
-  Cleaning and Inspection
-  Assembly
-  Installation
-2.13 REAR BRAKE CALIPER
-  Removal
-  Disassembly
-  Cleaning, Inspection and Repair
-  Assembly
-  Installation
-2.14 BLEEDING BRAKES
-  General
-  Procedure
-2.15 TIRES
-  General
-  Removal
-  Cleaning, Inspection and Repair
-  Installation
-  Checking Tire Runout
-  Wheel Balancing
-2.16 FRONT FORK
-  Removal
-  Disassembly
-  Disassembly: Cartridge Fork (FLD, Left Side)
-  Cleaning and Inspection
-  Assembly
-  Assembly: Cartridge Fork (FLD, Left Side)
-  Installation
-2.17 STEERING HEAD
-  Removal: All But FLD
-  Removal: FLD
-  Inspection
-  Disassembly
-  Assembly
-  Installation: All but FLD
-  Installation: FLD
-2.18 BELT GUARD
-  Removal
-  Installation
-2.19 DEBRIS DEFLECTOR
-  Removal
-  Installation
-2.20 THROTTLE CONTROL
-  Removal/Disassembly
-  Cleaning and Inspection
-  Assembly/Installation
-  Throttle Cable Routing
-2.21 REAR SHOCK ABSORBERS
-  General
-  Removal
-  Inspection
-  Installation
-2.22 REAR FORK
-  Removal
-  Disassembly
-  Cleaning and Inspection
-  Assembly
-  Installation
-2.23 CLUTCH CONTROL
-  Removal
-  Installation
-2.24 HANDLEBARS: FXDC, FXDL AND FLD
-  Removal
-  Installation
-  Left Hand Grip
-2.25 HANDLEBARS: FXDB/P/A, FXDF AND FXDWG
-  Removal
-  Installation
-2.26 FRONT FENDER
-  Removal
-  Installation
-2.27 REAR FENDER
-  General
-  FXDF
-  FXDC and FXDL
-  FXDB
-  FXDWG
-  FLD
-2.28 SEAT
-  Removal
-  Installation
-2.29 FOOTBOARDS AND FOOTRESTS
-  Rider Footboards
-  Rider Footrests: Mid Controls
-  Rider Footrests: Forward Controls
-  Passenger Footrests: All models except FXDF)
-2.30 HEADLAMP NACELLE: FLD
-  Upper and lower nacelle: FLD
-2.31 WINDSHIELD: FLD
-  Windshield
-  Windshield Window
-2.32 SADDLEBAGS: FLD
-  Saddlebags: FLD Model
-  Saddlebags
-  Saddlebag Lid
-2.33 JIFFY STAND
-  Cleaning
-  Jiffy Stand Sensor: HDI Models
-  Removal
-  Installation
-2.34 ENGINE MOUNTS
-  Removal
-  Installation
-2.35 SAREE GUARD: INDIA MODELS
-  Replacement
-2.36 MEDALLIONS, SERIALIZED BADGES AND TANK EMBLEMS
-  Removal
-  Installation
3. ENGINE
-3.1 FASTENER TORQUE VALUES
-  Fastener Torque Values in this Chapter
-3.2 SPECIFICATIONS
-  Specifications
-3.3 SERVICE WEAR LIMITS
-  General
-3.4 ENGINE OIL FLOW
-  Oil Feed
-  Top End
-  Bottom End
-  Oil Return
-3.5 OIL PUMP OPERATION
-  General
-  Operation
-3.6 BREATHER OPERATION
-  General
-3.7 OIL PRESSURE
-  Oil Pressure Indicator Lamp
-  Checking Oil Pressure
-3.8 TROUBLESHOOTING
-  Diagnosing Valve Train Noise
-  Compression Test
-  Cylinder Leakdown Test
-  Diagnosing Smoking Engine or High Oil Consumption
