Maintenance Dyna User Manual
able Of Contents
T
SUBJECT PAGE NO.
1.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Side Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
NOTE
This section provides information unique to the FXDP police model motorcycle. Any information not presented in this supplement can be found in the Dyna Models Service Manual.
MAINTENANCE 1
HOME
4
MAINTENANCE SCHEDULE 1.1
Table 1-1. Maintenance Schedule
1
1
1
1
2
2
2
2
3
3
3
3
4
4
4
4
5
7
0
5
0
0
0
0
0
M
M
I
I
I
7
8
6
0
0
0
0
0
0
0
K
K
M
M
MAINTENANCE TASK
AND SERVICE DATA
Engine oil (*)
Oil level:
Dipstick level depends on vehicle
temperature
Engine oil filter (*)
Filter tightening:
Hand tighten oil filter 1/2 to 3/4 turn
after gasket surface contacts filter
mounting surface.
1
2
5
7
0
2
5
7
0
2
5
7
0
2
5
7
0
5
0
5
0
5
0
5
0
5
0
5
0
5
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
M
M
M
M
M
M
M
M
I
I
I
I
I
I
P
R
1
E
R
D
E
4
6
0
0
0
I
0
0
K
K
M
M
IR
RRRRRRRRRRRRRRRRRRRR
R
RRRRRRRRRRRRRRRRRRRR
1
1
8
2
0
0
0
0
0
0
K
K
M
M
2
6
0
0
0
0
0
0
0
K
K
M
K
M
M
M
I
I
2
2
4
0
0
0
3
8
2
0
0
0
0
0
0
K
K
M
M
0
M
M
I
I
3
4
6
0
0
0
0
0
0
0
K
K
M
M
0
0
0
M
M
I
I
4
4
4
8
0
0
0
0
0
0
K
K
M
M
0
0
0
0
0
M
M
I
I
5
5
2
6
0
0
0
0
0
0
K
K
M
M
0
5
0
0
0
0
0
M
M
I
I
I
6
6
0
4
0
0
0
0
0
0
K
K
M
M
2
5
5
0
0
0
0
0
M
M
I
6
7
8
2
0
0
0
0
0
0
K
K
M
M
Battery (*)
Brake fluid level and condition
Brake fluid type:
D.O.T. 5 SILICONE BRAKE FLUID
Part No. 99902-77 (12 oz.) or
99901-77 (gallon)
Brake pads and discs for wear
Minimum pad thickness:
0.04 in. (1.02 mm)
II
Maximum brake disc lateral runout:
0.008 in. (0.2 mm)
Tire pressure and inspect tires for
wear/damage (*)
II
Primary chain adjustment
Deflection:
Cold: 5/8-7/8 in. (15.9-22.2 mm)
Hot: 3/8-5/8 in. (9.5-15.9 mm)
Tab le Code:
A
- Adjust.
I
- Inspect, and if necessary, correct, adjust, clean or replace.
L
- Lubricate with specified lubricant.
R
- Replace or change.
I
IIIIIIIIIIIIIIIIIIII
I
I
I I I I I I I I I I
IIIIIIIIIIIIIIIIIIII
IIIIIIIIIIIIIIIIIIII
I I I I I I I I I I
T
- Tighten to proper torque.
X
-Perform.
D
- Disassemble, lubricate and inspect.
(*)- Also perform prior to storage or annually.
2003 Dyna Police: Maintenance 1-1
HOME
MAINTENANCE TASK
AND SERVICE DATA
Primary chain lubricant
Lubricant level:
Visible between clutch and chaincase inner wall with vehicle upright,
26 oz (768.8 ml).
Lubricant type:
Part No. 99887-84 (quart) or
99886-84 (gallon)
Table 1-1. Maintenance Schedule
1
1
1
1
2
2
1
2
5
7
0
2
5
7
0
5
0
5
0
0
0
0
0
0
M
M
I
P
R
1
4
E
6
0
R
0
0
I
0
0
D
K
K
E
M
M
R
RRRRRRRRRRRRRRRRRRRR
0
0
0
M
M
I
I
1
8
2
0
0
0
0
0
0
K
K
M
M
5
0
0
0
0
M
M
I
M
I
I
1
2
6
0
0
0
0
0
0
0
K
K
K
M
M
M
0
0
5
0
0
0
0
0
0
0
M
M
I
I
2
2
3
4
8
2
0
0
0
0
0
0
0
0
0
K
K
M
M
2
2
5
5
0
0
0
0
0
M
M
I
I
I
3
4
6
0
0
0
0
0
0
0
K
K
M
M
2
3
3
3
3
4
4
4
4
7
0
2
5
7
0
2
5
0
5
0
5
0
0
0
M
4
4
0
0
0
K
M
0
0
0
M
M
I
K
M
M
I
I
4
5
8
2
0
0
0
0
0
0
K
K
M
M
0
0
0
0
0
0
0
M
M
I
I
5
6
6
6
0
4
0
0
0
0
0
0
0
0
0
K
K
M
M
5
5
0
0
0
0
0
M
M
I
I
6
7
8
2
0
0
0
0
0
0
K
K
M
M
5
7
0
5
0
0
0
0
0
M
M
I
I
I
7
8
6
0
0
0
0
0
0
0
K
K
M
M
Clutch adjustment
Hand lever free play:
1/16-1/8 in. (1.6-3.2 mm)
Transmission lubricant (*)
Lubricant level:
Bottom edge of FULL mark on dipstick with vehicle upright.
