2001–2004 Harley-Davidson Dyna Glide FXD, FXDL, FXDX, FXDXT and FXDWG Carbureted Service Manual (P/N 99481-03A)

This 2001–2004 Harley-Davidson Dyna Glide service manual covers the carbureted FXD, FXDL, FXDX, FXDXT, and FXDWG. P/N 99481-03A, November 2002 printing, documents maintenance and repair for the Twin Cam 88 platform.

• Engine repair: Engine removal and installation, top-end and bottom-end overhaul, cylinder-head service, camshaft-bearing replacement, and oil-pump inspection.

• Fuel and emissions: Carburetor disassembly, vacuum-piston checks, float adjustment, fuel-supply-valve testing, and California evaporative-emissions service.

• Primary drive and clutch: Chaincase removal, compensating-sprocket alignment, clutch-pack and bearing repair, and drive-belt replacement.

• Transmission service: Mainshaft and countershaft disassembly, shifter-cam and fork inspection, main-drive-gear bearing replacement, and linkage adjustment.

• Brakes and chassis: Master-cylinder and caliper rebuilding, wheel lacing and truing, sealed wheel-bearing replacement, steering adjustment, and model-specific fork overhaul.

• Starting and charging: Starter-motor and solenoid repair, jackshaft service, alternator inspection, voltage-regulator replacement, and battery load testing.

• Electrical systems: Ignition-module, MAP and CKP sensor service, TSM/TSSM replacement, wiring diagrams, and connector repair instructions.

Owners can use the basic maintenance and repair sections; major repair procedures are intended for professional Harley-Davidson technicians with the required tools and shop equipment.

Maintenance Checks and Troubleshooting

Service schedules and fluid-capacity tables cover engine oil, primary-chaincase lubricant, and transmission fluid. Battery maintenance, rear-belt deflection, and symptom-based engine, electrical, and handling troubleshooting are included.

Engine Overhaul and Lubrication

Engine work extends from compression and cylinder-leakage testing to valve-guide replacement, valve-seat refacing, cylinder boring and honing, and crankcase disassembly. The Oversize Pistons/Cylinder Bores table accompanies machining guidance, while separate service wear limits identify when used components require replacement. Torque references cover fuel-tank fasteners and spark plugs, with a multistage cylinder-head bolt tightening sequence.

Cam drive: Cam-support-plate service covers bearing replacement, tensioner inspection, and oil-pump alignment. Engine Oil Flow schematics trace the feed and return circuits alongside gerotor inspection procedures.

The manual cautions that uncontrolled release of a cam-chain tensioner with the chains and sprockets removed can stretch the spring or crack the shoe. Oil-filter removal also presents a clearance risk to the CKP sensor and cable; the specified filter wrenches are HD-42311 or HD-44067.

Clutch, Gearbox, and Final Drive

Clutch service reaches the shell bearing and release mechanism, with alignment checks for the primary-drive sprockets. Transmission instructions cover gear-stack assembly and shifter positioning, supported by gear-by-gear power-flow illustrations.

The Drive Belt Wear Analysis table separates wear conditions and their required action, helping distinguish acceptable belt marks from damage that calls for replacement.

Wheels, Suspension, and Brakes

Wheel procedures cover lacing and truing 16-, 19-, and 21-inch rims, plus cast-wheel runout checks. Separate fork sections distinguish FXD/FXDL, FXDWG, and the adjustable 39 mm cartridge forks on FXDX/FXDXT, including compression, rebound, and spring-preload settings.

Brake sections document internal master-cylinder and caliper inspection as well as bleeding. Steering-head fall-away adjustment, vehicle alignment, and engine-mount inspection provide the related chassis checks.

Carburetor and Fuel-Supply Diagnosis

Symptom charts connect overflow, poor idling, hard starting, and weak acceleration with checks of the float system, enrichener, accelerator pump, and vacuum piston. Vacuum-operated fuel-valve flow and leak testing, tank service, exhaust removal, and California canister hose routing are also covered.

Starter, Ignition, and Wiring Coverage

Starter procedures include armature and field tests. Electrical references include the Voltmeter Test For Battery Charge Conditions table and Dyna Glide Bulb Chart, with ignition-module input descriptions and MAP/CKP sensor replacement instructions.

Harness repair: Wiring diagrams distinguish standard Dyna and FXDWG circuits for domestic and international models. Connector-location tables and Amp Multilock, Deutsch, Mini-Deutsch, and Packard terminal procedures support circuit tracing and harness repair.

Diagnostic scope: Trouble-code diagnosis and post-replacement TSM/TSSM vehicle-delivery procedures refer to the separate Dyna Models Electrical Diagnostic Manual, which is not included.

Observe the manual’s precautions for gasoline handling, battery isolation, and brake service during actual repair work.

A Preview of Oil-Pressure and Piston-Fit Specifications

Oil pressure: The operating-pressure check specifies 30–38 PSI at 2,000 RPM with engine oil at 230°F (110°C).

Piston fit: The engine specifications distinguish piston-to-cylinder clearance for early fully coated pistons, 0.0006–0.0017 in., from later pistons with bare-aluminum measuring windows, 0.0014–0.0025 in. The inspection section explains the different measuring locations and micrometer requirements for those designs.

Bookmarks, Wiring Detail, and PDF Contents

Search and diagram detail: PDF text search is not available. Embedded bookmarks lead to the main service sections, appendices, and index. Small appendix wiring labels require enlargement; some instrument labels in the ignition-circuit illustration remain faint even when enlarged.

Supplied as one printable English-language PDF with 526 pages, including one added cover page and 22 wiring-diagram title pages. The file contains a single service manual with its tool, wiring, and conversion appendices.