-3.9 HOW TO USE THIS SECTION
-  Top End Repair
-  Bottom End Repair
-  Typical Symptoms
-3.10 TOP END SERVICE
-  Engine in Chassis
-  Engine Removed from Chassis
-3.11 CAM COMPARTMENT SERVICE
-  Engine in Chassis
-  Engine Removed From Chassis
-3.12 STRIPPING MOTORCYCLE FOR SERVICE
-  Procedure
-3.13 ASSEMBLING MOTORCYCLE AFTER SERVICE
-  Procedure
-3.14 REMOVING ENGINE FROM CHASSIS
-  Procedure
-3.15 INSTALLING ENGINE IN CHASSIS
-  Procedure
-3.16 TOP END OVERHAUL: DISASSEMBLY
-  General
-  Rocker Covers
-  Rocker Arm Support Plate
-  Pushrods, Lifters and Covers
-  Cylinder Head
-  Cylinder
-  Piston
-3.17 BREATHER ASSEMBLY
-  Disassembly
-  Cleaning and Inspection
-  Assembly
-3.18 ROCKER ARM SUPPORT PLATE
-  Disassembly
-  Cleaning and Inspection
-  Assembly
-3.19 PUSHRODS, LIFTERS AND COVERS
-  Disassembly
-  Cleaning and General Inspection
-  Lifter Inspection
-  Assembly
-3.20 CYLINDER HEAD
-  Disassembly
-  Cleaning
-  Inspection
-  Valve Guide Replacement
-  Valve and Seat Refacing
-  Assembly
-3.21 CYLINDER
-  Cleaning
-  Inspection
-  Deglazing Cylinder
-  Boring and Honing Cylinder
-3.22 PISTON
-  Disassembly
-  Cleaning
-  Inspection
-  Assembly
-3.23 TOP END OVERHAUL: ASSEMBLY
-  General
-  Piston
-  Cylinder
-  Cylinder Head
-  Pushrods, Lifters and Covers
-  Rocker Arm Support Plate
-  Breather and Rocker Cover
-3.24 CAM COMPARTMENT AND COMPONENTS
-  Cam Support Plate and Cover Removal
-  Cam Support Plate Cleaning and Inspection
-  Camshafts
-  Oil Pressure Relief Valve
-  Cam Needle Bearings
-  Cam Support Plate and Cover Installation
-3.25 OIL PUMP
-  Removal
-  Cleaning and Inspection
-  Installation
-3.26 CRANKCASE DISASSEMBLY AND REPAIR
-  Crankcase Disassembly
-  Cleaning and Inspection
-  Right Crankcase Half
-  Left Crankcase Half
-  Sprocket Shaft Bearing Inner Race
-  Cylinder Studs
-  Pipe Plug and Oil Fittings
-3.27 FLYWHEEL AND CONNECTING RODS
-  General
-  Inspection
-  Measuring Crankshaft Runout
-3.28 CRANKCASE ASSEMBLY
-  Crankcase Assembly
-3.29 OIL PAN
-  Removal
-  Installation
4. FUEL SYSTEM
-4.1 FASTENER TORQUE VALUES
-  Fastener Torque Values in this Chapter
-4.2 SPECIFICATIONS: FUEL SYSTEM
-  Specifications
-4.3 AIR CLEANER ASSEMBLY
-  Removal
-  Installation
-  Backplate Assembly: HDI Models
-4.4 FUEL TANK
-  General
-  Removal
-  Cleaning and Inspection
-  Installation
-4.5 THROTTLE POSITION SENSOR (TPS)
-  General
-  Removal
-  Installation
-4.6 INTAKE AIR TEMPERATURE SENSOR (IAT)
-  General
-  Removal
-  Installation
-4.7 ENGINE TEMPERATURE SENSOR (ET)
-  General
-  Removal
-  Installation
-4.8 INDUCTION MODULE
-  Removal
-  Installation