Lubricant type:
Part No. 99892-84 (quart)
Drain plug:
14-21 ft-lbs (19.0-28.5 Nm)
Rear belt deflection inspection (*)
Deflection:
5/16-3/8 in. (7.9-9.5 mm)
Bottom strand with 10 lb. (4.5kg)
upward force.
Specialty tool:
Part No. HD-35381
Rear belt and sprocket (*)
Steering head bearing
Front fork oil
X
R
II
I
A
X X X X X X X X X X
IRIRIRIRIRIRIRIRIRIR
IIIIIIIIIIIIIIIIIIII
I I I I I I I I I I
A A D A A
R
R
Tab le Code:
A
- Adjust.
I
- Inspect, and if necessary, correct, adjust, clean or replace.
L
- Lubricate with specified lubricant.
R
- Replace or change.
1-2 2003 Dyna Police: Maintenance
T
- Tighten to proper torque.
X
-Perform.
D
- Disassemble, lubricate and inspect.
(*)- Also perform prior to storage or annually.
HOME
MAINTENANCE TASK
AND SERVICE DATA
Table 1-1. Maintenance Schedule
1
1
1
1
2
2
1
2
5
7
0
2
5
7
0
5
0
5
0
5
0
0
0
0
0
0
M
P
R
1
E
6
R
0
I
0
D
K
E
M
0
M
M
I
I
4
8
0
0
0
0
0
0
K
K
M
M
0
0
0
M
M
I
I
1
1
2
6
0
0
0
0
0
0
K
K
M
M
0
0
0
0
0
M
M
I
I
2
2
0
4
0
0
0
0
0
0
K
K
M
M
0
5
0
0
0
0
0
M
M
I
I
2
3
8
2
0
0
0
0
0
0
K
K
M
M
2
2
5
5
0
0
0
0
0
M
M
I
I
I
3
4
6
0
0
0
0
0
0
0
K
K
M
M
2
3
3
3
3
4
4
4
4
7
0
2
5
7
0
2
5
0
5
0
5
0
0
0
0
0
M
M
I
4
4
4
8
0
0
0
0
0
0
K
K
M
M
0
0
0
M
M
I
I
5
5
2
6
0
0
0
0
0
0
K
K
M
M
0
0
0
0
0
M
M
I
I
6
6
0
4
0
0
0
0
0
0
K
K
M
M
5
5
0
0
0
0
0
M
M
I
I
6
7
8
2
0
0
0
0
0
0
K
K
M
M
5
7
0
5
0
0
0
0
0
M
M
I
I
I
7
8
6
0
0
0
0
0
0
0
K
K
M
M
Check air suspension - pressure,
operation and leakage
Spark plugs (*)
Plug type:
No. 6R12
Plug gap:
0.038-0.043 (0.97-1.09 mm)
Plug torque:
11-18 ft-lbs (14.9-24.4 Nm)
Air cleaner filter (*)
Cover screw torque:
36-60
in-lbs
(4.1-6.8 Nm)
Lubricate controls (*)
Front brake hand lever, clutch hand
lever, throttle control cables, clutch
control cable, rear brake pedal and
jiffy stand
Shift Lever
Operation of throttle controls
Enrichener operation
I
I
I
L
L
I
I
I I I I I I I I I I
I R I R I R I R I R
IIIIIIIIIIIIIIIIIIII
L L L L L L L L L L
L L L L L L L L L L
IIIIIIIIIIIIIIIIIIII
IIIIIIIIIIIIIIIIIIII
Engine idle speed
Idle speed:
950-1050 RPM
Fuel supply valve filter screen
Filter hex fitting torque:
15-20 ft-lbs (20.3-27.1 Nm)
Fuel system lines and fittings (*)
Repack rear fork bearings
Hinges, latches - saddlebags,
fuel door
Tab le Code:
A
- Adjust.
I
- Inspect, and if necessary, correct, adjust, clean or replace.
L
- Lubricate with specified lubricant.
R
- Replace or change.
I
I
L
I I I I I I I I I I
X
IIIIIIIIIIIIIIIIIIII
X
L L L L L L L L L L
T
- Tighten to proper torque.
X
-Perform.
D
- Disassemble, lubricate and inspect.
(*)- Also perform prior to storage or annually.
