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    Dyna 91 98 Service Manual

    Uploaded by

    Victor Ortiz

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Dyna 91 98 Service Manual

    Uploaded by

    Victor Ortiz
    18 views544 pages

    Copyright

    © © All Rights Reserved

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    PDF, TXT or read online from Scribd

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    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    18 views544 pages

    Dyna 91 98 Service Manual

    Uploaded by

    Victor Ortiz

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    You are on page 1of 544

    Jade's Collection .

    net Archives
    Jade's Collection .net Archives
    MAINTENANCE LOG
    DATE MILES TYPE OF SERVICE
    Chapter One
    1 General Information
    Chapter Two
    2 Troubleshooting
    Chapter Three
    3 Periodic Lubrication, Maintenance and Tune-up
    Chapter Four
    4 Engine
    Chapter Five
    5 Clutch, Primary Drive and Starter Drive
    Chapter Six
    6 Transmission
    Chapter Seven
    7 Fuel, Exhaust and Emission Control Systems
    Chapter Eight
    8 Electrical System
    Chapter Nine
    9 Wheels, Hubs and Tires
    Chapter Ten
    10 Front Suspension and Steering
    Chapter Eleven
    11 Rear Suspension
    Chapter Twelve
    12 Brakes
    Supplement
    13 1996-1998 Service Information

    14 Index

    15 Wiring Diagrams
    CONTENTS

    QUICK REFERENCE DATA ........................................................................................................ IX

    CHAPTER ONE
    GENERAL INFORMATION ............................................................................................................1

    Manual organization Expendable supplies


    Notes, cautions and warnings Basic hand tools
    Safety first Test equipment
    Service hints Precision measuring tools
    Serial numbers Other special tools
    Parts replacement Mechanic's tips
    Torque specifications Ball bearing replacement
    Fasteners Oil seals
    Lubricants Riding safety
    Sealant, cements and cleaners

    CHAPTER TWO
    TROUBLESHOOTING....................................................................................................................36

    Operating requirements Engine noises


    Troubleshooting instruments Engine lubrication
    Testing electrical components Clutch
    Emergency troubleshooting Transmission
    Engine performance Electrical problems
    Electric starting system Excessive vibration
    Charging system Front suspension and steering
    Ignition system Brake problems
    Fuel system

    CHAPTER THREE
    PERIODIC LUBRICATION, MAINTENANCE AND TUNE-UP ......................................................89

    Routine safety checks Periodic maintenance


    Maintenance intervals Tune-up
    Cleaning your motorcycle Ignition service
    Tires and wheels Idle speed adjustment
    Periodic lubrication
    CHAPTER FOUR
    ENGINE .................................................................................................................................... 127

    Service precautions Pushrods


    Special tools Lifters and lifter guides
    Servicing engine in frame Oil pump
    Engine Oil filter mount (1992-on)
    Rocker arm cover and cylinder head Gearcase cover and timing gears
    Valves and valve components Crankcase and crankshaft
    Cylinders Engine break-in
    Pistons and piston rings

    CHAPTER FIVE
    CLUTCH AND PRIMARY DRIVE............................................................................................. 210

    Outer primary cover Primary chain alignment


    Clutch plates Compensating sprocket inspection
    Clutch, compensating sprocket and primary Inner primary housing
    drive chain removal and installation Starter jackshaft
    Clutch overhaul Clutch cable replacement
    Primary chain and guide inspection

    CHAPTER SIX
    TRANSMISSION....................................................................................................................... 238

    Production gear changes Transmission shafts


    Shifter adjustment Main drive gear
    Transmission top cover Transmission case
    Shifter cam Transmission side cover
    Shift forks Oil tank
    Transmission side door

    CHAPTER SEVEN
    FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS..................................................... 275

    Air filter backplate (all 1991-1995 domestic Fuel tank


    and 1991-1994 international models) Fuel valve
    Air filter backplate (1995 international models) Exhaust system
    Carburetor Evaporative emission control system
    Throttle and idle cable replacement (California models)
    Enrichener cable replacement Evaporative emission control system service
    CHAPTER EIGHT
    ELECTRICAL SYSTEM ........................................................................................................... 321

    Battery Switches
    Charging system Horn
    Ignition system Turn signal module
    Ignition coil Speedometer speed sensor (1995)
    Vacuum operated electric switch Indicator lights
    Starter Electric panel
    Starter solenoid Starter relay switch replacement
    Lighting system Circuit breakers

    CHAPTER NINE
    WHEELS, HUBS AND TIRES...................................................................................................376

    Front wheel Wire spoke wheels


    Front hub Cast wheels
    Rear wheel Wheel balance
    Rear hub Tires
    Driven sprocket assembly Tire repairs (tube-type tires)
    Secondary drive belt Tire repairs (tubeless type)
    Drive sprocket Vehicle alignment

    CHAPTER TEN
    FRONT SUSPENSION AND STEERING ................................................................................ 409

    Handlebar Steering head bearing race


    Front forks Steering play adjustment
    Steering head and stem

    CHAPTER ELEVEN
    REAR SUSPENSION............................................................................................................... 427

    Shock absorbers Rear swing arm

    CHAPTER TWELVE
    BRAKES................................................................................................................................... 439

    Front brake pads Rear master cylinder


    Front brake caliper Brake hose and line replacement
    Front master cylinder Brake disc (front and rear)
    Rear brake pads Bleeding the system
    Rear brake caliper
    SUPPLEMENT
    1996-1998 SERVICE INFORMATION....................................................................................478
    Periodic lubrication Charging system
    Periodic maintenance Ignition system
    Ignition service Starter
    Clutch plates (1998 models) Switches
    Clutch overhaul Front master cylinder
    Battery

    INDEX .....................................................................................................................................506

    WIRING DIAGRAMS ..............................................................................................................510


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