-4.9 IDLE AIR CONTROL (IAC)
-  General
-  Removal
-  Installation
-4.10 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP)
-  General
-  Removal
-  Installation
-4.11 OXYGEN SENSOR
-  General
-  Removal
-  Installation
-4.12 FUEL INJECTORS
-  General
-  Removal
-  Installation
-4.13 FUEL PUMP
-  General
-  Removal
-  Disassembly and Assembly
-  Installation
-4.14 FUEL PRESSURE TEST
-  General
-  Testing
-4.15 EXHAUST SYSTEM
-  Removal: FXDB, FXDC and FXDL
-  Disassembly: FXDB/P/A, FXDC and FXDL
-  Assembly: FXDB/P/A, FXDC and FXDL
-  Installation: FXDB/P/A, FXDC and FXDL
-  Removal: FXDF and FXDWG
-  Installation: FXDF and FXDWG
-  Removal: FLD
-  Installation: FLD
-4.16 INTAKE LEAK TEST
-  General
-  Leak Tester
-  Procedure
-4.17 EVAPORATIVE EMISSIONS CONTROL (CA MODELS)
-  General
-  Charcoal Canister
5. DRIVE
-5.1 FASTENER TORQUE VALUES
-  Fastener Torque Values in this Chapter
-5.2 SPECIFICATIONS: DRIVE
-  Specifications
-5.3 PRIMARY CHAINCASE COVER
-  General
-  Removal
-  Installation
-5.4 DRIVE COMPONENTS
-  Removal
-  Installation
-5.5 PRIMARY CHAINCASE HOUSING
-  Removal
-  Inspection
-  Mainshaft Bearing and Seal
-  Mainshaft Bearing Inner Race
-  Shifter Shaft Bushing
-  Installation
-5.6 CLUTCH
-  Removal and Installation
-  Clutch Pack Only
-  Clutch Pack and Bearing
-5.7 TRANSMISSION SPROCKET
-  Removal
-  Cleaning and Inspection
-  Installation
-5.8 DRIVE BELT
-  Removal
-  Installation
6. TRANSMISSION
-6.1 FASTENER TORQUE VALUES
-  Fastener Torque Values in this Chapter
-6.2 SPECIFICATIONS: TRANSMISSION
-  Specifications
-  Service Wear Limits
-6.3 TRANSMISSION
-  Power Flow
-6.4 SHIFTER LINKAGE
-  Adjustment
-6.5 CLUTCH RELEASE COVER
-  Removal and Disassembly
-  Cleaning and Inspection
-  Assembly and Installation
-6.6 TRANSMISSION ASSEMBLY
-  Removal
-  Disassembly
-  Cleaning and Inspection
-  Assembly
-  Installation
-6.7 MAIN DRIVE GEAR AND BEARING
-  Removal
-  Cleaning and Inspection
-  Installation
-6.8 TRANSMISSION CASE
-  Removal
-  Installation
-  Disassembly
-  Cleaning and Inspection
-  Assembly
7. ELECTRICAL
-7.1 FASTENER TORQUE VALUES
-  Fastener Torque Values in this Chapter
-7.2 SPECIFICATIONS: ELECTRICAL
-  Specifications
-7.3 ELECTRICAL CADDY
-  Removal
-  Installation
-7.4 ELECTRONIC CONTROL MODULE (ECM)
-  General
-  Replacement
-7.5 BODY CONTROL MODULE (BCM)
-  General
-  Removal
-  Installation
-7.6 SECURITY SIREN
-  Removal
-  Installation
-7.7 SPARK PLUG CABLES
-  Removal
-  Installation
-7.8 FUSES
-  General
-  Replacement
-7.9 IGNITION SWITCH/FORK LOCK
-  General
-  FXDL Models
-  FXDC, FXDF, FXDWG, FLD, FXDB/P/A Models: Ignition Switch Only