X
X
2003 Dyna Police: Maintenance 1-3
HOME
MAINTENANCE TASK
AND SERVICE DATA
Check oil and brake lines for leaks
Table 1-1. Maintenance Schedule
1
1
1
1
2
2
1
2
5
7
0
2
5
7
0
5
0
5
0
0
0
0
0
0
M
M
I
P
R
1
4
E
6
0
R
0
0
I
0
0
D
K
K
E
M
M
I
0
0
0
M
M
I
I
1
8
2
0
0
0
0
0
0
K
K
M
M
IIIIIIIIIIIIIIIIIIII
5
0
0
0
0
M
M
I
M
I
I
1
2
6
0
0
0
0
0
0
0
K
K
K
M
M
M
0
0
5
0
0
0
0
0
0
0
M
M
I
I
2
2
3
4
8
2
0
0
0
0
0
0
0
0
0
K
K
M
M
2
2
5
5
0
0
0
0
0
M
M
I
I
I
3
4
6
0
0
0
0
0
0
0
K
K
M
M
2
3
3
3
3
4
4
4
4
7
0
2
5
7
0
2
5
0
5
0
5
0
0
0
M
4
4
0
0
0
K
M
0
0
0
M
M
I
K
M
M
I
I
4
5
8
2
0
0
0
0
0
0
K
K
M
M
0
0
0
0
0
0
0
M
M
I
I
5
6
6
6
0
4
0
0
0
0
0
0
0
0
0
K
K
M
M
5
5
0
0
0
0
0
M
M
I
I
6
7
8
2
0
0
0
0
0
0
K
K
M
M
5
7
0
5
0
0
0
0
0
M
M
I
I
I
7
8
6
0
0
0
0
0
0
0
K
K
M
M
Engine mounts
Operation of all electrical equipment and switches (*)
All critical fasteners except engine
head bolts
Road test
Tab le Code:
A
- Adjust.
I
- Inspect, and if necessary, correct, adjust, clean or replace.
L
- Lubricate with specified lubricant.
R
- Replace or change.
I
I
IIIIIIIIIIIIIIIIIIII
T
X
XXXXXXXXXXXXXXXXXXXX
T T T T T
I I I I
T
- Tighten to proper torque.
X
-Perform.
D
- Disassemble, lubricate and inspect.
(*)- Also perform prior to storage or annually.
1-4 2003 Dyna Police: Maintenance
HOME
9845
1. Rear turn signal lamp
2. Tail/stop lamp
3. Battery
4. Air cleaner
5. Fuel filler cap
6. Throttle control grip
7. Front brake hand lever
8. Front brake
master cylinder/reservoir
9. Front turn signal/running lamp
10. Fork Lock
11. Rear brake pedal
12. Footrest
13. Engine oil fill plug/dipstick
14. Engine oil pan drain
15. Transmission fill plug
16. Transmission drain plug
17. Rear brake
master cylinder/reservoir
18. Electric starter motor
10
11121314
15161718
7
9
6
5
4
3
2
1
8
SIDE VIEWS 1.2
9844
3
2
1
1. Pursuit lamp
2. Headlamp
3. Speedometer/tachometer
4. Front turn signal/running lamp
5. Clutch hand lever
6. Fuel gauge
7. Ignition/light key switch
8. Horn
17
76
16
4
21
9. Enrichener
10. Fuel supply valve
11. Ignition coil
12. Accessory connector
13. Main 30 amp circuit breaker,
5
20
(under seat)
system fuses/relays (under
electrical panel cover)
19
18
8
15
14
9
10
11
12
13
14. Primary drain plug
15. Clutch inspection cover
16. Primary chain inspection cover
17. Jiffy stand
18. Footrest
19. Engine oil filter
20. Voltage regulator
21. Gear shifter lever
Figure 1-1. FXDP (Left Side View)
Figure 1-2. FXDP (Right Side View)
2003 Dyna Police: Maintenance 1-5
HOME
NOTES
1-6 2003 Dyna Police: Maintenance
T
able Of Contents
CHASSIS 2
SUBJECT PAGE NO.
2.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5 Saddlebags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.6 Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.7 Pursuit Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.8 Footboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.9 Radio Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
NOTE
This section provides information unique to the FXDP police model motorcycle. Any information not presented in this supplement can be found in the Dyna Models Service Manual.
2
HOME
SPECIFICATIONS 2.1
Table 2-1. Capacities
FUEL TANK
TOTAL
gal. liter gal. liter qt. liter oz. liter oz. liter oz. liter
5.2 19.68 1.1 4.16 3.0 2.84 24 0.71 26 0.77 11.5 0.34
FUEL TANK
RESERVE
OIL TANK
W/FILTER
TRANSMISSION
(APPROX.)
