1999–2005 Harley-Davidson Dyna FXD Super Glide, Low Rider, Wide Glide, T-Sport, and Defender Service Manual (P/N M425-3)

• 1999-2005 model coverage: Identifies FXD Super Glide, FXDL Low Rider, FXDWG Wide Glide, FXDS-CONV Convertible, FXDX Super Glide Sport, FXDXT T-Sport, and FXDP Defender models. The 2004-on material adds FXDI, FXDLI, FXDWGI, and FXDXI fuel-injected variants; 2005 adds the FXDC/FXDCI Super Glide Custom.
• Twin Cam 88 engine repair: Covers engine removal and installation, in-frame top-end work, cylinder-head and valve inspection, pistons and rings, hydraulic lifters, oil pump, camshafts and chain tensioners, crankcase disassembly, crankshaft bearing service, reassembly, and break-in.
• Clutch, primary drive, and five-speed transmission: Details clutch plates and friction discs, compensating sprocket, primary chain alignment, chaincase housings, starter jackshaft, shifter adjustment, shift cam and forks, transmission shafts, main drive gear, bearings, and case removal.
• Carbureted and EFI fuel systems: Includes carburetor disassembly, inspection, assembly, and float adjustment; intake, fuel tank, shutoff-valve, and California EVAP service; plus sequential-port EFI operation, induction-module removal, sensor coverage, fuel-system depressurizing, and 2004-on pump, filter, regulator, and strainer service.
• Electrical testing and fault isolation: Provides battery, charging, alternator, regulator, ignition, starting, lighting, switch, TSM/TSSM, fuse, relay, ICM, and ECM service, backed by diagnostic trouble-code tables, voltage-drop checks, starter current-draw tests, and charging-output procedures.
• Wheels, suspension, steering, and brakes: Covers laced and cast wheels, hubs, drive belt, vehicle alignment, conventional and FXDX/FXDXT cartridge-fork service, steering-head bearings, shock absorbers, swingarm, calipers, master cylinders, brake lines, discs, and hydraulic bleeding.
• 595-page PDF reference: Supplies quick-reference data, component-specific torque tables, capacities, wear limits, clearances, shim and spacer data, electrical test specifications, special-tool part numbers, exploded views, and a dedicated model/year wiring-diagram section.

This is a Clymer aftermarket service and repair manual, not a Harley-Davidson factory/OEM publication. Its step-by-step format is suited to experienced DIY owners and independent technicians, including readers new to this Dyna platform, provided they have the measuring tools and mechanical or electrical test skills required for the repair. The text flags operations that call for specialist equipment or dealer-level support.

Model-Year Changes Are Kept Separate

The main chapters carry the core repair procedures, while the dedicated 2002-2005 supplement supplies only the revised procedures and specifications that differ from the earlier build. It identifies the 2003 one-piece breather change, the 2003-on integral shift-arm arrangement, 2004-on carbureted-versus-EFI fuel and electrical layouts, and 2005 valve and clutch-cover revisions. This organization helps prevent an earlier procedure or component arrangement from being applied to a later motorcycle.

EFI coverage has a defined limit. The manual explains the ECM inputs, induction module, injectors, fuel supply, sensors, and replaceable in-tank components, but states that full EFI service and idle-speed setting require the Harley-Davidson Digital Technician and other specialty equipment. Those operations are directed to a dealership rather than presented as ordinary shop adjustments. Body coverage is limited to the seat, FXDS-CONV and FXDXT windshield assemblies, and saddlebags.

Tools, Diagrams, and Specification Data

The special-tool tables identify equipment by maker and part number. Examples include the JIMS 1022 Twin Cam 88 engine stand, JIMS 1283 cam-chain tensioner tool, H-D 39618 transmission pawl adjuster, and Motion Pro 08-0121 fork oil-level gauge. These references make it easier to judge whether a planned repair can be completed with the equipment already in the shop.

Named illustrations include the starter/solenoid voltage-drop test, early- and later-1999 camshaft-and-cover assemblies, transmission-case bearings and covers, the EFI induction module, and the 2004-on fuel-pump-and-filter assembly. The wiring section is indexed as printed pages 571-590 and contains ten named layouts: separate 1999-2000 and 2001-2003 groups, 2001-2004 FXDP wiring, distinct 2004-2005 EFI and carbureted diagrams for FXDWG and non-FXDWG models, and a speedometer/tachometer schematic.

Manual-Specific Repair Cautions

The 2004-on stator section specifies new threadlocked mounting screws because reused screws can loosen and cause engine damage. During 2005 valve repair, the manual warns that the stem-seal protector is needed to keep the keeper groove from tearing the seal, and that an incorrect valve-guide tool can expand the guide and damage the cylinder-head bore.

Brake, fuel-system, engine-removal, and suspension work must be performed with the motorcycle securely supported and with the manual's fire, electrical-isolation, and hydraulic-safety precautions observed.