-7.10 BATTERY TRAY AND BATTERY CABLES
-  Battery Tray
-  Battery Cables
-7.11 STARTER
-  General
-  Removal
-  Drive Assembly
-  Solenoid
-  Installation
-7.12 HEADLAMP
-  General
-  Bulb Removal: Except For FLD
-  Bulb Installation: Except FLD
-  Headlamp Assembly Removal: Except FLD
-  Headlamp Assembly Installation: Except FLD
-  Headlamp: FLD Models
-7.13 TAIL LAMP
-  General
-  Tail Lamp Bulb Replacement: Standard Style
-  Base Replacement: All But FXDB/P/A and FXDWG
-  Base Replacement: FXDWG/HDI and Canada
-7.14 TURN SIGNALS
-  Turn Signal Bulb Replacement: Bullet Style
-  Front Lamp Housing Replacement: All Except FLD
-  Rear Lamp Housing Replacement: All Except FLD
-  Front Turn Signal Lamps: FLD
-  Rear Turn Signal Lamps and Bracket: FLD
-  Rear Turn Signal Reflector/Isolator Repair: FLD
-7.15 CRANK POSITION SENSOR (CKP)
-  General
-  Removal
-  Installation
-7.16 AUTOMATIC COMPRESSION RELEASE (ACR)
-  General
-  Removal
-  Installation
-7.17 VOLTAGE REGULATOR
-  Removal
-  Installation
-7.18 ALTERNATOR
-  Removal
-  Cleaning and Inspection
-  Installation
-7.19 FUEL GAUGE
-  General
-  Removal
-7.20 FUEL GAUGE SENDER
-  Removal
-  Installation
-7.21 INSTRUMENTS: FXDC, FXDF AND FLD
-  Speedometer
-7.22 INSTRUMENTS: FXDB/P/A, FXDL AND FXDWG
-  Removal
-  Installation
-7.23 VEHICLE SPEED SENSOR (VSS)
-  General
-  Removal
-  Installation
-7.24 INDICATOR LAMPS
-  General
-  Removal
-  Installation
-7.25 NEUTRAL SWITCH
-  General
-  Removal
-  Installation
-7.26 OIL PRESSURE SWITCH
-  General
-  Removal
-  Installation
-7.27 REAR STOPLAMP SWITCH
-  General
-  Removal
-  Installation
-7.28 HORN
-  Inspection
-  Replacement
-7.29 ACTIVE EXHAUST
-  General
-  Removal
-  Repair
-  Installation
-7.30 MAIN WIRING HARNESS
-  General
-  Removal
-  Installation
-7.31 HANDLEBAR CONTROL MODULES
-  General
-  Repair Procedures
-7.32 LEFT HANDLEBAR CONTROL MODULE
-  Removal
-  Clutch Switch Replacement
-  Installation
-7.33 RIGHT HANDLEBAR CONTROL MODULE
-  Removal
-  Front Brake Switch Replacement
-  Installation
-7.34 H-DSSS MAINTENANCE
-  Fob Battery
-  Smart Siren (If Installed)
-7.35 PERSONAL IDENTIFICATION NUMBER (PIN)
-  General
-  Changing the PIN
-7.36 H-DSSS ACTUATION
-  Sidecar Configuration
-  Actuation
-  Fob Assignment
A. APPENDIX A CONNECTOR REPAIR
-A.1 AUTOFUSE UNSEALED ELECTRICAL CONNECTORS
-  Autofuse Unsealed Connector Repair
-A.2 BOSCH COMPACT 1.1M CONNECTOR
-  Bosch Compact 1.1M Connector
-A.3 DELPHI 100W MICRO-PACK SEALED CONNECTOR
-  Delphi 100W Micro-Pack Sealed Connector Repair
-  Crimping Terminals
