1991–1998 Harley-Davidson Dyna Super Glide, Low Rider, Wide Glide, Sturgis & Convertible Service and Repair Manual (P/N 99501-06)

• Built for professional technicians, independent repair shops, and experienced owners servicing the 2006 Harley-Davidson VRSCR.
• Contains the complete Maintenance section and Chassis coverage through Section 2.28, Wheel Alignment, from Harley-Davidson Service Manual P/N 99501-06, supplied as a 134-page PDF.
• Covers scheduled maintenance, valve-lash shim inspection and adjustment, cam-timing verification, secondary cam-chain measurement, drive-belt service, brake and clutch bleeding, steering-head fall-away, suspension setup, and headlamp alignment.
• Details frame and lower-rail repair, engine-mount service, engine removal and replacement, exhaust removal, foot controls, hydraulic clutch components, front and rear brake systems, handlebars, wheels, sealed bearings, tires, runout, balancing, and final wheel alignment.
• Provides 177 numbered figures, 17 numbered tables, VIN and configuration identification, troubleshooting charts, component-specific torque and inspection specifications, and factory tool references for engine, cam, belt, and wheel-bearing work.

Technical Documentation Overview

This is a focused factory service manual extract rather than an owner’s handbook or a generic maintenance guide. The Maintenance section begins with the VRSCR service schedule and carries routine work into the procedures and specifications needed to complete it correctly. Coverage includes the airbox and air filter, radiator side covers, cooling-system service, engine oil and filter, battery maintenance, brakes, tires and wheels, hydraulic clutch service, rear-belt inspection and replacement, suspension adjustment, steering-head bearing checks, spark plugs and coils, throttle cables, critical-fastener checks, and system-based troubleshooting.

The valve-train material gives this PDF substantially more repair depth than a basic maintenance booklet. It covers valve-lash measurement, shim selection and replacement, crankshaft positioning, camshaft timing verification, and final inspection. The secondary cam-chain section adds chain measurement and adjustment using the dedicated factory fixture. Drive-belt procedures address condition checks, deflection measurement, replacement, and post-installation verification, while the brake and clutch chapters include hydraulic bleeding, pad and disc inspection, line checks, and fluid-related service precautions.

Chassis coverage extends through work that commonly requires shop equipment and model-specific reference data. The manual addresses the steel perimeter frame and bolt-on lower rails, front and rear engine mounts, exhaust-system removal, engine replacement, jiffy stand, footrests and foot controls, throttle cables, clutch master cylinder and reservoir, clutch hand lever, clutch fluid line, secondary clutch actuator, brake master cylinders and calipers, handlebars, and both wheels. Wheel repair includes sealed-bearing removal and installation, disc and rim runout checks, tire removal and installation, balancing, and wheel alignment with engine centering.

Factory tools are identified by part number where the procedure depends on them. Examples include the HD-35381 Belt Tension Gauge, HD-45653 TDC Positioning Tool, HD-45306 Crankshaft Locking Pin, HD-45334 Secondary Cam Chain Measurement Tool, HD-45317 Engine Assembly Support Fixture, and HD-44060 Wheel Bearing Installer/Remover. These references help a shop determine tool requirements before beginning a repair instead of discovering them after the motorcycle is disassembled.

The figure set supports the written procedures with views such as Steel Perimeter Frame and Bolt-on Lower Frame Rails (typical), Engine Strapped for Hoisting, TDC Cam Timing Orientation, Cam, Tappet, Shim Orientation, HD-44060 Wheel Bearing Tools, and Wheel Alignment. Exploded component drawings, fastener callouts, routing illustrations, and inspection views are used throughout the maintenance and chassis sections.

Specification Highlights

Specifications are organized around the assemblies being serviced rather than presented as an isolated collection of numbers. The tables cover maintenance intervals, approved fluids and capacities, torque requirements, inspection and wear limits, drive-belt and steering adjustments, suspension settings, brake pad and disc limits, tire and wheel checks, valve-lash data, secondary cam-chain measurements, and troubleshooting criteria.

The VIN material identifies the VRSCR by model code HC and distinguishes engine code Z from code A, used for the 105 HP HDI-only VRSCR configuration. It also explains domestic and international market identifiers and the regular, mid-year, and California introduction codes, giving technicians a factory basis for confirming the machine configuration before parts or procedures are selected.

Several warnings are specific to this chassis. The engine stabilizer link is a horizontal locator, not a wheel-alignment adjustment; changing its effective length can place damaging stress on the crankcase mounting boss. During front brake-control repair, failing to protect the lever-to-bracket relationship can damage the front stoplight-switch boot or plunger. During valve-train work, rotating the engine in the wrong direction or with the secondary cam-chain tensioner removed can disturb timing and cause internal damage.

Secure the motorcycle on suitable lifting equipment and support the engine and frame as specified before engine-mount, removal, or wheel-alignment work. Electrical power, brake and clutch hydraulics, and the cooling system must be placed in the safe service condition described by the manual before related components are opened.

Scope ends at Chassis Section 2.28, Wheel Alignment. This PDF does not include the later chassis chapters covering the front fender, fork caps, front fork, steering head, fork lock, belt guard and debris deflector, rear shock absorbers, rear fork, seat, or rear fender. It also does not contain the full repair sections for the engine, fuel system, electric starter, cooling system, transmission, electrical system, or fuel injection, the appendices, or the separate Electrical Diagnostic Manual.