Harley Davidson 2009 Dyna Models. Service manual — page 32
7.6
VOLTAGE REGULATOR
REMOVAL
NOTE
The voltage regulator cannot be repaired. Replace the unit if
it fails.
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
1.
Disconnect negative battery cable.
2.
See
. Release latches (1) from each connector.
3.
Disconnect stator connector (3) and regulator output con-
nector (2).
4.
Remove voltage regulator fasteners (4).
NOTE
If removing wiring, carefully note wire routing.
2
1
3
4
sm03723
1.
Connector latch
2.
Regulator output connector
3.
Stator connector
4.
Regulator fastener (2)
Figure 7-8. Voltage Regulator
INSTALLATION
1.
See
. Install voltage regulator into position and
install voltage regulator fasteners (4). Tighten fasteners
to 60-80 in-lbs (6.8-9.0 Nm).
2.
Connect voltage regulator output connector (2).
3.
Connect stator connector (3).
4.
Secure latches (1) on both connectors.
5.
Connect negative battery cable.
7-8 2009 Dyna Service: Electrical
7.7
FUSES AND RELAYS
GENERAL
The fuse block is under the electrical caddy cover. The block
contains eight (nine on HDI models) 15 ampere replaceable
fuses. All models utilize a 40 ampere main fuse as well as two
spare 15 ampere fuses. The fuse block also contains the starter
relay and system relay.
REMOVAL AND INSTALLATION
Relays
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
1.
Disconnect negative battery cable..
2.
. Firmly grasp both sides of electrical caddy
cover and pull outward to remove.
3.
See
. Remove starter relay (1) or system relay
(2) as needed: grasp body of relay and pull straight away
from fuse block.
4.
Plug in new relay.
5.
Grasp caddy cover by both sides and push firmly into
electrical caddy.
6.
Connect negative battery cable.
Fuses
1.
Make sure ignition switch is turned OFF.
2.
. Firmly grasp both sides of electrical caddy
cover and pull outward to remove.
3.
Remove suspect fuse.
4.
Plug in new fuse.
5.
Grasp caddy cover by both sides and push firmly into
electrical caddy.
sm02029
Figure 7-9. Electrical Caddy Cover
3
2
1
4
7
8
9
10
11
12
13
14
15
5
6
sm02546
1.
Start relay
2.
System relay
3.
Main fuse (maxi-fuse) (40A)
4.
ECM fuse (15A)
5.
Fuel pump fuse (15A)
6.
Engine control fuse (HDI models only) (15A)
7.
Spare fuse (15A)
8.
Spare fuse (15A)
9.
Customer accessory fuse (15A)
10. P and A ignition fuse (15A)
11. Battery fuse (15A)
12. Accessories fuse (15A)
13. Instruments fuse (15A)
14. Ignition fuse (15A)
15. Lights fuse (15A)
Figure 7-10. Fuses and Relays
2009 Dyna Service: Electrical 7-9
7.8
IGNITION SWITCH/FORK LOCK
GENERAL
The automatic-on headlamp feature provides increased
visibility of the rider to other motorists. Be sure headlamp
is on at all times. Poor visibility of rider to other motorists
can result in death or serious injury. (00030b)
Dyna model ignition/light/key switches are non-repairable. If a
switch is damaged, it must be replaced. Key switch functions
and locations are listed in
NOTES
•
FXD, FXDL and FXDB models have a combination ignition
switch/ fork lock. To replace the ignition switch/ fork lock,
see
7.8 IGNITION SWITCH/FORK LOCK, FXD, FXDL,
•
To replace the fork lock only on FXDF and FXDC models,
see
7.8 IGNITION SWITCH/FORK LOCK, FXD, FXDL,
•
To replace the ignition switch on FXDF and FXDC models,
see
7.8 IGNITION SWITCH/FORK LOCK, FXDC, FXDF
.
FXD, FXDL, FXDB MODELS
TOOL NAME
PART NUMBER
IGNITION SWITCH/FORK LOCK
WRENCH
HD-47853
Removal
1.
Remove seat.
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)
2.
Purge the fuel supply line of high pressure gasoline.
a.
See
. Remove the fuel pump fuse located
in the electrical caddy.
b.
Start the engine and allow the vehicle to run.
c.
When the engine stalls, operate the starter for 3
seconds to remove any remaining fuel from the fuel
lines.
