2002 Harley-Davidson Dyna Service & Repair Manual (P/N 99481-02, 99496-02)

• Model coverage: 2002 FXD Dyna Super Glide, FXDL Dyna Low Rider, FXDWG Dyna Wide Glide, FXDX Dyna Super Glide Sport, and FXDXT Dyna Super Glide T-Sport, all identified for the carbureted Twin Cam 88 engine; the included supplement adds FXDP Dyna Police coverage.
• Engine and fuel-system work: engine removal and installation, top- and bottom-end overhaul, cylinder head and piston service, cam support plate and oil pump work, crankcase and flywheel/connecting-rod inspection, plus carburetor service and adjustment.
• Chassis and drivetrain procedures: wheel bearing service, wheel lacing and truing, brake master-cylinder and caliper repair, brake bleeding, model-specific fork service, steering-head work, clutch and primary-drive repair, drive-belt service, and transmission disassembly.
• Electrical fault isolation: starter voltage-drop and current-draw testing, stator and voltage-regulator diagnosis, battery load testing, ignition-coil checks, Scanalyzer and check-engine-lamp diagnostics, breakout-box tests, and intermittent-harness troubleshooting.
• TSM/TSSM and instruments: key-fob assignment, personal-code entry, arming and disarming, transport and storage modes, security and turn-signal fault charts, speedometer performance checks, and FXDWG indicator-lamp diagnosis.
• Wiring and police equipment: domestic and international main, starting, charging, ignition, lighting, security, and instrument diagrams, with separate FXDWG circuits and FXDP police-equipment, pursuit-light, siren/PA, and air-horn coverage.
• 824 PDF pages total — Service Manual P/N 99481-02: 509 pages; Electrical Diagnostic Manual P/N 99496-02: 218 pages; FXDP Police Service Supplement: 95 pages; master contents file: 2 pages.

Twin Cam 88, Chassis, and Drivetrain Repair

This three-publication set joins the 2002 Dyna service information, electrical diagnostics, and FXDP-specific material. Harley-Davidson prepared the service manual for users performing basic maintenance and repair and for professional technicians applying factory-approved major repair methods. Deeper engine, transmission, chassis, and electrical procedures assume the listed tools and test equipment.

Routine coverage includes the factory maintenance schedule, lubrication, battery care, brake and clutch adjustment, primary-chain and rear-belt checks, suspension settings, fork oil, ignition timing, and headlamp alignment. Chassis sections separate the FXD/FXDL, FXDWG, and FXDX/FXDXT fork assemblies and account for the dual front calipers on FXDX and FXDXT models. Wheel work includes sealed bearings, cast-wheel runout, and lacing and truing.

The Twin Cam 88 section follows repair work from engine removal through top- and bottom-end overhaul. It covers the valve train, pistons, cam drive, oil pump, crankcase, and flywheel/connecting-rod assembly, backed by torque tables, wear limits, clearances, lubrication data, and inspection criteria. Fuel-system material is for the carbureted 2002 Dyna configuration, including the enrichener, carburetor, tank and valve, and California evaporative-emissions equipment; it is not an EFI repair manual.

Primary drive and transmission sections address chaincase and clutch work, the transmission sprocket and belt, shifter cam and forks, mainshaft/countershaft disassembly, and case repair. The tool appendix identifies fixtures and test equipment by part number, including the HD-42310 engine/transmission stand, HD-42313 cam-chain tensioner unloader, HD-35316A main-drive-gear remover/installer, HD-41325-95C Scanalyzer cartridge, and HD-42682 breakout box.

Electrical Diagnosis, TSM/TSSM, and Wiring

The Electrical Diagnostic Manual is organized around symptom and DTC flow charts. Starting and charging sections cover starter activation, on-motorcycle and assembled-starter tests, battery load testing, alternator and stator checks, regulator diagnosis, and ignition-coil testing. Engine-management coverage includes current, historic, and functional codes; no-start and misfire diagnosis; check-engine-lamp retrieval; Scanalyzer active tests; and wiggle testing for intermittent connections.

TSM/TSSM material covers vehicle-delivery setup, two-key-fob assignment, five-digit personal-code programming, market-dependent auto-arming, transport and storage modes, bank-angle operation, and DTC diagnosis. It traces security-lamp faults, weak or failed fob response, starter-disable faults, and turn-signal errors. Connector sections show Amp Multilock, Deutsch, Mini-Deutsch, sealed butt-splice, and Packard terminal service.

Named illustrations include Engine Oil Flow - Cam Support Plate/Right Crankcase Half, Install Cam Bearings/Camshafts, and Transmission Power Flow. Electrical examples include Simplified TSM/TSSM Wiring, the dedicated Dyna Wide Glide Security diagrams, and the 2002 FXDP Police Equipment Circuit.

FXDP Supplement and Service Cautions

The FXDP publication is a supplement, not a stand-alone replacement for the base manual. It documents police-only work on the seat and saddlebags, windshield and radio bracket, pursuit lights, fuel tank, marker and pole lamps, siren/PA system, switches, air horn, charging system, fuel gauge, connectors, and wiring. Unchanged engine, starter, drive, and transmission repair remains in the base book.

The repair cautions are component-specific. The transmission section warns that hammering the shafts from the opposite side can damage the side-door bearings, while unsupported press work can ruin the bearing races. During cam-support-plate assembly, incorrect rear-cam alignment can catch the bearing rollers, and allowing the chain to contact the tensioner shoe can require tensioner replacement. 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.