PRIMARY
CHAINCASE
FRONT
FORKS
Table 2-2. Dimensions
WHEELBASE
in. mm in. mm in. mm in. mm in. mm in. mm in. mm
63.5 1612.9 91.6 2326.6 33.5 850.9 5.5 139.7 47.5 1206.5 31.0 787.4 28.0 711.2
OVERALL
LENGTH
OVERALL
WIDTH
ROAD
CLEARANCE
OVERALL
HEIGHT
SADDLE HEIGHT
Solo Seat
Frame Mount
Seat
Table 2-3. Weight
DRY WEIGHT
lb. kg lb. kg lb. kg lb. kg
697.4 316.3 1200.0 544.3 460.0 208.6 740.0 335.7
NOTE
Gross vehicle weight rating (GVWR) (maximum allowable
loaded vehicle weight) and corresponding gross axle weight
rating (GAWR) are given on a label located on the frame
steering head.
GVWR GAWR FRONT GAWR REAR
Table 2-4. Tire Data
TIRE LOCATION SIZE
Front MT9019 Dunlop D402F PT 30 psi (206 kPa)
Rear MT90B16 Dunlop D402 PT 36 psi (248 kPa)
MANUFACTURER’S
DESIGNATION
TIRE PRESSURE (Cold)
2003 Dyna Police: Chassis 2-1
HOME
TORQUE VALUES 2.2
ITEM
Footboard mounting nuts 84-108
Footboard support mounting
bolts
Front seat mounting nut 120-216
Lower engine guard mounting
nuts
Pursuit lamp mounting bracket
screw
Radio mounting bracket screws 12-18 ft-lbs 16.3-24.4 Nm page 2-14
Rear seat mounting nuts 12-18 ft-lbs 16.3-24.4 Nm page 2-4
Saddlebag guard mounting nut 25-30 ft-lbs 33.9-40.7 Nm page 2-6
Saddlebag guard mounting
screw
Saddlebag mounting acorn nut 96-120
Shock mount stud nut 25-30 ft-lbs 33.9-40.7 Nm page 2-6
Tu rn signal mounting nut 12-15 ft-lbs 16.3-20.3 Nm page 2-6
25-35 ft-lbs 33.9-47.5 Nm page 2-12
18-22 ft-lbs 24.4-29.8 Nm page 2-12
30-35 ft-lbs 40.7-47.5 Nm page 2-10
12-18 ft-lbs 16.3-24.4 Nm page 2-6
TORQUE NOTES
in-lbs
in-lbs
in-lbs
9.5-12.2 Nm page 2-12
13.6-24.4 Nm page 2-4
10.8-13.6 Nm page 2-6
2-2 2003 Dyna Police: Chassis
HOME
VEHICLE IDENTIFICATION NUMBER 2.3
GENERAL
See Figure 2-1. A 17-digit serial number, or Vehicle Identification Number (V.I.N.), is stamped on the top of the right front
frame downtube.
A label bearing the V.I.N. number is affixed to the right front
frame downtube.
Market Designation
Manufacturer and Make
Motorcycle Type
Model Designation
Engine
Harley-Davidson
V= Twin Cam 88TM (Carbureted)
An abbreviated V.I.N. is stamped on the left side crankcase at
the base of the cylinders.
NOTE
Always give the complete 17 digit V.I.N. when ordering parts
or making inquiries about your motorcycle.
1=Domestic
5=International
1=Heavyweight
GK = FXDP
Varies: 1-8
Model Year
K=Manufactured in Kansas City, MO
3=2003
Sequential Number
1HD1GK V 1* 3 K 100000
*Varies - can be 0-9 or X
Sample V.I.N. as it appears on the steering head - 1HD1GKV103K100000
Sample abbreviated V.I.N. as it appears on the left side crankcase - GKV3100000
Figure 2-1. Vehicle Identification Number (V.I.N.)
2003 Dyna Police: Chassis 2-3
HOME
SEAT 2.4
REMOVAL
Solo Seat
1. See Figure 2-2. Remove screws (1), washers (2) and
nuts (5) from right and left side saddlebag guards.
2. Remove acorn nut (17) and washer (16).
3. Remove fuel tank screw (11) and washer (13) from rod
end (12), fuel tank mounting tabs, and frame backbone.
NOTE
If switching from solo seat to frame mounted seat, be sure to
remove seat cover (26).
Frame Mount Seat
1. See Figure 2-2. Remove screw (23) to detach seat from
fender.
2. Slide seat rearward to remove from frame.
INSTALLATION
Solo Seat
1. See Figure 2-2. Place rod ends (12) over rear fuel tank
mounting tabs.
2. Insert screw (11) with washer (13) through rod ends (12),
fuel tank mounting tabs, and frame backbone.
3. Loosely install acorn nut (17) and washer (16) on screw
(11).
4. Install screws (1), washers (2) and nuts (5) on right and
left side saddlebag guards. Tighten nuts to 12-18 ft-lbs
(16.3-24.4 Nm).
5. Tighten acorn nut (17) to 120-216
in-lbs
(13.6-24.4 Nm).