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
3.
Disconnect negative battery cable.
4.
Remove instrument console.
a.
For FXDC, FXDF models, see
b.
For FXDL, FXDB models, see
.
c.
For FXD models, see
5.
Disconnect console wiring.
6.
Gain access to the ignition switch fork/lock wiring by
removing fuel tank hardware and fuel line. Carefully pivot
tank upward and prop in position. See
7.
. Remove harness shield (1) by pushing
both tabs of shield in at the same time.
8.
While leaving harness connectors engaged, pull harness
connectors from inside frame.
9.
Remove decal (6).
10. See
. Place IGNITION SWITCH/FORK LOCK
WRENCH (Part No. HD-47853) (1) on face nut (2). Turn
ignition switch/fork lock wrench clockwise to loosen face
nut. Turn face nut clockwise until it bottoms on ignition
switch/fork lock.
11. See
. Rotate ignition switch/fork lock (2)
clockwise to allow fork lock boss (3) to clear fork lock cavity
(4). Remove ignition switch/fork lock from frame.
12. On FXD, FXDL, FXDB models, remove connector from
ignition switch/fork lock.
sm02188
Figure 7-11. Fuel Pump Fuse
7-10 2009 Dyna Service: Electrical
1
2
4
3
5
6
sm02547
1.
Harness shield
2.
Grommet (2)
3.
Fork lock (FXDC, FXDF models)
4.
Ignition switch/fork lock (FXD, FXDL, FXDB
models)
5.
Face nut
6.
Decal
Figure 7-12. Harness Shield
2
1
sm02548
1.
Ignition switch/fork lock wrench (HD-47853)
2.
Face nut
Figure 7-13. Fork Lock/Ignition Switch Wrench
4
3
2
1
sm02549
1.
Face nut
2.
Ignition switch/fork lock
3.
Fork lock boss
4.
Fork lock boss cavity
Figure 7-14. Fork Lock/Ignition Switch
Installation
1.
. Apply a drop of LOCTITE THREAD-
LOCKER 243 (blue) to threads of face nut (1).
2.
Install face nut on ignition switch/fork lock (2). Turn face
nut clockwise until it bottoms on ignition switch/fork lock.
3.
On FXD, FXDL, FXDB models, install connector on ignition
switch/fork lock.
4.
With fork lock boss (3) facing front of vehicle, install ignition
switch/fork lock into frame.
5.
See
. Align flats on ignition switch/fork lock
with slots (2) in fork lock cavity (1).
NOTE
In next step, setting fork lock in the "locked" position may ease
installation.
6.
. Rotate ignition switch/fork lock until fork
lock boss (3) engages fork lock boss cavity (4).
7.
To verify proper fork lock positioning, hold ignition
switch/fork lock as far forward as possible in frame while
tightening.
2009 Dyna Service: Electrical 7-11
8.
See
. Using IGNITION SWITCH/FORK LOCK
WRENCH (Part No. HD-47853), turn face nut counter-
clockwise until tight.
9.
. Install decal (6).
10. Remove and save key code tag (on key ring with two
keys). Key code is not marked on keys.
11. Push wiring harness into frame. Install harness shield by
installing tab of shield into frame first then engaging tabs
in holes in frame.
12. Place fuel tank into position and tighten hardware. Connect
fuel line. See
13. Install console wiring.
14. Install instrument console.
a.
For FXDC, FXDF models, see
.
b.
For FXDL, FXDB models, see
c.
For FXD models, see
15. Connect negative battery cable.
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
16. Install seat.
17. Refer to
. Test vehicle and fork lock operation.
2
1
sm02550
1.
Fork lock cavity
2.
Slot
Figure 7-15. Fork Lock/Ignition Switch Cavity
Table 7-6. Key Switch Functions and Positions: 2009 Dyna Models
FUNCTION
SWITCH
POSITION
LOCATION AND OPERATION
MODEL
Ignition, lamps and accessories are off.
OFF
On the right front of the motorcycle on the
steering head.
FXD, FXDL,
FXDB
Accessories and hazard warning flasher can be
turned on. Instrument lamps are on. Brake lamp
and horn can be activated. Key may be removed
except on international models.
ACC*
To unlock the switch and the front fork, push
the key in and turn it counterclockwise.
HDI: Press the lever/key (international) in and
turn it clockwise to the OFF position. Be sure
to push key in to move key to either position.
