Harley-Davidson Dyna & FXDSE 2007 Service Manual Set (P/N 99481-07)

The service manual moves from scheduled maintenance through mechanical repair, while the electrical diagnostics volume supplies circuit descriptions and fault-isolation charts. Use the FXDSE supplement with the base manual: its Drive and Transmission sections refer back to the standard Dyna procedures.

PDF Search, Bookmarks and Wiring Detail

Search and diagram detail: Service and diagnostic text is searchable. The FXDSE electrical section is partially searchable; labels within its four wiring sheets are not searchable. Embedded bookmarks are present in 38 files, while the 24 separate contents PDFs have no bookmarks. Small labels in the wiring sheets require zooming.

The ZIP download contains 62 printable PDFs totaling 1,154 pages. The publication totals above include their contents pages, appendices, notes pages and wiring-sheet reverse pages; the two-page shared index is also included.

Engine, Chassis and Electrical Service Coverage

These are selected areas of coverage, rather than a complete contents list. Other topics include storage preparation and active exhaust module service.

• Engine repair: Step-by-step engine removal and installation, top- and bottom-end overhaul, cylinder-head service, and cam support plate, oil pump and crankcase work.

• Primary drive and transmission: Primary chaincase service, clutch disassembly and inspection, drive-belt replacement, gearset repair, shifter-fork inspection, and main-drive-gear bearing replacement.

• Brakes and chassis: Brake bleeding and hydraulic component overhaul, sealed wheel bearings, wheel lacing and truing, alignment, fork and steering-head service, and rear suspension.

• EFI and fuel system: Induction module, fuel tank, pump and injector service; fuel-pressure and intake-leak testing; exhaust repair; and California evaporative-emissions equipment.

• Starting and charging: Starter activation-circuit diagnosis, battery and charging-system tests, starter-motor and solenoid service, and parasitic-current checks.

• Instruments and security: Speedometer self-diagnostics, indicator-lamp circuit checks, turn-signal faults, HFSM fob and antenna diagnosis, and Japan/Korea TSM/TSSM coverage.

• Wiring and service data: Model-specific wiring diagrams, connector and sealed-splice repair, specialty-tool references, DTC priorities, torque tables, fluid capacities, wear limits and electrical test specifications.

This set 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.

Engine Overhaul and Lubrication Diagnosis

Oil-flow diagrams explain the pump, breather and lubrication circuits, including Engine Oil Flow – Top End. Compression, cylinder-leakage and oil-pressure tests support investigation of valvetrain noise, smoking and high oil consumption before teardown.

Cylinder-head work covers valves, guides, seats, springs and gasket-surface inspection. Subassembly sections extend through cylinders and pistons, camshafts, crankcase bearings and the oil pan. The flywheel/connecting-rod section provides inspection and assembly replacement criteria; replacement of the flywheel, connecting rods or right-side bearing inner race calls for replacement of the complete flywheel assembly.

Drivetrain, Wheels and Controls

Internal transmission coverage explains power flow, dog-ring operation, shifter forks, side-door bearings, gearset assembly and transmission-case removal. Transmission Power Flow illustrates the gear paths. Tool references include HD-35316-C for main-drive-gear and bearing work.

Wheel chapters distinguish 17-, 19- and 21-inch lacing procedures and cover cast-wheel runout. Model-dependent handlebar, instrument and lighting arrangements are treated separately.

EFI Fault Isolation and Electrical Testing

Symptom tables, DTC priorities and branching test charts connect reported faults to the relevant circuit checks. They cover crank/no-start, start-and-stall and misfire complaints, helping distinguish fuel-delivery, ignition and control-circuit problems before component replacement.

Engine-management diagnosis addresses ECM power, fuel-pump and system-relay faults, injector circuits, crank-position and vehicle-speed signals, and IAC, MAP, IAT, engine-temperature, throttle-position and oxygen-sensor faults.

Starting tests include voltage-drop checks, free-running starter current draw, and solenoid pull-in, hold-in and return tests. Charging coverage adds rotor and stator inspection, stator AC-output and grounding checks, voltage-regulator tests, and battery milliamp-draw checks.

Instruments, Security and Diagnostic Equipment

Instrument sections explain DTC retrieval through the speedometer and distinguish indicator-lamp arrangements. TSM and Hands-Free Security Module (HFSM) coverage addresses turn signals, fob and antenna faults, PIN functions, arming and disarming, alarm and transport modes, password learn, serial-data loss and siren service.

A separate appendix covers TSM/TSSM systems for Japan and Korea. HFSM fob assignment and ECM reprogramming require Digital Technician HD-44750; these are not ordinary meter-test operations.

Wiring Sheets and Connector Repair

The service-manual appendix and diagnostics volume contain the same 22-sheet wiring series. Layouts separate FXDWG/FXDC from the other Dyna models and distinguish domestic and international configurations across main-harness, instrument, lighting, horn, charging, starting, ignition and security circuits.

Connector procedures cover AMP, Delphi, Deutsch, Metri-Pack, Packard, Molex and sealed splices. Equipment references include the HD-42682 instrument/security breakout box, HD-43876 EFI breakout box, and HD-41182 fuel-pressure gauge with HD-44061 adapters.

FXDSE Engine and Chassis Differences

The supplement adds unique engine specifications and wear limits, cylinder-head repair, piston measurement, cylinder boring and honing, and the crankcase assembly difference. Its ECM-operated automatic compression release has dedicated diagnostic charts and an ACR Circuit diagram.

Chassis coverage includes inverted-fork rebuild procedures, hydraulic clutch master-cylinder and fluid-line service, the wider rear-wheel and fender arrangement, special controls and instruments, domestic/HDI equipment differences, and California evaporative-emissions mounting. Illustrations include Front Fork/Steering Head Assembly and Cylinder Head/Cylinder/Piston Assemblies (Exploded View).

Tooling and Component-Specific Cautions

Mechanical tool references include HD-42317 and HD-42320-A for piston service and HD-47941 for camshaft locking. Some diagnostic charts also carry warranty job/time codes for dealership claims.

The piston procedures warn that reused piston-pin circlips can break or dislodge and damage the engine. 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.

Selected Piston-Fit and Fuel-Pressure Specifications

The engine tables distinguish manufacturing fit from service wear limits. Piston-to-cylinder fit is 0.0014–0.0025 in. for the standard Twin Cam 96 and 0.0018–0.0027 in. for the FXDSE Twin Cam 110.

The EFI fuel-pressure test specifies a steady 55–62 psi as engine speed changes. The related diagnostic chart addresses pressure outside that range, alongside the gauge and adapter requirements.