Harley-Davidson Dyna FXD, FXDL, FXDWG, FXDS, FXDB, FXDC, FXDX 1991–1998 Service Manual (P/N 99450-98A)

This repair manual covers Harley-Davidson Dyna Glide models from 1991–1998: the 1991 FXDB Sturgis; 1992 FXDB Dyna Daytona and FXDC Dyna Glide Custom; 1993–1994 FXDL and FXDWG; and 1995–1998 FXD, FXDL, FXDWG, and FXDS-CONV. The 1993 FXDWG Anniversary and accessorized Wide Glide editions are included.

PDF Search and Diagram Viewing

Text access and navigation: Text search is limited to the contents pages and maintenance log; repair chapters and wiring diagrams are not searchable. Bookmarks provide access to the chapters, supplement, index, and wiring diagrams. Small wiring labels and connector numbers require zooming.

One printable 544-page PDF contains 477 pages across 12 main chapters, a 28-page 1996–1998 supplement, a four-page index, and 24 pages of color wiring diagrams. The total also includes nine cover, contents, and quick-reference pages, one maintenance-log page, and one notes page.

Evolution Engine, Drivetrain, and Electrical Service

These coverage highlights are a selection from the manual; other topics include ball-bearing replacement and oil-seal installation.

• Maintenance and tune-up: Lubrication schedules, oil and filter changes, belt and clutch adjustment, compression and cylinder-leakage tests, ignition timing, and air-filter service.

• Engine repair: Step-by-step instructions for engine removal and installation, rocker-box and cylinder-head work, valve service, cylinders, pistons, pushrods, lifters, oil pump, and lower-end repair.

• Clutch and transmission: Clutch overhaul, primary-chain alignment, compensating-sprocket inspection, starter-jackshaft repair, shifter adjustment, and five-speed transmission disassembly and reassembly.

• Fuel and emissions: CV-carburetor overhaul and troubleshooting, float-level adjustment, throttle and enrichener cables, fuel-delivery checks, exhaust service, and California evaporative-emission controls.

• Electrical diagnosis: Starter voltage-drop and current-draw tests, solenoid checks, charging-output tests, ignition-coil and module diagnostics, vacuum-operated electric switch (VOES) testing, and color wiring diagrams.

• Wheels and suspension: Wheel and hub service, final-drive belt replacement, vehicle alignment, FXDWG fork procedures, steering-head bearings, swingarm service, and shock-absorber inspection.

• Disc brakes: Pad and disc inspection, caliper and master-cylinder overhaul, hose and line replacement, hydraulic bleeding, and later front-master-cylinder procedures.

Written for first-time DIY owners through professional mechanics, the manual directs specialized work to a dealership or machine shop; major engine disassembly requires substantial mechanical ability.

Model Differences and Supplement Use

Separate procedures distinguish 1991 from 1992-on oil-tank and oil-line routing, domestic from international air-filter backplates, and 1992-on California emission hardware. These distinctions help match parts and procedures to the motorcycle’s configuration.

The main chapters describe common 1991–1995 procedures; use the 1996–1998 supplement alongside them. It updates maintenance and ignition service, battery care, switch work, the front master cylinder, and the 1998 clutch arrangement, with model-year wiring references for charging, ignition, and starter service.

Engine Inspection and Overhaul

Rocker-arm and cylinder-head exploded views accompany checks of valve guides and seats, cylinder wear, piston/ring fit, and piston-pin bushings. Hydraulic-lifter and guide service, oil-pump work, cam and breather gear inspection, crankshaft end play, main bearings, and crankcase assembly extend coverage into the lower end.

The engine chapter identifies components serviceable in the frame and includes post-repair break-in instructions. Wear limits and component-specific torque tables accompany the relevant work; accurate cylinder-head and bore work calls for suitable measuring equipment and experience.

Primary Drive and Transmission Internals

Wet-clutch and primary-chaincase drawings support clutch-shell and hub inspection, primary-chain guide checks, and inner-primary work. Transmission coverage includes gear engagement, the top cover, shift cam, forks, side door, mainshaft, countershaft, main drive gear, case, and clutch-release mechanism.

The domestic and HDI gear-identification drawings matter during parts selection: mixing these gear families can damage the transmission. Tool references include the HD-41214 primary-drive lock, HD-39618 pawl adjuster, and HD-35316A main-drive-gear remover/installer.

Electrical Fault Isolation and Carburetor Details

Starter-solenoid voltage-drop diagrams and free-running tests support fault isolation alongside sensor-plate, switch-continuity, and turn-signal-module checks. Wiring sheets distinguish early models, FXDL and FXDWG configurations, 1995 FXD/FXDS-CONV, and the 1996, 1997, and 1998 all-FXD layouts. The 1995 electronic speedometer also has its own circuit information.

CV-carburetor troubleshooting and fuel-level drawings accompany the fuel-system procedures. Forcing the later float pin from the wrong side can break its mounting pedestal and require carburetor replacement.

California sections include carbon-canister and vapor-valve service plus solenoid-operated butterfly-valve tests.

Chassis, Steering, and Brake Details

Fork assembly drawings distinguish FXDWG hardware. Listed tools include the HD-36583 fork-seal driver and HD-39301 steering-head bearing-race installer; rear-suspension work includes shock spring and bushing replacement.

Brake instructions specify DOT 5 silicone fluid and explain its incompatibility with glycol-based fluids. Position-sensitive caliper bushings and early/late-1991 rear pad-and-shim arrangements are illustrated. The supplement distinguishes single- and dual-front-disc master-cylinder piston kits.

Fuel and electrical work present fire and chemical hazards; brake and suspension repairs affect vehicle control. Follow the manual’s cautions on secure motorcycle support, suitable tools, and stored spring energy.

Starter Test and 1998 Clutch Specification Samples

The starter test table lists a minimum no-load speed of 3,000 rpm and maximum no-load current of 90 amps, both at 11.5 volts. These are free-running test specifications, separate from loaded cranking-current limits.

For the 1998 clutch, the inspection table gives a friction-disc thickness service limit of 0.143 in. (3.63 mm) and a clutch-plate warpage service limit of 0.006 in. (0.15 mm).