Ignition, lamps and accessories are on.
IGNITION*
Fork Lock: To lock the fork, move the fork to
the full left position. Push down on key and turn
it to the right, clockwise, to the closed lock icon.
Remove the key.
Ignition, lamps and accessories are off.
OFF
Switch is on fuel tank instrument panel.
FXDC, FXDF
FXDF switch is locked or unlocked by lifting
switch cover, inserting key and turning key
counterclockwise to lock or clockwise to unlock.
Key may be removed in any position.
Accessories are on. Hazard warning flashers
can be operated. Instrument lamps are on.
Brake lamp and horn can be activated.
ACC*
Ignition, lamps and accessories are on.
IGNITION*
Fork Lock: The fork lock is on the right front of
the motorcycle on the steering head. Insert key
and press to turn the lock to the closed lock
icon. Remove the key.
To unlock the fork lock, insert key and press to
turn the lock to the open lock icon. Remove the
key.
*International models have an additional function - position lamp and tail lamp are also on.
7-12 2009 Dyna Service: Electrical
FXDC, FXDF MODELS (IGNITION SWITCH
ONLY)
1.
Remove seat.
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2.
Disconnect negative battery cable.
3.
. Remove fasteners (1) from instrument
panel (2) and remove panel. Note position and color of
the switch wire connectors. Disconnect wires.
4.
Remove mounting screws (4). Replace switch (3).
5.
Reconnect switch wire connectors in their original posi-
tions.
6.
Install instrument panel with fasteners. Tighten fasteners
to 18-24 in-lbs (2.0-2.7 Nm).
7.
Connect negative battery cable.
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
8.
Install seat.
9.
Refer to
. Test vehicle operation.
2
3
4
1
sm02551
1.
Fastener (2)
2.
Panel
3.
Ignition switch
4.
Mounting screws (4)
Figure 7-16. Ignition Switch: FXDC, FXDF
2009 Dyna Service: Electrical 7-13
7.9
BATTERY TRAY AND BATTERY CABLES
BATTERY TRAY
Removal
1.
Remove battery.
2.
See
. Remove two top screws and washers
(1).
3.
Remove screw and washer (2).
4.
Guide battery cables out through holes in rear of battery
tray (3) and remove tray.
Installation
1.
Guide battery cables through holes in rear of battery tray
(3) and place tray in position.
2.
. Place battery cables in recesses at upper
corners of battery tray.
3.
. Install screws and washers (1, 2). Tighten
screws to 96-120 in-lbs (10.8-13.6 Nm).
1
3
2
sm02556
1.
Screws and washers (2)
2.
Screw and washer
3.
Battery tray
Figure 7-17. Battery Tray
7-14 2009 Dyna Service: Electrical
BATTERY CABLES
Routing
1.
Install battery.
Connect the cables to the correct battery terminals. Failure
to do so could result in damage to the motorcycle electrical
system. (00215a)
2.
Route positive cable from battery positive terminal through
upper front hole in battery tray. Continue to route positive
battery cable to starter post on right side of chassis.
Be sure rubber boot covers starter solenoid terminal
connected to positive (+) battery cable. An uncovered
terminal can short and cause sparks, which could result
in a battery explosion and death or serious injury. (00463c)
Do not over-tighten bolts on battery terminals. Use
recommended torque values. Over-tightening battery ter-
minal bolts could result in damage to battery terminals.
(00216a)
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)
3.
Install positive cable to starter post with nut. Orient terminal
so cable faces away (towards left side of motorcycle).
a.
Tighten nut to 65-85 in-lbs (7.3-9.6 Nm).
b.
Cover nut with protective rubber boot.
4.
. Route negative battery cable toward left
side of motorcycle and then down to transmission ground
stud.
5.
Install negative battery cable on transmission ground stud.
Tighten to 13-20 ft-lbs (17.6-27.1 Nm).
3
2
1
sm02557
1.
Negative battery cable
2.
Groove
3.
Positive battery cable
Figure 7-18. Battery Cables
2009 Dyna Service: Electrical 7-15
7.10
STARTER
GENERAL
The starter is made up of a field coil assembly, solenoid
assembly and drive assembly. The repair instructions contained
in this section are divided into three major service areas
accordingly.
NOTE
For troubleshooting and diagnostic information, see the
ELECTRICAL DIAGNOSTIC MANUAL for this motorcycle.
