2007 Harley-Davidson Dyna Models Service & Repair Manual (P/N 99496-07)

This three-publication factory set moves from scheduled service through full mechanical repair and electrical fault isolation, with a separate supplement for the FXDSE. It is suited to professional technicians and experienced owner-mechanics because the procedures assume engine and transmission experience, precision measuring tools, specialty fixtures, and electronic test equipment.

• Three factory publications, 1,154 PDF pages: 2007 Dyna Models Service Manual P/N 99481-07, 590 pages; Electrical Diagnostics P/N 99496-07, 440 pages; FXDSE Service Supplement P/N 99525-07, 122 pages; plus a two-page shared index.
• Standard Dyna model coverage: FXD, FXDB, FXDL, FXDWG, and FXDC, with Twin Cam 96 EFI and six-speed transmission information plus model-specific instrument, handlebar, lighting, and wiring coverage.
• FXDSE-specific coverage: Twin Cam 110 engine data, automatic compression release, hydraulic clutch, inverted front fork, model-specific wheels and bodywork, and separate domestic and HDI details.
• Engine and drivetrain repair: Engine removal and installation, top- and bottom-end overhaul, cylinder heads, pistons, cam support plate, oil pump, crankcase, primary drive, clutch, belt drive, and transmission assembly work.
• Chassis service and repair: Brake bleeding and hydraulic component overhaul, sealed wheel bearings, wheel lacing and truing, cast-wheel runout, vehicle alignment, fork and steering-head service, rear suspension, and controls.
• EFI and electrical diagnosis: Crank/no-start, start-and-stall and misfire faults; fuel pressure and injector testing; starter and charging tests; speedometer self-diagnostics; and TSM, TSSM, and HFSM security-system checks.
• Wiring and shop data: 22 model-specific wiring sheets grouped for FXDWG/FXDC and the other Dyna models, connector repair procedures, specialty-tool callouts, DTC and terminal tables, torque data, capacities, service wear limits, and electrical test specifications.

Mechanical Repair Coverage

The base service manual moves beyond scheduled maintenance into motorcycle stripping, engine removal and installation, full top- and bottom-end overhaul, and subassembly repair. It traces oil flow, explains pump and breather operation, and provides oil-pressure diagnosis. Cylinder-head work covers valves, guides, seats, springs, and gasket-surface inspection; separate chapters handle cylinders and pistons, cam support plate and camshafts, oil pump, crankcase, flywheel/connecting rods, and oil pan.

Drivetrain chapters cover the primary chaincase, clutch, transmission sprocket and belt, plus internal six-speed repair: power flow, shifter forks, gearset service, main drive gear and bearing replacement, and case removal. Chassis procedures include sealed wheel bearings, 17-, 19-, and 21-inch wheel lacing and truing, cast-wheel runout, alignment, brake hydraulic overhaul, front-fork disassembly, steering-head bearings, rear suspension, and model-dependent handlebars. Named illustrations include Engine Oil Flow – Top End, Front Fork/Steering Head Assembly, Transmission Power Flow, Cylinder Head/Cylinder/Piston Assemblies (Exploded View), and ACR Circuit.

Fuel Injection, Electrical Diagnosis, and Wiring

Base fuel-system procedures cover the induction module, IAC and EFI sensors, fuel tank, pump and injectors, fuel-pressure and intake-leak testing, exhaust service, and California evaporative-emissions hardware. The electrical diagnostics volume is organized around symptom tables, DTC priorities, circuit descriptions, and branching test charts. Starting-system coverage includes relay and activation-circuit checks, voltage-drop testing, free-running starter current draw, and solenoid pull-in, hold-in, and return tests. Charging diagnosis covers the battery, rotor and stator inspection, stator AC output and grounding checks, voltage-regulator testing, and battery milliamp-draw checks for parasitic loads.

Instrument sections explain DTC retrieval through the speedometer and separate indicator-lamp arrangements. Turn Signal Module (TSM) and Hands-Free Security Module (HFSM) coverage addresses turn-signal operation, fob and antenna faults, PIN functions, arming and disarming behavior, alarm and transport modes, password learn, serial-data loss, and siren service. A separate appendix covers TSM/TSSM systems for Japan and Korea. Engine-management charts isolate ECM power, fuel-pump and system-relay faults, injector circuits, crank-position and vehicle-speed signals, IAC, MAP, IAT, engine-temperature, throttle-position, and oxygen-sensor faults. Operations requiring Digital Technician—such as HFSM fob assignment and ECM reprogramming—are identified rather than presented as ordinary meter tests.

Both the service-manual appendix and the diagnostics volume carry the same 22-sheet wiring series. It separates FXDWG/FXDC layouts from the other Dyna models and includes main-harness, instruments and indicators, lighting, horn, charging, starting, ignition, and security circuits for domestic and international configurations. Connector sections cover AMP, Delphi, Deutsch, Metri-Pack, Packard, Molex, and sealed-splice repair. Useful equipment callouts include the HD-42682 instrument/security breakout box, HD-43876 EFI breakout box, HD-44750 Digital Technician, and HD-41182 fuel-pressure gauge with HD-44061 adapters.

FXDSE Supplement Scope

The FXDSE supplement is meant to be used with the base service manual. For the 1,800 cc Twin Cam 110, it supplies unique specifications and wear limits plus repair material for cylinder heads, pistons, cylinder boring and honing, crankcase work, and the ECM-operated automatic compression release. Chassis chapters address the inverted fork, hydraulic clutch master cylinder and fluid line, wider rear-wheel and fender arrangement, special controls and instruments, domestic/international (HDI) equipment differences, and California evaporative-emissions mounting. Its Drive and Transmission sections contain no separate FXDSE procedures; those jobs refer back to the base Dyna manual.

Factory Specifications, Tooling, and Repair Cautions

Tables collect component-specific torque values, fluid capacities, inspection dimensions, service wear limits, tire and wheel data, electrical voltage, resistance and current criteria, fuel-system test data, connector terminal functions, and DTC priorities. Some diagnostic charts also print warranty job/time codes for dealership claims. Mechanical tool references include HD-42317 and HD-42320-A for piston service, HD-47941 for camshaft locking, and HD-35316-C for main-drive-gear and bearing work.

Component-specific repair cautions state that piston-pin circlips are single-use because reuse can lead to engine damage. The transmission section warns that installing the main-drive-gear bearing without HD-35316-C can cause premature bearing and related-part failure. These procedures involve a supported motorcycle or engine, high-current battery circuits, pressurized fuel, brake fluid, compressed air, and heavy components. Follow the manuals’ battery-disconnection, lifting, fire-prevention, ventilation, and personal-protection warnings before beginning any repair.