-A.4 DELPHI 150 METRI-PACK SEALED CONNECTORS
-  Delphi 150 Metri-Pack Sealed Connector Repair
-A.5 DELPHI 280 METRI-PACK UNSEALED CONNECTORS
-  Fuse Block Repair
-A.6 DELPHI 480 METRI-PACK UNSEALED CONNECTORS
-  Delphi 480 Metri-Pack Unsealed Connector Repair
-A.7 DELPHI 630 METRI-PACK UNSEALED CONNECTORS
-  Delphi 630 Metri-Pack Unsealed Connector Repair
-A.8 DELPHI 800 METRI-PACK SEALED MAIN FUSE HOUSING
-  Delphi 800 Metri-Pack Sealed Main Fuse Housing Repair
-A.9 DELPHI METRI-PACK TERMINAL REPAIR
-  Metri-Pack Terminal Crimps
-A.10 DELPHI MICRO-64 SEALED CONNECTORS
-  Delphi Micro 64 Sealed Connector Repair
-A.11 DELPHI GT 150 SEALED CONNECTORS
-  Delphi GT 150 Sealed Connector Repair
-A.12 DELPHI GT 280 SEALED 73-TERMINAL ECM CONNECTOR
-  Delphi GT 280 Sealed 73-Terminal ECM Connector
-A.13 DEUTSCH DT SEALED CONNECTORS
-  Deutsch DT Sealed Connector Repair
-A.14 DEUTSCH DT SEALED TERMINAL REPAIR
-  Deutsch DT Sealed Terminal Crimps
-A.15 DEUTSCH DTM SEALED MINI TERMINAL REPAIR
-  Deutsch DTM Sealed Mini Terminal Crimps
-A.16 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR
-  Deutsch DTM Sealed Solid Barrel Terminal Crimps
-A.17 JAE MX19 SEALED CONNECTORS
-  JAE MX19 Sealed Connectors
-  Crimping Terminals
-A.18 MOLEX CMC SEALED CONNECTORS
-  Molex CMC Sealed Connectors
-  Crimping Terminals
-A.19 MOLEX MX 150 SEALED CONNECTORS
-  Molex MX 150 Sealed Connector Repair
-  Crimp Terminal to Lead
-A.20 TYCO 070 MULTILOCK UNSEALED CONNECTOR
-  Tyco 070 Multilock Unsealed Connector Repair
-A.21 TYCO GET 64 SEALED CONNECTOR
-  Tyco GET 64 Sealed Connector
-  Crimping Terminals
-A.22 TYCO MCP SEALED CONNECTOR
-  Tyco MCP Sealed Connector
-  Crimping Terminals
-A.23 SEALED SPLICE CONNECTORS
-  Sealed Splice Connector Repair
B. APPENDIX B WIRING
-B.1 CONNECTORS
-  Connector Locations
-B.2 WIRING SCHEMATICS
-  Wiring Schematics Information
-  2013 Dyna Wiring Schematics
C. APPENDIX C ABS
-C.1 FASTENER TORQUE VALUES
-  Fastener Torque Values in this Chapter
-C.2 ABS MODULE
-  General
-  Electro Hydraulic Control Unit (EHCU)
-C.3 WHEEL SPEED SENSORS
-  Front Wheel Speed Sensor (WSS)
-  Rear Wheel Speed Sensor (WSS)
-C.4 ABS BRAKE LINES
-  Front Master Cylinder to Front Caliper Line Assembly
-  Front ABS Lines
-  Rear Master Cylinder to ABS Module
-  ABS Module to Rear Brake Caliper
D. APPENDIX D CONVERSIONS
-D.1 LENGTH CONVERSION
-  Conversion Table
-D.2 FLUID CONVERSION
-  United States System
-  Metric System
-  British Imperial System
-D.3 TORQUE CONVERSION
-  United States System
-  Metric System
E. APPENDIX E GLOSSARY
-E.1 GLOSSARY
-  Acronyms and Abbreviations
TOOLS
TORQUE VALUES
INDEX