Wiring Diagrams
The starting circuit wiring diagram contains information about
wiring configuration. For additional information, see the
ELECTRICAL DIAGNOSTIC MANUAL for this motorcycle.
Paint Touch-Up
On painted starters, paint is applied to the starter after
assembly. Many of the procedures in this section involve dis-
assembly of several painted joints. When servicing the starter,
paint damage or flaking may occur in the area of these joints.
Any damaged paint should be touched up after assembly prior
to installation using the appropriate touch up paint. Follow the
directions provided with the paint. Paint flaking does not require
the starter to be replaced.
REMOVAL
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
1.
Remove battery. See
2.
Remove battery tray. See
3.
. Remove starter cover fastener (1) and
starter cover (2) from starter.
4.
Disconnect starter wiring:
a.
Remove protective boot (4).
b.
Remove nut with washer (metric).
c.
Remove positive battery cable ring terminal.
d.
Detach solenoid wire (5).
5.
Remove both starter mounting bolts and washers (3).
6.
Remove starter from right side of motorcycle.
7.
Discard starter housing O-ring.
8.
Before disassembling the starter, perform diagnostics.
FIELD COIL ASSEMBLY
Disassembly
1.
Remove allen head screw to release chrome end cover,
if equipped.
2.
Remove two Keps nuts to release end cover bracket from
thru bolts, if equipped.
3.
Pull up rubber boot and remove hex nut with captive
lockwasher to release field wire ring terminal from post on
solenoid housing.
4.
Using a 5/16 inch socket, loosen two thru bolts to release
field coil from solenoid housing.
5.
Pull field coil with end cap from solenoid housing.
6.
Remove armature from field coil. Separating end cap and
field coil flanges will facilitate removal.
7.
Placing field coil on wooden block to prevent damage, use
impact driver to remove two Phillips screws with captive
washers from end cap. Discard screws.
8.
Remove end cap from field coil.
9.
Locate the two brushes attached to the field coil winding.
Pushing on inboard side of one brush, grasp free end of
brush spring on outboard side with the hooked end of a
suitable pick. Raise end of brush spring only as far as
necessary to free brush from brush holder. Repeat step
to release second brush and then remove brush holder
from field coil.
Inspection
1.
For testing procedures, see the ELECTRICAL DIA-
GNOSTIC MANUAL.
2.
Inspect two o-rings in field coil bore for cuts, tears or signs
of deterioration.
3.
Place armature in lathe or truing stand and check runout
of commutator. Commutators with more than 0.015 in.
(0.38 mm) of runout should be replaced or machined on
a lathe. Commutators should be replaced when diameter
is less than 1.141 in. (29.98 mm).
4.
Check depth of mica on commutator. If undercut is less
than 0.008 in. (0.20 mm), use an undercutting machine to
undercut the mica to 1/32 in. (0.79 mm) deep. The slots
should then be cleaned to remove any dirt or copper dust.
NOTES
•
See
. If an undercutting machine is not avail-
able, undercutting can be done satisfactorily using a thin
hacksaw blade. After undercutting, lightly sand the arma-
ture with crocus cloth to remove any burrs.
•
Do not use sandpaper or emery cloth on commutator. The
abrasive grit may remain on commutator segments and
could cause excessive brush wear.
5.
Inspect armature roller bearings. Bearings must rotate
freely without drag or sticking. Replace the bearings if
pitted or grooved.
6.
Replace brush springs if bent or distorted.
7-16 2009 Dyna Service: Electrical
5
6
1
1
2
2
3
4
7
7
sm02320
1.
Segments
2.
Mica
3.
Incorrect (Mica must not be left with a thin edge next to segments)
4.
Correct (Mica must be cut away clean between segments)
5.
Starting groove in mica with 3 cornered file
6.
Undercutting mica with piece of hacksaw blade
7.
Commutator
Figure 7-19. Undercutting Mica Separators
Assembly
1.
Attach brush holder to field coil. Locate the two brushes
attached to the field coil winding. Catch free end of brush
spring with the hooked end of a suitable pick. Raise end
of brush spring only as far as necessary to install brush
into brush holder. Repeat step to install second brush.
2.
