Contents of this 2007 Factory Harley Davidson Dyna Service and Repair Manual: This instant eBook contains fully detailed step-by-step repair procedures with hundreds of high quality photos and illustrations to guide you through any repair, maintenance, overhaul, service specifications or troubleshooting procedure. This expert text guide book will give you the knowledge and experience you need to perform simple basic maintenance or more complicated service procedures like engine overhaul. Covers every thing you will ever need to know to fix anything on your your 2007 Harley Davidson HD FXD Dyna Super Glide, FXDB Dyna Street Bob, FXDL Dyna Low Rider, FXDC Dyna Super Glide Custom, FXDWG Dyna Wide Glide & FXDSE Screamin' Eagle Dyna Motorcycle Chopper. Why Pay a mechanic when you can do it for free.
3.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Service Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Engine Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.5 Oil Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.6 Breather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.7 Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.8 How To Use This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.9 Top End Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.10 Bottom End Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.12 Stripping Motorcycle For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.13 Assembling Motorcycle After Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.14 Removing Engine From Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.15 Installing Engine In Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.16 Top End Overhaul: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.17 Top End Overhaul: Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.18 Bottom End Overhaul: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
3.19 Bottom End Overhaul: Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3.20 Breather Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
3.21 Rocker Arm Support Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
3.22 Push Rods, Lifters and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
3.23 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
3.24 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
3.25 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
3.26 Cover and Cam Support Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97
3.27 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
3.28 Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
3.29 Flywheel/Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114
3.30 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-
Oil passes through a channel in the cam support plate exiting
the inboard side through two holes near the top (A11, A12).
Entering two holes in the crankcase flange (B13, B14), one
leading to the front cylinder and the other to the rear, the oil
travels through passageways in the crankcase to the hydraulic
lifter bores (D15).
To diagnose and correct noisy hydraulic lifters and valve train
components, use the following procedures:
1. With engine and oil at normal operating temperature,
check oil pressure at 2000 RPM. If oil pressure is above
50 PSI (345 kN/m
2) or below 5 PSI (34 kN/m2
), inspect
COMPRESSION TEST
NOTE
The Twin Cam 88 Engine uses a 12 mm adapter with the
compression gauge.
Satisfactory engine performance depends upon a mechanically
sound engine. In many cases, unsatisfactory performance
is caused by combustion chamber leakage. A
compression test can help determine the source of cylinder
leakage. Use CYLINDER COMPRESSION GAUGE (Part No.
HD-33223-1) that has a screw-in type adapter.
A proper compression test should be performed with the
engine at normal operating temperature when possible.
1. Disconnect spark plug wires, clean around plug base
and remove plugs.
2. Connect compression tester to front cylinder per manufacturer’s
instructions.
3. Make sure transmission is in neutral. With throttle body
butterfly plate in wide open position, crank engine continuously
through 5 to 7 full compression strokes.
4. Note gauge readings at the end of the first and last compression
strokes. Record test results.
5. Repeat steps 2 through 4 on rear cylinder.
6. If the final readings are 100 PSI (689 kPa) or more, and if
the final readings do not indicate more than a 10% variance
between cylinders, compression is considered normal.
If compression does not meet specifications, refer to
Table 3-1.
7. Inject approximately 1/2 oz. (15 ml) engine oil into each
cylinder and repeat the compression tests on both cylinders.
Readings that are considerably higher during the
second test indicate worn piston rings.
NOTE
After installing spark plugs, be sure that throttle plate is in the
closed position before starting the engine.
Table 3-1. Compression Test Results
oil pump, crankcase passages, and oil hoses for restrictions
or blockage. Repair or replace parts as necessary.
2. If oil is reaching the hydraulic lifters, remove and inspect.
See LIFTER INSPECTION under 3.22 PUSH RODS,
LIFTERS AND COVERS. Clean lifter bore of all foreign
material. Replace hydraulic lifter if required.
3. Examine push rod, lifter and lifter block for proper fit and
any signs of unusual wear. Replace parts as necessary.
4. Visually inspect camshaft lobes for abnormal wear.
5. Check cam chain tensioning spring and shoe for wear.
6. Remove cylinder head and rocker box assemblies.
Check rocker arm end play and check for binding.
Inspect valve stems for scuffing and check stem to guide
clearance. Check valve seats for signs of looseness or
shifting.
7. Grind valves and valve seats.