Frame Mount Seat
1. See Figure 2-2. Ver ify that seat bracket (24) is securely
fastened to bottom of seat. Position seat on frame with
bracket at rear.
2. Slide seat forward until tongue on front of seat bottom
engages bracket on frame.
3. Install screw (23) to fasten seat bracket to top of rear
fender. Tighten mounting bracket screw.
11WARNING1WARNING
After installing seat, pull upward on front of seat to be
sure it is locked in position. if seat is loose, it could shift
during vehicle operation and startle the rider, causing
loss of control and death or serious injury.
4. Pull up on seat to verify that it is locked in place.
2-4 2003 Dyna Police: Chassis
HOME
p0080a2x
23
9
8
10
24
25
22
7
6
11
5
20
12
21
19
18
17
16
13
14
15
4
2
1
3
26
1. Screw (2)
2. Washer (2)
3. Right saddlebag guard
4. Spring (2)
5. Nut (2)
6. Nut (2) @12-18 ft-lbs (16.3-24.4 Nm)
7. Washer (2)
8. Screw (2)
9. Seat, solo
10. Seat support bracket
11. Fuel tank screw
12. Rod end (2)
13. Washer
14. Washer
15. Screw @ 18-22 ft-lbs (24.4-29.8 Nm)
16. Washer
17. Acorn nut @ 120-216 in-lbs (13.6-24.4 Nm)
18. Lockwasher (2)
19. Left saddlebag guard
20. Screw (2) @ 18-22 ft-lbs (24.4-29.8 Nm)
21. Nut (2) @ 96-120 in-lbs (10.8-13.6 Nm)
22. Seat, frame mount
23. Screw, frame mount
24. Bracket, seat - frame mount
25. Screw, frame mount (2)
26. Cover seat, plastic - spring mount
Figure 2-2. Seat
2003 Dyna Police: Chassis 2-5
HOME
SADDLEBAGS 2.5
REMOVAL
1. See Figure 2-3. Remove acorn nuts (1) and washers (2)
from front, middle and rear of saddlebag (16).
2. Remove screws (15) and washers (14) from inside of
saddlebag. Note position of washers (7) between saddlebag and saddlebag guard (3, 17).
3. Remove saddlebag.
INSTALLATION
1. See Figure 2-3. Place saddlebag (16) into position inside
saddlebag guards (3, 17).
NOTE
In next step, be sure washers (7) are installed in between
saddlebag and saddlebag guard.
2. Insert screws (15) and washers (14) through saddlebag
grommets (8) and saddlebag guards.
3. Install acorn nuts (1) and washers (2) at front, middle
and rear of saddlebag (16). Tighten nuts to 96-120
(10.8-13.6 Nm).
in-lbs
SADDLEBAG GUARDS
Installation
1. See Figure 2-3. Place saddlebag mount into position on
shock mount stud (25).
2. Loosely install washer (11) screw (12), and saddlebag
mount to fender.
3. On left side, insert screw (18) and washer (19) thru left
saddlebag guard (17) and upright bracket (22). Install nut
(23) and tighten securely.
4. On right side, install washer (31) and nut (32) on screw
(27). Tighten to 25-30 ft-lbs (33.9-40.7 Nm).
5. Install nut (30) on shock mount stud (25). Tighten to 2530 ft-lbs (33.9-40.7 Nm).
6. Tighten screw (12) to 12-18 ft-lbs (16.3-24.4 Nm).
7. Install washer (10) and rubber washer (9) over threads
on turn signal (13).
8. Install turn signal thru mounting tab on saddlebag guard.
9. Install lockwasher (5) and nut (4) on turn signal. Tighten
nut to 12-15 ft-lbs (16.3-20.3 Nm).
10. Insert wire terminals into connector (6).
11. Connect turn signal connector.
12. Install pole lamp. See 8.5 POLE LAMP.
13. Install saddlebags (16).
14. Connect negative battery cable.
Removal
11WARNING1WARNING
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
1. Disconnect negative battery cable.
2. Remove saddlebag (16).
3. See 8.5 POLE LAMP. Remove pole lamp.
4. See Figure 2-3. Disconnect turn signal connector (6) [18,
19].
5. Remove wire terminals from turn signal connector.
6. Remove nut (4) and washer (5) from turn signal (13).
7. Remove turn signal (13), washer (10) and rubber washer
(9) from saddlebag guard (3, 17).
8. Remove nut (30) from shock mount stud (25).
9. On left side, remove screw (18) washer (19) and nut (23)
from upright bracket (22).
10. On right side, remove nut (32) and washer (31) from
screw (27).