Retract all four brushes for armature installation. For good
results, obtain four paper clips. Bend free end of each
paper clip outward approximately 90°. Then, pushing on
inboard side of brush, insert straight end of paper clip
between outboard side of brush and inboard side of brush
spring. Properly installed, the paper clip contacts the
framework of the brush holder to keep spring pressure off
the brush. Repeat step on remaining three brushes as
shown in
.
3.
Install armature in solenoid housing so that larger bearing
on splined end seats in counterbore. Lubricate armature
bearings with high temperature grease, such as LUBRI-
PLATE 110, before installation.
4.
Mate field coil and solenoid housings. For proper
assembly, a nub on the field coil housing flange must
engage the slot on solenoid housing flange closest to the
short (field wire) post on the solenoid housing.
5.
Carefully place brush holder over armature. If additional
clearance is needed, use a small flat blade screwdriver to
gently push back the brushes slightly.
6.
When the brush holder is centered over the armature,
remove four paper clips to release brush springs. Verify
that ends of brush springs make proper contact with brush
sides.
2009 Dyna Service: Electrical 7-17
7.
Install end cap aligning holes in cap with those in brush
holder. Start two new Phillips screws with captive washers.
Alternately tighten Phillips screws until snug.
8.
Install thru bolts to fasten field coil to solenoid housing.
Using a 5/16 inch socket, alternately tighten thru bolts to
39-65 in-lbs (4.4-7.3 Nm).
9.
Attach field wire ring terminal to short post on solenoid
housing and install hex nut with captive lockwasher.
Tighten hex nut to 70-90 in-lbs (7.9-10.2 Nm). Cover field
wire ring terminal with rubber boot.
10. Install end cover bracket onto threaded end of thru bolts,
if equipped. For proper orientation, be sure that the longest
end of the bracket (before the bend) is on the field wire
side. Install two Keps nuts and alternately tighten until
snug.
11. Install allen head screw to fasten chrome end cover to end
cover bracket, if equipped. Tighten screw to 90-110 in-lbs
(10.2-12.4 Nm).
sm03714
Figure 7-20. Install Paper Clips to Hold Brush Springs
DRIVE ASSEMBLY
Disassembly
1.
Remove field coil. See
2.
Pull field coil with end cap from solenoid housing. Hold
end cap to field coil to avoid pulling armature out of brush
holder. If armature is pulled from brush holder, further
disassembly is required.
3.
Using a 9 mm socket, remove two hex screws with Phillips
recess to release drive housing from solenoid housing.
4.
Use a rubber mallet to separate drive and solenoid hous-
ings, if necessary.
5.
Remove idler gear from bearing cage in drive housing.
Remove bearing cage with five steel cylinders from shaft
in drive housing.
6.
Push on end of drive shaft to remove starter clutch
assembly from drive housing.
7.
Compressing internal springs, remove snap ring from
groove at end of drive shaft.
8.
Remove cup, pinion gear, short spring and spring seat
from splined end of drive shaft.
9.
Push on splined end of drive shaft to remove from starter
clutch bore.
10. Remove long spring from drive shaft. Remove steel ball
from drive shaft bore.
11. Remove return spring from solenoid plunger shaft.
Inspection
1.
Inspect two o-rings in drive housing bore for cuts, tears or
signs of deterioration.
2.
Replace springs if kinked, elongated or distorted.
3.
Inspect pinion gear and drive shaft gear. Replace if pitted,
scored, rounded, cracked, chipped or worn.
4.
Inspect roller bearings. Bearings must rotate freely without
drag or sticking. Replace the bearings if pitted or grooved.
5.
Inspect the steel ball for wear, pitting, surface breakdown
or other damage.
6.
Replace snap ring if bent or distorted.
Assembly
1.
Install long spring onto drive shaft. Install steel ball in drive
shaft bore. Insert splined end of drive shaft into starter
clutch bore (gear side).
2.
Insert a deepwell socket into starter clutch bore and stand
assembly upright on work bench with the socket side
down.
3.
Push down on starter clutch, so that installed socket
pushes against the drive shaft gear to compress the spring.
Holding assembly with spring compressed, install spring
seat, short spring, pinion gear and cup on splined end of
drive shaft. Be sure that the collar on the pinion gear and
the concave side of the cup both face the splined end of
the drive shaft.
4.
While pushing down to simultaneously compress both the
long and short springs installed, install snap ring in groove
at splined end of drive shaft. Verify that snap ring is fully
seated in the groove and that it resides in concave portion
of cup when spring tension is released.
