2006 Harley-Davidson Dyna FXD, FXDC, FXDL, FXDWG, FXD35 & FXDB Service & Electrical Diagnostics Manual (P/N 99481-06)

This publication combines the 2006 Harley-Davidson Dyna Service Manual (P/N 99481-06) and Electrical Diagnostics Manual (P/N 99496-06) for FXD, FXDC, FXDL, FXDWG, FXD35, and FXDB models.

• Engine repair: Engine removal, top- and bottom-end overhaul, cylinder-head service, cam-support-plate work, oil-pump inspection, and compression and cylinder-leakage testing.

• Chassis and brakes: Wheel lacing and truing, sealed wheel-bearing replacement, steering-head adjustment, fork overhaul, brake-caliper rebuilding, and hydraulic brake bleeding.

• Drive and transmission: Clutch service, automatic primary-chain tensioner replacement, main-drive-gear bearing work, transmission disassembly, and shift-linkage adjustment.

• Fuel injection: Induction-module and injector service, fuel-pump repair, fuel-pressure testing, intake-leak checks, and California evaporative-emissions components.

• Starting and charging: Starter-solenoid repair, assembled-starter tests, alternator and voltage-regulator diagnosis, and battery testing.

• Engine management and security: Diagnostic trouble-code charts, idle air control (IAC) testing, TSM/TSSM configuration, password learning, key-fob assignment, and personal-code entry.

• Wiring and connectors: Model-specific wiring diagrams, connector-location tables, terminal repair, and ECM breakout-box testing.

This material suits mechanically qualified owners and technicians who have the specified service tools, measuring equipment, and experience with electrical diagnosis.

Twin Cam Engine and Drivetrain Repair

The engine chapters distinguish top-end and cam-compartment work performed in the chassis from repairs requiring engine removal. Valve-guide replacement, valve-seat refacing, cylinder boring and honing, and piston inspection are covered alongside component wear limits. Engine Oil Flow views trace lubrication through the cam support plate, top end, and bottom end.

Flywheel and connecting rods: The manual provides inspection and replacement criteria for the complete assembly. Replacement of the flywheels, connecting rods, or right-side bearing inner race calls for replacement of the entire flywheel assembly.

Primary drive: The primary chain uses an automatic tensioner; a worn or damaged tensioner is replaced as an assembly. The instructions identify locking tool HD-47977 and warn that substituting HD-41214 can damage drive components. The Clutch Cover Torque Sequence illustration supports cover reassembly.

Wheel, Suspension, and Brake Service

Chassis procedures include vehicle alignment, cast-wheel runout checks, fork-fluid replacement, and rear-shock spring adjustment for different loads. The master-cylinder section distinguishes single- and dual-caliper repair parts and warns against interchanging them.

Drive Belt Wear Patterns pairs visual examples with condition assessments. Maintenance schedules, fluid-capacity tables, and fastener torque references support routine servicing; storage preparation is supplemented by the Battery Self-Discharge Rate chart.

Follow the manual's safety procedures and torque specifications, particularly for brake work and pressurized fuel-system testing.

EFI Fault Tracing and Security-System Setup

The electrical diagnostics manual separates cranking/no-start, starts-then-stalls, misfire, charging, and communication faults. Its symptom charts and circuit tests help distinguish a fuel-delivery problem from an ignition or wiring fault before components are replaced.

Fuel-system testing: The fuel-pressure procedure specifies gauge HD-41182 and adapters HD-44061. It warns that an incorrect adapter arrangement can twist and break a fuel line or fitting.

HDI equipment and adjustments: Active-intake-solenoid diagnosis applies to HDI models, including fault codes P0661 and P0662. Idle-speed adjustment requires Digital Technician HD-44750.

Circuit diagnosis: Starting Circuit and EFI System Circuit diagrams accompany connector and terminal information. Breakout Box HD-43876 supports ECM circuit checks with a digital volt/ohmmeter without probing connections with sharp objects. Wiring sections distinguish FXDWG/FXD35 layouts from the other covered models.

TSM/TSSM coverage includes weak or failed key-fob signals, security-lamp faults, and the password-learning requirements after module replacement. Configuration, key-fob assignment, and personal-code procedures are provided together with the related diagnostic charts.

A Sample of Axle Torque and Pressure-Test Data

These examples represent a small selection of the manual's chassis and engine test specifications. The rear axle nut specification is 60–65 ft-lbs.

For the Twin Cam engine, oil pressure is specified at 30–38 psi at 2,000 RPM with the oil at 230°F (110°C). EFI fuel pressure should remain at 55–62 psi during the documented running-engine test as engine speed changes.

Searchable Text, Bookmarks, and PDF Contents

Finding procedures and reading circuits: Searchable PDF text and embedded chapter bookmarks cover both manuals. Small connector numbers and wire-color labels require zooming for comfortable reading.

The English download is one printable, 914-page PDF: 568 pages of service-manual content, 344 pages of electrical diagnostics, one combined contents page, and one blank closing page. These totals already include 15 blank pages, 11 notes pages, and 42 pages containing wiring-diagram headings only.