11. Remove screw (12) and washer (11) from rear fender.
12. Remove saddlebag mount.
2-6 2003 Dyna Police: Chassis
HOME
p0081a2x
35
39
38
13
1
10
9
5
4
1. Acorn nut (6)
2. Washer (6)
3. Right saddlebag guard
4. Nut (2)
5. Lockwasher (2)
6. Connector (2) [18, 19]
7. Washer (4)
8. Grommet (6)
9. Rubber washer (2)
10. Washer (2)
11. Washer (2)
12. Screw (2)
13. Turn signal (2)
14. Washer (6)
15. Screw (6)
42
41
40
36
37
16
34
15
14
15
8
14
17
8
12
18
11
24
2
7
8
25
26
23
19
33
29
6
3
2
1
16. Saddlebag (2)
17. Left saddlebag guard
18. Screw
19. Washer
20. Screw @ 25-30 ft-lbs
21. Washer
22. Upright bracket
23. Nut
24. Washer (2)
25. Shock mount stud (2)
26. Shock absorber (2)
27. Screw
28. Nut @ 25-30 ft-lbs
30
7
32
(33.9-40.7 Nm)
(33.9-40.7 Nm)
27
28
2
31
22
Motorcycle
frame
20
21
1
29. Washer (2)
30. Nut (2)
31. Washer
32. Nut
33. Spacer
34. Gasket (2)
35. Saddlebag lid (2)
36. Lockwasher, internal (2)
37. Nut (2)
38. Hinge (2)
39. Rivet, blind (32)
40. Tab pull, latch (2)
41. Lock mechanism
42. Key
Figure 2-3. Saddlebags and Saddlebag Guards
2003 Dyna Police: Chassis 2-7
HOME
WINDSHIELD 2.6
REMOVAL
1. Cover the front fender with suitable material to protect
the fender paint.
2. See Figure 2-4. Loosen, but do not remove, four screws
(2) securing mounting brackets (1) to windshield clamps
(6).
3. Carefully pull windshield straight forward and up slightly,
so that mounting bracket slots (5) clear screws. Remove
windshield.
INSTALLATION
1. See Figure 2-4. Lower windshield into position, so that
right and left windshield brackets (1) are on the outboard
side of windshield clamps (6).
11WARNING1WARNING
Do not replace the screws and washers with ordinary
hardware. The screws and washers are designed to maintain a specific clamping force which other hardware does
not provide. Use of other hardware may allow the windshield to detach during riding, which can startle the rider
and cause loss of vehicle control, which could result in
death or serious injury.
2. Slide mounting brackets rearward so screws (2) on windshield clamps fit in slots in brackets. Make sure that
mounting bracket slots are positioned between flat washers (4) and windshield clamps.
NOTE
In the next step, position windshield so that it does not contact headlamp bracket, gauges, pursuit lamp brackets, handlebars, or any other part of vehicle.
3. Adjust windshield to desired angle and position. Using a
crosswise pattern, tighten all four mounting screws.
4. Turn the front forks to the full left and full right positions to
verify that movement is unrestricted.
8857
3
1
2
5
6
1. Windshield mounting bracket (2)
2. Screw (4)
3. Lockwasher (4)
4. Flat washer (4)
5. Adjustment slot
6. Windshield clamp (4)
Figure 2-4. FXDP Windshield Mounting Bracket
4
CARE
CAUTION
Do not clean Lexan® polycarbonate in hot sun or high
temperature. Powdered, abrasive or alkaline cleanser will
damage the windshield. Never scrape the windshield
with a razor blade or other sharp instruments because
permanent damage will result. Sunlight reflections off of
the inside curvature of a windshield can, at certain times
of the day, cause extreme heat build-up on motorcycle
instruments. Exercise care in parking. Park facing the
sun, place an opaque object over the instruments, or
adjust the windshield to avoid reflections. Harley-Davidson windshields are made of Lexan®, a more durable
and distortion-resistant material than other types of
motorcycle windshield material, But Lexan® still requires
attention and care to maintain.
Do not use liquid windshield “protectors” on your
●
windshield. Although they may work well on automobile safety glass, Harley-Davidson cannot ensure the
results when used on Lexan® Harley-Davidson windshields.
Do not use benzene, paint thinner, gasoline, or other
●
types of harsh cleaning agents on windshield. They
will damage the windshield surface.
Do not use benzene, paint thinner, gasoline, lubri-
●
cants or other cleaning agents on the rubber bushings. They will damage the bushing surfaces.
2-8 2003 Dyna Police: Chassis
1. Shoulder screw (7)
2. Shoulder screw (2)
3. Vertical brace (2)
4. Cushion tape (vertical) (2)
5. Outer horizontal brace
6. Windshield
7. Cushion tape (inner horizontal)
8. Inner horizontal brace
9. Mounting bracket (2)
10. Cushion tape (cut to length)
11. Acorn nut (9)
12. Screw (4)
13. Lockwasher (4)
14. Flat washer (4)
15. Screw (4)
16. Windshield clamp (complete) (4)
1
2
3
4
5
6
7
8
9
10
11
12
15
16
13
14
p0114a2x
HOME
Notes
To remove minor surface scratches, use NOVUS® No. 2
●
SCRATCH REMOVER (Part No. 99836-94).
