Index Harley Davidson Harley Davidson Dyna evolution 1991-1998. Service manual

Harley Davidson Dyna evolution 1991-1998. Service manual - page 1

Chapter One General Information

Chapter Two Troubleshooting

Chapter Three

Periodic Lubrication, Maintenance and Tune-up

Chapter Four Engine

Chapter Five

Clutch, Primary Drive and Starter Drive

Chapter Six Transmission

Chapter Seven

Fuel, Exhaust and Emission Control Systems

Chapter Eight Electrical System

Chapter Nine Wheels, Hubs and Tires

Chapter Ten

Front Suspension and Steering

Chapter Eleven Rear Suspension

Chapter Twelve Brakes

Supplement

1996-1998 Service Information Index
Wiring Diagrams

CHAPTER ONE
GENERAL INFORMATION
This service shop manual covers the Harley-Davidson Dyna Glide produced from 1991-1998.

Procedures unique to 1996-1998 models are covered in the supplement at the end of the manual.

Troubleshooting, tune-up, maintenance and repair are not difficult, if you know what tools and equipment to use and what steps to follow. Step-by-step instructions guide you through jobs ranging from simple maintenance to engine and suspension repair.

Anyone from a first time do-it yourselfer to a professional mechanic can use this manual. Detailed drawings and clear photographs give you the information you need to work on your Dyna Glide correctly.

Table 1 lists model coverage.

Table 2 lists general specifications.

Table 3 lists overall vehicle weight specifications.

Table 4 lists gross vehicle weight ratings.

Table 5 lists fuel capacity.

Table 6 lists U.S. to metric conversion. Metric and U.S. standards are used throughout this manual.

Table 7 lists general torque specifications. Critical torque specifications are found in table form at the end of each chapter (as required). Use the general torque specifications in Table 7 if a chapter ta-
ble does not list a torque specific tightening.

Table 8 lists conversion tables.

Table 9 lists tap drill sizes.

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

MANUAL ORGANIZATION

This chapter provides general information useful to Dyna Glide owners and mechanics. In addition, information in this chapter discusses the tools and techniques for preventive maintenance, troubleshooting and repair.

Chapter Two provides methods and suggestions for quick and accurate diagnosis of problems. Troubleshooting procedures discuss typical symptoms and logical methods to pinpoint the cause of the trouble.

Chapter Three explains all periodic lubrication and routine maintenance necessary to keep your Dyna Glide operating well.

Chapter Three also includes recommended tune-up procedures, eliminating the need to consult other chapters on the various assemblies.

Subsequent chapters describe specific systems, providing disassemby, repair, assembly and adjustment

procedures in simple step-by-step form. If a repair is impractical for a home mechanic, the text will suggest that you have the service done at a dealership or repair shop. Doing so will save you time and money. Service specifications and tightening torques are listed at the end of the appropriate chapter.

NOTES, CAUTIONS AND WARNINGS

The terras NOTE, CAUTION and WARNING have specific meanings in this manual. A NOTE provides additional information to make a step or procedure easier or clearer. Disregarding a NOTE could cause inconvenience, but would not cause damage or personal injury.

A CAUTION emphasizes areas where equipment damage could occur. Disregarding a CAUTION could cause permanent mechanical damage; however, personal injury is unlikely.

A WARNING emphasizes areas where personal injury or even death could result from negligence. Mechanical damage may also occur. WARNINGS must be taken seriously. Sometimes, serious injury and death have resulted from disregarding similar warnings.

SAFETY FIRST

Professional mechanics can work for years and never sustain a serious injury. If you observe a few rules of common sense and safety, you can enjoy many safe hours servicing your own machine. If you ignore these rules you can hurt yourself or damage the equipment.

1. Never use gasoline as a cleaning solvent.

WARNING Store gasoline in an approved gasoline storage container, properly labeled.

Wipe spilled gasoline up immediately.

2. Never smoke or use a torch near flammable liquids, such as cleaning solvent in an open container.

3. Before welding or brazing on the machine, remove the fuel tank to a safe distance, at least 50 ft. (15m) away.

4. Use the proper sized wrenches to avoid damage to fasteners and injury to yourself.

5. When loosening a tight or stuck fastener, protect yourself should the wrench slip or the fastener break.

6. When replacing a fastener, make sure to use one with the same measurements and strength as the old one. Incorrect or mismatched fasteners can result in damage to your motorcycle and possible personal injury. Beware of fastener kits filled with cheap and poorly-made nuts, bolts, washers and cotter pins. Refer to Fasteners in this chapter for additional information.

7. Keep all hand and power tools in good condition. Wipe greasy and oily tools after using them. They are difficult to hold and can cause injury. Repair or replace worn or damaged tools.

8. Keep your work area clean and uncluttered.

9. Wear safety goggles during all operations involving drilling, grinding, the use of a cold chisel or whenever you feel unsure about the safety of your eyes. Also, wear safety goggles (Figure 1) when using solvent and compressed air to clean parts.

WARNING The improper use of compressed air is very dangerous. Using compressed air to dust off your clothes, bike or workbench can cause flying particles to blow into your eyes or skin. Never direct compressed air directly at your skin or into body openings (including cuts) as this can cause severe injury or death. Use compressed air carefully. Never allow children to use or play with compressed air.

10. Keep an approved fire extinguisher nearby (Figure 2). The correct ratings are Class В for gasoline fires and Class С for electrical fires.

11. When drying bearings or other rotating parts with compressed air, never allow the air jet to rotate

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