5.
Remove deepwell socket from starter clutch bore.
6.
Install bearing cage with five steel cylinders onto shaft in
drive housing. Be sure that all five steel cylinders are
installed in grooves of bearing cage. Install idler gear over
bearing cage. Lubricate parts with high temperature
grease, such as LUBRIPLATE 110, during assembly.
7.
Install starter clutch assembly in drive housing seating the
larger bearing in the counterbore. Lubricate bearings with
LUBRIPLATE 110 before installation.
8.
Apply a light film of Lubriplate 110 to solenoid plunger
shaft. Install return spring on solenoid plunger shaft.
9.
Mate the solenoid and drive housings and install two hex
screws using a 9 mm socket. Alternately tighten hex
screws until snug.
7-18 2009 Dyna Service: Electrical
10. Lubricate armature bearing with LUBRIPLATE 110.
Seating armature bearing in counterbore, mate field coil
and solenoid housings. For proper assembly, a nub on
the field coil housing flange must engage the slot on
solenoid housing flange closest to the short (field wire)
post on the solenoid housing.
11. Install field coil. See
7.10 STARTER, Field Coil Assembly
.
INSTALLATION
1.
Examine two split ring dowel bushings in inner primary
housing where starter motor assembly mounts. If dowel
bushings are loose, remove bushings and pry open slightly
to provide an interference fit in primary housing. Reinstall
bushings into primary housing.
2.
Install new starter housing O-ring.
3.
Install starter from right side of motorcycle.
4.
See
. Apply a drop of LOCTITE THREAD-
LOCKER 243 (blue) to threads of starter mounting bolts
(3).
5.
Install the two starter mounting bolts (3) and washers.
Tighten to 25-27 ft-lbs (33.9-36.6 Nm).
Be sure rubber boot covers starter solenoid terminal
connected to positive (+) battery cable. An uncovered
terminal can short and cause sparks, which could result
in a battery explosion and death or serious injury. (00463c)
6.
. Attach positive battery cable, and
solenoid wire (5). Tighten nut (metric) to 65-85 in-lbs (7.3-
9.6 Nm). Place protective boot (4) securely over terminal.
7.
Attach starter cover (2) using fastener (1).
8.
Install battery tray. See
.
9.
Install battery. See
4
1
3
2
5
3
sm03330
1.
Starter cover fastener*
2.
Starter cover*
3.
Starter mounting fasteners
4.
Protective boot
5.
Solenoid wire
Figure 7-21. Starter
NOTE
Items marked with an asterisk (*) not used on all models.
2009 Dyna Service: Electrical 7-19
7.11
STARTER SOLENOID
SOLENOID ASSEMBLY
Disassembly
1.
Remove field coil. See
2.
Pull field coil with end cap from solenoid housing. Hold
end cap to field coil to avoid pulling armature out of brush
holder. If armature is pulled from brush holder, further
disassembly is required.
3.
Using a 9 mm socket, remove two hex screws with Phillips
recess to release solenoid housing from drive housing.
4.
Use a rubber mallet to separate solenoid and drive hous-
ings, if necessary.
5.
Remove return spring from solenoid plunger shaft.
Assembly
1.
Install return spring on solenoid plunger shaft.
2.
Mate the solenoid and drive housings and install two hex
screws using a 9 mm socket. Alternately tighten hex
screws until snug.
3.
Lubricate armature bearing with LUBRIPLATE 110.
Seating armature bearing in counterbore, mate field coil
and solenoid housings. For proper assembly, a nub on
the field coil housing flange must engage the slot on
solenoid housing flange closest to the short (field wire)
post on the solenoid housing.
4.
Install field coil. See
7.10 STARTER, Field Coil Assembly
.
SOLENOID PLUNGER
Disassembly
1.
Remove three hex screws to release solenoid cover.
2.
Remove rubber gasket from solenoid cover flange.
3.
Remove plunger and return spring.
Assembly
1.
Apply a light film of LUBRIPLATE 110 to plunger shaft and
install return spring. Install plunger in solenoid.
2.
Install new rubber gasket on solenoid cover flange.
3.
Install three hex screws to secure solenoid cover. Altern-
ately tighten hex screws until snug.
SOLENOID CONTACTS
Disassembly
1.
Remove three hex screws to release solenoid cover.
2.
