Harley Davidson 2009 Dyna Models. Service manual — page 10

sm02268

Figure 2-29. Wheel Completely Laced

Table 2-10. Spoke Nipple Torque Specification

MINIMUM TORQUE

RIM TYPE

55 in-lbs (6.2 Nm)

All

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2009 Dyna Service: Chassis 2-23

2.8

WHEEL LACING: 19 INCH RIM

PROCEDURE

NOTE

If only rim is to be replaced, tape spokes together to hold pos-
ition on hub and remove spokes from rim. Install taped
hub/spoke assembly to new rim and tighten spokes. Then
remove tape and true wheels.

Divide spokes into two groups.

Inner spokes have long heads.

Outer spokes have short heads.

Lubricate spoke threads and nipple shoulders with tire
mounting lubricant.

NOTE

The primary brake disc side of the hub can be identified by
having one or two grooves cut into the disc mounting surface.

See

Figure 2-30

. Place hub on bench with the primary

brake disc side up. Insert one outer spoke (short head)
into any bottom flange hole and swing it clockwise. Insert
an inner spoke (long head) in the next hole to the left of
the outer spoke. Swing the inner spoke counterclockwise
over the outer spoke.

Find the hole in the upper flange directly above the two
spokes just inserted. This hole uses a long head inner
spoke. Insert inner spoke into the hole on the upper flange
that directly bisects the two spokes in the bottom flange.
Insert all remaining spokes in upper flange alternating the
inner and outer spokes.

After one flange side is completed flip wheel hub upside
down and repeat to finish other flange.

See

Figure 2-31

. With all forty spokes inserted in hub,

group all spokes on top flange into two bundles. Secure
each group with throttle grips to keep the spokes together.

sm02245

Outer spoke (short head)

Inner spoke (long head)

Figure 2-30. Lacing 19 Inch Wheel Hub

sm02246

Figure 2-31. Bundling Top Spokes

Swing all bottom flange outer spokes (short head) clock-
wise.

Swing the inner spokes (long head) counterclockwise,
crossing over the outer spokes (short head).

Angle all spokes as far as they will go without overlapping
the next LIKE spoke. For instance, swing an inner spoke
(long head) counter clockwise across four spokes as far
as it will go before crossing another inner spoke (laced in
a cross-four pattern).

NOTES

•

All inside spokes lay over all outside spokes.

•

See

Figure 2-32

. The valve stem hole is centered of the

rim; you do not have to worry about choosing the correct
relationship between the rim and the hub.

10. Center the rim over the hub assembly.

NOTE

It is recommended that you lace the first spoke next to the
valve stem hole. When lacing your first spoke, place spoke
nipples through several rim holes to determine the correct
lacing direction. Only one spoke will fit into the spoke nipple
correctly. When connecting the spoke to the spoke nipple,
finger tighten two to three threads.

11. Straighten any spokes that were accidentally bumped or

moved on the bottom flange.

12. Work with the bottom flange of outer spokes (short head)

first.

13. See

Figure 2-33

. Using the spoke alignment method dis-

cussed previously, locate a hole pointing downward and
outward toward the bottom flange of outer spokes (short
head).

Verify outer spoke (short head) reaches the spoke
nipple and secure spoke loosely by hand. Skip three
rim holes and repeat lacing. Follow pattern to com-
plete bottom flange outer spokes (short head).

See

Figure 2-34

. Once you have completed lacing

the bottom row of outer spokes (short head) double
check for three empty holes in between each spoke.

HOME

2-24 2009 Dyna Service: Chassis

sm02247

Figure 2-32. Valve Stem Hole Location

sm02248

Figure 2-33. Beginning Spoke: Bottom Flange Outer

sm02249

Figure 2-34. Completed Spokes: Bottom Flange Outer

14. Work with bottom flange inner spokes (long head) next.

Choose a beginning spoke closest to the valve stem hole.

See

Figure 2-35

. Each inner spoke (long head)

crosses four outer spokes (short head).

See

Figure 2-36

. Verify inner spoke reaches spoke

nipple and secure spoke loosely by hand. Skip every
other hole and repeat lacing. Follow pattern to com-
plete bottom row inner spokes (long head).

15. See

Figure 2-37

. Undo each top bundle and fan the spokes

out (in a starburst pattern) around the top rim edge.

sm02250

Figure 2-35. Beginning Spoke: Bottom Flange Inner

sm02251

Figure 2-36. Completed Spokes: Bottom Flange Inner

sm02252

Figure 2-37. Fanning Top Flange Spokes

16. See

Figure 2-38

. Point all the top flange inner spokes (long

head) clockwise one at a time leaving the outer spokes
(short head) resting on the rim.

HOME

2009 Dyna Service: Chassis 2-25

NOTE

Do not knock outer spokes (short head) under inner spokes
(long head) or they will be trapped underneath the inner row
of spokes.

17. Using the spoke alignment method discussed previously,

choose a beginning spoke closest to the valve stem hole.
Start with top flange inner spokes (long head) first.

See

Figure 2-39

. Verify spoke reaches spoke nipple

and secure spoke by hand. Follow pattern to complete
top flange inner spokes (long head).

See

Figure 2-40

. Once you have completed the top

flange of inner spokes (long head) double check for
one empty hole after every third spoke.

sm02253

Figure 2-38. Setting Top Flange Inner Spokes

sm02254

Figure 2-39. Beginning Spoke: Top Flange Inner

sm02255

Figure 2-40. Completed Spokes: Top Flange Inner

18. See

Figure 2-41

. Finish with top flange outer spokes (short

head). Point the top flange outer spokes (short head)
counterclockwise and make sure each one crosses four
inner spokes before securing it to the rim.

19. See

Figure 2-42

. Verify spoke reaches spoke nipple and

secure spoke by hand. Follow pattern to complete top
flange outer spokes (short head).

20. Tighten spoke nipples to specification listed in

Table 2-11

21. True the wheel. See

2.10 TRUING LACED WHEELS

sm02256

Figure 2-41. Beginning Spoke: Top Flange Outer

HOME

2-26 2009 Dyna Service: Chassis

sm02257

Figure 2-42. