Harley-Davidson Dyna 2002 Service Manual Set (P/N 99481-02)

The service manual supplies the mechanical repair procedures, the diagnostic manual traces electrical symptoms and DTCs, and the FXDP supplement adds police equipment. Unchanged engine, starter, drive, and transmission service for the police model remains in the base manual.

Carbureted models: Fuel-system repair does not cover EFI. The 2002 police wiring diagrams are in spabk_tc.pdf; the additional spa_appa.pdf wiring file carries 2001 diagram labels.

Searchable PDFs and Wiring Detail

Text search and diagram detail: The PDFs support text search. Embedded bookmarks are available in many chapter files, but some contents and wiring files have none. Small wire codes, connector numbers, and pin labels on dense diagrams require zooming.

ZIP download with 58 printable English PDFs: 30 service files, 13 diagnostic files, 14 police-supplement files, and a 2-page master contents file. The 824-page total includes that master file, 2 foreword pages, 23 section-contents pages, 21 blank or folio-only pages, 18 notes pages, 43 repeated wiring pages, and an additional 10-page police-wiring appendix with its own notes page.

Twin Cam Repair, Electrical Fault Tracing, and Police Equipment

This selected content overview highlights the main workshop areas. Other documented topics include storage preparation and vehicle alignment; the list is not a complete table of contents.

• Engine repair: Step-by-step engine removal and installation, top- and bottom-end overhaul, cam-support-plate and oil-pump service, with component inspection and assembly specifications.

• Chassis and brakes: Sealed wheel bearings, wheel lacing and truing, cast-wheel runout, master-cylinder and caliper repair, brake bleeding, steering-head work, and model-specific forks.

• Primary drive and transmission: Clutch and chaincase repair, drive-belt service, transmission disassembly, shaft inspection, and reassembly procedures.

• Electrical fault isolation: Starter voltage-drop and current-draw tests, stator and regulator diagnosis, battery load testing, ignition-coil checks, Scanalyzer diagnostics, and breakout-box testing.

• TSM/TSSM and instruments: Key-fob assignment, personal-code programming, arming and disarming, transport and storage modes, security fault charts, speedometer checks, and FXDWG indicator-lamp diagnosis.

• Wiring and police equipment: Domestic and international system diagrams, separate FXDWG circuits, and FXDP police-equipment, pursuit-light, siren/PA, and air-horn procedures.

Harley-Davidson prepared the service manual to assist users with basic maintenance and repair and to introduce professional technicians to factory-approved major repair methods; deeper work requires the listed tools and test equipment.

Twin Cam 88 and Carburetor Service

Engine chapters cover the cylinder heads, valve train, pistons, crankcase, and flywheel/connecting-rod assembly, backed by torque tables, wear limits, clearances, and lubrication data. Illustrations include Engine Oil Flow - Cam Support Plate/Right Crankcase Half and Install Cam Bearings/Camshafts.

The fuel section addresses the enrichener, carburetor vacuum piston and float adjustment, tank and fuel valve, air cleaner, exhaust, and California evaporative-emissions equipment.

Cam-support-plate cautions explain how rear-cam misalignment can damage bearing rollers and how chain contact during pressing can damage the tensioner shoe.

Chassis and Drivetrain Variants

Routine coverage includes the factory maintenance schedule, lubrication, battery care, brake and clutch adjustment, and primary-chain and rear-belt checks. Suspension settings, fork oil, ignition timing, and headlamp alignment are also covered.

Fork procedures distinguish FXD/FXDL, FXDWG, and FXDX/FXDXT assemblies; FXDX and FXDXT have dual front calipers. FXDXT-specific sections address saddlebags and the windshield.

Transmission chapters detail the shifter cam and forks, mainshaft/countershaft assembly, case repair, and Transmission Power Flow. Hammering shafts out from the opposite side can damage side-door bearings; unsupported press work can also damage the bearings.

The tool appendix identifies the HD-42310 engine/transmission stand, HD-42313 cam-chain tensioner unloader, and HD-35316A main-drive-gear remover/installer. Electrical procedures identify the HD-41325-95C Scanalyzer cartridge and HD-42682 breakout box.

Electrical Diagnosis, Security, and Connectors

Engine-management sections distinguish current, historic, and functional codes, with no-start and misfire charts, check-engine-lamp retrieval, Scanalyzer active tests, and wiggle testing for intermittent connections. Charging flowcharts compare system output with vehicle current draw, helping separate a charging-component fault from accessory demand.

TSM/TSSM coverage includes vehicle-delivery setup, two-fob assignment, five-digit personal codes, market-dependent auto-arming, bank-angle operation, weak fob response, starter-disable faults, and turn-signal errors. Simplified TSM/TSSM Wiring and dedicated Dyna Wide Glide Security diagrams support circuit tracing.

Connector sections cover Amp Multilock, Deutsch, Mini-Deutsch, sealed butt-splice, and Packard terminal service.

FXDP Police Equipment

Police chassis procedures cover the seat, saddlebags, windshield, and radio bracket. Electrical work adds pursuit, marker, and pole lamps, siren/PA equipment, handlebar switches, air horn, charging-system service, and fuel-gauge work, with connector information and the 2002 FXDP Police Equipment Circuit diagram.

Brake, fuel-system, spring-loaded fork, press, and high-current electrical work should be handled with the precautions, tools, and experience specified in the manuals.

A Preview of Chain and Brake Inspection Data

Primary-chain inspection: With the motorcycle upright and level, the manual gives upward free play of 5/8–7/8 in. with the engine cold and 3/8–5/8 in. when hot, checked at the tightest point midway between the sprockets.

Brake wear checks: Front and rear pads reach their replacement limit at 0.04 in. (1.02 mm) of friction material or less above the backing plate. Maximum disc lateral runout is 0.008 in. (0.2 mm), measured near the outside diameter.