●
If you wish to use a windshield protectant on your windshield, use Harley® Glaze Polish and Sealant (Part No.
99701-84).
●
Covering the windshield with a clean, wet cloth for
approximately 15-20 minutes before washing will make
dried bug removal easier.
1. Use mild soap and warm water to wash the windshield.
2. Wipe dry with a soft, clean towel.
Figure 2-5. Windshield and Brackets
2003 Dyna Police: Chassis 2-9
HOME
PURSUIT LAMPS 2.7
MOUNTING BRACKET REPLACEMENT
Removal
11WARNING1WARNING
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
1. Disconnect negative battery cable.
2. Remove fuel tank outer console assembly.
a. Remove the two screws securing the console above
the ignition switch.
b. Remove screw ahead of seat.
c. See Figure 2-6. Lift outer console assembly (1),
removing wiring harnesses (3) from slot (2) in front
of outer console.
3. See Figure 2-7. Disconnect pursuit lamp connector [73]
(5).
NOTE
Right pursuit lamp is connected to pin 1 of connector [73],
and left pursuit lamp is connected to pin 3.
4. Remove wire terminals from pursuit lamp connector shell
[73B] using appropriate pick tool (Snap-On TT600-3)
according to instructions in the AMP Multilock Electrical
Connector section of Appendix B in the Dyna Models
Service Manual.
5. Cut any cable straps holding pursuit lamp wiring harness
to vehicle, noting position(s) of cable strap(s) and wire
harness routing for replacement.
6. See Figure 2-8. Remove screw (7) and lamp mounting
bracket (8) with pursuit lamp assembly (1-6).
7. Repeat steps 5-6 for opposite side.
4. Install fuel tank outer console assembly.
a. See Figure 2-6. While lowering outer console
assembly (1) onto fuel tank console, push wiring
harnesses (3) into outer console slot (2).
b. Install the two screws above ignition switch and one
ahead of seat. Tighten screws securely.
5. Connect negative battery cable.
8855
3
1
1. Outer console assembly
2. Slot
3. Wiring harnesses
Figure 2-6. FXDP Console Wiring Harnesses
8856
2
1
2
3
4
Installation
1. See Figure 2-8. Mount pursuit lamp mounting bracket (8)
to lower triple clamp with screw (7). Tighten to 30-35 ftlbs (40.7-47.5 Nm). Repeat for opposite side.
2. See Figure 2-7. Route pursuit lamp wiring harnesses up
to fuel tank console. Install wire terminals into connector
[73] (5).
a. Install wire terminal from right pursuit lamp into pin 1
hole in connector shell.
b. Install wire terminal from left pursuit lamp into pin 3
hole in connector shell.
3. Connect pursuit lamp connector [73]. Secure cable with
cable straps.
2-10 2003 Dyna Police: Chassis
5
1. Right handlebar control connector [22]
2. Pursuit lamp flasher connector [69]
3. Left handlebar control connector [24]
4. Ignition switch connector [33]
5. Pursuit lamp connector [73]
Figure 2-7. FXDP Console Connectors
HOME
11WARNING1WARNING
p0083b2x
10
7
8
1
2
5
1. Pursuit lamp shell
2. Mounting ring
3. Pursuit lamp bulb
(right side - blue, left side - red)
4. Bezel ring
5. Screw (2)
6. Nut (2)
7. Screw (2)
8. Lamp mounting bracket (2)
9. Nut (2)
10. Socket housing
Figure 2-8. FXDP Pursuit Lamp Assembly
HOUSING REPLACEMENT
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
1. Disconnect negative battery cable.
2. See Removal under 2.7 PURSUIT LAMPS, MOUNTING
BRACKET REPLACEMENT. Follow instructions and
remove pursuit lamp and mounting bracket.
9
3
4
6
3. See Figure 2-8. Remove nut (6), screw (5) and bezel ring
(4).
4. Loosen screws and disconnect two wire terminals from
back of pursuit lamp bulb (3).
5. Pull GY/BK wire through plastic conduit and pursuit lamp
housing (1).
6. Remove nut (9) securing pursuit lamp housing to mounting bracket (8).
7. Install new pursuit lamp housing onto mounting bracket
and secure with nut.
8. Temporarily mount pursuit lamp housing and mounting
bracket on lower triple clamp and check that housing
points straight ahead when vehicle is upright with front
fork pointing straight. If housing is not straight, loosen nut
and readjust housing, then retighten nut.
9. Push GY/BK wire through pursuit lamp housing, mounting bracket and plastic conduit.
10. See Installation under 2.7 PURSUIT LAMPS, MOUNT-
ING BRACKET REPLACEMENT. Follow instructions
and install pursuit lamp and mounting bracket.
11. Connect two wire terminals to pursuit lamp bulb.
12. Install pursuit lamp bulb in pursuit lamp housing. Make
certain to install mounting ring (2) between bulb and
housing. Install bezel ring. Secure with nut and screw.