Remove rubber gasket from solenoid cover flange.
3.
Remove plunger and return spring.
4.
Obtain Solenoid Contact Repair Kit.
5.
Disassemble short post (field coil):
a.
See
. Remove hex nut from post, if still
installed. Remove jam nut, wave washer, round
bushing and o-ring from post.
b.
On inside of solenoid housing, remove post bolt, hold-
in terminal, contact plate and square bushing.
6.
Disassemble long post (battery):
a.
Remove hex nut from post, if still installed. Remove
jam nut, wave washer, round bushing and o-ring from
post.
b.
On inside of solenoid housing, remove post bolt,
contact plate, square bushing and paper insulator
washer.
7-20 2009 Dyna Service: Electrical
1
2
3
4
5
6
7
8
9
10
11
12
16
13
14
15
9
10
11
12
8
13
14
17
15
sm03715
10.
1.
Wave washer
Solenoid
2.
11.
Hex screw
O-ring
12.
3.
Round bushing
Solenoid cover
4.
13.
Rubber gasket
Square bushing
14.
5.
Contact plate
Plunger
6.
15.
Return spring
Post bolt
16.
7.
Paper insulator washer
Rubber boot
8.
17.
Hex nut
Hold-in terminal
9.
Jam nut
Figure 7-22. Solenoid Assembly
Assembly
1.
Assemble short post (field coil):
a.
From inside solenoid housing, insert sleeve on square
bushing into hole in solenoid housing.
b.
With the foot inboard against solenoid winding, align
hole in contact plate with hole in square bushing.
c.
Slide short post bolt through holes in hold-in terminal,
contact plate, square bushing and solenoid housing.
d.
At outside of solenoid housing, install round bushing,
O-ring and wave washer onto end of post. Install jam
nut, but do not tighten.
2.
Assemble long post (battery):
a.
On inside of solenoid housing, align hole in paper
insulator washer with hole in solenoid housing. Insert
sleeve on square bushing into holes.
b.
With the foot inboard against solenoid winding, align
hole in contact plate with hole in square bushing.
c.
Slide long post bolt through holes in contact plate,
square bushing, paper insulator washer and solenoid
housing.
d.
At outside of solenoid housing, install round bushing,
o-ring and wave washer onto end of post. Verify that
index pin on round bushing engages blind hole in
solenoid housing. Install jam nut, but do not tighten.
3.
Apply a light film of LUBRIPLATE 110 to plunger shaft and
install return spring. Install plunger in solenoid.
2009 Dyna Service: Electrical 7-21
4.
While depressing plunger, alternately tighten jam nuts to
65-80 in-lbs (7.3-9.0 Nm). Verify that contact plates have
not rotated out of alignment with plunger.
5.
Install new rubber gasket on solenoid cover flange.
6.
Install three hex screws to secure solenoid cover. Altern-
ately tighten hex screws until snug.
7-22 2009 Dyna Service: Electrical
7.12
HEADLAMP
GENERAL
When replacement is required, use only the specified
sealed beam unit or bulb, available from a Harley-Davidson
dealer. An improper wattage sealed beam or bulb, can
cause charging system problems. (00209a)
If either headlamp bulb filament burns out, the bulb must be
discarded and a new bulb installed. Use only direct replace-
ment bulbs as specified in the Parts Catalogs and
.
BULB REMOVAL
Never touch the quartz bulb. Fingerprints will etch the
glass and decrease bulb life. Grab the bulb with paper or
a clean, dry cloth. Failure to do so could result in bulb
damage. (00210a)
Single Bulb Headlamp
1.
See
. Loosen trim ring clamp screw (19) and
nut (18). Remove trim ring (17).
2.
Disconnect headlamp connector (2) from bulb (6) prongs.
3.
Remove rubber boot (4) from back of headlamp lens (16).
4.
. Squeeze wire retaining clip ends to
unhook them from notches in headlamp assembly.
Handle bulb carefully and wear eye protection. Bulb con-
tains gas under pressure, which, if not handled carefully,
could cause serious eye injury. (00062b)
5.
Pivot wire retaining clip away from bulb. Remove bulb from
headlamp assembly.
NOTE
When installing new bulb, be sure connector contacts are clean
to ensure good electrical contact.
sm02558
Figure 7-23. Wire Retaining Clip
2009 Dyna Service: Electrical 7-23
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