Harley-Davidson Dyna: Low Rider, Super Glide, Super Glide Sport, Wide Glide, and Low Rider, FXD Dyna/FXDL/FXDX/FXDWG 2004 Service & Diagnostic Manual Set (P/N 99481-04)

The Service Manual covers mechanical work and component service. Electrical Diagnostics adds symptom-based testing and circuit checks, while the Police Service Supplement covers FXDP-specific equipment and service differences.

For FXDP engine, starter, drive, and transmission procedures, the Police Service Supplement directs readers to the main Dyna Service Manual.

Search, Chapter Navigation, and Wiring Detail

Text search and diagram labels: The service and diagnostic text is searchable within the individual PDFs. Embedded bookmarks are available in selected files, and some links between files may not resolve. Small connector IDs, pin numbers, and wire-color codes are easier to read when zoomed in. The forward ground stud label on Service Manual sheet B-27 is clipped at the right edge and appears in full on Electrical Diagnostics sheet 6-27.

The ZIP contains 1,067 pages across 60 printable PDFs. The total includes the separate two-page master contents PDF, chapter contents, appendices, and 24 blank pages.

Mechanical Overhaul, Fuel Systems, and Electrical Fault Finding

This is a selection of the procedures covered. The Service Manual also includes headlamp alignment and jiffy stand service.

• Maintenance and chassis: Scheduled maintenance, brake bleeding, wheel lacing and truing, and separate front-fork procedures for FXD/FXDL, FXDX, and FXDWG hardware.

• Engine overhaul: Step-by-step engine removal and installation, top- and bottom-end overhaul, and inspection of the cam support plate, oil pump, and flywheel assembly.

• Starter, primary drive, and transmission: Starter rebuilding, primary chaincase and clutch service, transmission teardown, and separate mainshaft and countershaft procedures for Japan-market transmissions.

• Carburetor and EFI service: Carburetor overhaul and adjustment, plus fuel-pressure, fuel-pump, injector, and idle-air-control testing for fuel-injected models.

• Electrical and security diagnosis: Starter and charging tests, speedometer and tachometer checks, diagnostic trouble code charts, serial-data-bus testing, and turn signal module and security module diagnostics.

• FXDP Police equipment: Police-specific maintenance and service for pursuit lamps, the siren and public-address system, handlebar controls, saddlebags, the windshield, and the radio bracket.

The set suits technicians and experienced owners familiar with Dyna maintenance. Internal overhaul and module diagnosis call for additional experience with the specified service tools, electrical test equipment, and programming equipment.

Chassis, Twin Cam 88, and Drivetrain Service

The chassis chapters cover sealed wheel bearings, three laced rim sizes, wheel runout, and vehicle alignment. Brake service includes the master cylinders and calipers. Other procedures cover the steering head, rear shocks, rear fork, and engine mounts.

The engine chapter explains oil flow and crankcase breathing. Its compression-test chart helps distinguish ring leakage from likely valve or head-gasket faults. Overhaul procedures cover rocker-arm supports, pushrods, lifters, cylinder heads, pistons, the crankcase, flywheel and connecting rods, and the oil pan. Reference tables give torque values, fluid capacities, and service wear limits.

Drive procedures include the compensator, transmission sprocket, and final belt. The transmission section covers the shifter cam, forks, shafts, and case. Appendix D uses the transmission build code to identify when the Japan-market shaft procedures apply.

Carbureted and EFI Fault Isolation

The carbureted ICM charts cover intake leaks, crank-no-start, start-and-stall, loss of spark or module power, and misfire. The EFI ECM charts add system-relay, induction-module, and intermittent-combustion checks. Separate routines cover the MAP, intake air temperature, engine temperature, throttle position, crank position, and vehicle speed inputs.

The instrument chapter covers diagnostic code retrieval, speedometer self-diagnostics, fuel-gauge operation, and separate indicator-lamp layouts for Wide Glide and other Dyna models. The TSM/TSSM chapter covers delivery setup, bank-angle functions, key-fob assignment, personal codes, alarm sensitivity, transport and storage modes, and turn signal faults.

Wiring Sheets, Connector Service, and Test Tools

The Service Manual and Electrical Diagnostics each index 41 Dyna wiring sheets for domestic and international applications. Examples include the carbureted main harness for models other than the Wide Glide, carbureted Wide Glide lights and indicators, the two-sheet EFI ignition circuit for models other than the Wide Glide, and the EFI Wide Glide charging and starting circuits. The FXDP supplement adds eight police wiring sheets, including the police equipment circuit.

For the EFI Wide Glide security circuit, see Service Manual sheets B-66 and B-67. The corresponding Electrical Diagnostics sheets 6-66 and 6-67 carry carbureted captions.

Connector coverage includes locations, pinouts, terminal removal, and crimping for AMP Multilock, Deutsch, Mini-Deutsch, Packard, and Packard ECM connectors, as well as sealed butt-splice repair. The test procedures identify the HD-42682 Breakout Box with HD-46601 instrument harness adapters, the HD-43876 EFI breakout box, the HD-41182 fuel-pressure gauge, and the HD-42376 battery and charging-system load tester.

Police Service Details and Repair Cautions

The FXDP supplement covers seat and footboard service, fuel-tank work, rear marker and pole lamps, fuses, charging checks, and police connector locations.

The starter chapter warns that incorrect relay-test connections can damage the suppression diode. The carburetor chapter flags the risk of manifold seal damage if the fasteners are tightened before the carburetor and backplate are aligned. Replacement ICM or ECM work calls for the HD-44750 Digital Technician and the password-learn procedure.

Belt Deflection and EFI Fuel Pressure Examples

The Service Manual specifies 5/16–3/8 in. of rear belt deflection at the belt’s tightest point under 10 lb of upward force, with the motorcycle cold and the rider’s approximate weight on the seat.

The EFI fuel-pressure test calls for a steady 55–62 psi as engine speed changes. The fuel-system section also warns that the line can retain pressure before it is disconnected.