13. Connect negative battery cable.
BULB REPLACEMENT
11WARNING1WARNING
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
1. Disconnect negative battery cable.
2. See Figure 2-8. Remove nut (6), screw (5) and bezel ring
(4).
3. Loosen screws and disconnect two wire terminals from
back of pursuit lamp bulb (3).
4. Connect two wire terminals to new pursuit lamp bulb.
5. Install pursuit lamp bulb in pursuit lamp housing (1).
Make certain to install mounting ring (2) between bulb
and housing. Install bezel ring. Secure with nut and
screw.
6. Connect negative battery cable.
2003 Dyna Police: Chassis 2-11
HOME
FOOTBOARDS 2.8
REMOVAL
Left Side, Footboard Only
1. See Figure 2-9. Remove two screws (8) and nuts (11)
securing footboard (14) to footboard support brackets
(13 and 18).
2. Remove footboard from brackets.
Right Side, Footboard Only
1. See Figure 2-9. Remove two screws (8) and nuts (11)
securing footboard (12) to footboard support brackets
(10 and 23).
2. Remove footboard from brackets.
Left Side Footboard Assembly
1. See Figure 2-9. Remove screw (15), washer (16) and nut
(19) securing left engine guard mount (17) to left front
footboard support (18).
2. Remove bolts (6) and lockwashers (7) securing left front
footboard support (18) and left rear footboard support
(13) to frame.
Right Side Footboard Assembly
1. See Figure 2-9. Remove cotter pin (3) and washer (2)
from clevis pin (1).
2. Remove clevis pin from push rod (5).
3. Remove screw (29), washer (30) and nut (31) securing
right engine guard mount (24) to right front footboard
support (23).
4. Remove bolts (6) and lockwashers (7) securing right
front footboard support (23) and right rear footboard support (10) to frame.
INSTALLATION
Left Side, Footboard Only
1. See Figure 2-9. Mount footboard (14) to footboard support brackets (13 and 18) with two screws (8) and nuts
(11).
2. Tighten nuts to 84-108 in-lbs (9.5-12.2 Nm).
Right Side, Footboard Only
1. See Figure 2-9. Mount footboard (12) to footboard support brackets (10 and 23) with two screws (8) and nuts
(11).
2. Tighten nuts to 84-108 in-lbs (9.5-12.2 Nm).
Left Side Footboard Assembly
1. See Figure 2-9. Secure left rear footboard support (13)
and left front footboard support (18) to frame.
a. Install bolts (6) and lockwashers (7).
b. Tighten bolts to 25-35 ft-lbs (33.9-47.5 Nm).
2. Secure left engine guard mount (17) to left front footboard support.
a. Install screw (15), washer (16), and nut (19).
b. Tighten nut to 18-22 ft-lbs (24.4-29.8 Nm).
Right Side Footboard Assembly
1. See Figure 2-9. Secure right rear footboard support (10)
and right front footboard support (23) to frame.
a. Install bolts (6) and lockwashers (7).
b. Tighten bolts to 25-35 ft-lbs (33.9-47.5 Nm).
2. Secure right engine guard mount (24) to right front footboard support (23).
a. Install screw (29), washer (30), and nut (31).
b. Tighten nut to 18-22 ft-lbs (24.4-29.8 Nm).
3. Install push rod (5) over mounting hole in brake pedal
(4).
4. Push clevis pin (1) through push rod and brake pedal.
5. Install washer (2) and cotter pin (3).
2-12 2003 Dyna Police: Chassis
HOME
p0101a2x
14
12
11
10
7
7
6
9
4
27
28
5
3
2
1. Clevis pin
2. Washer
3. Cotter pin
4. Brake pedal
5. Push rod
6. Bolt (8) @ 25-35 ft-lbs (33.9-47.5 Nm)
7. Lockwasher (8)
8. Screw (4)
9. Nut
10. Right rear footboard support
11. Nut (4)@ 84-108 in-lbs (9.5-12.2 Nm)
12. Right footboard
13. Left rear footboard support
14. Left footboard
15. Screw
16. Washer
11
26
11
6
7
13
11
8
6
8
7
7
8
20
21
19
25
22
22
6
18
15
16
17
31
7
6
30
29
1
17. Left engine guard mount
18. Left front footboard support
19. Nut @ 18-22 ft-lbs (24.4-29.8 Nm)
20. Washer
21. Nut @ 30-35 ft-lbs (40.7-47.5 Nm)
22. Bushing
23. Right front footboard support
24. Right engine guard mount
25. Wave washer
26. Pivot shaft
27. Washer
28. Screw @ 30-35 ft-lbs (40-7-47.5 Nm)
29. Screw
30. Washer
31. Nut @ 18-22 ft-lbs (24.4-29.8 Nm)
23
8
24
Figure 2-9. Footboards
2003 Dyna Police: Chassis 2-13
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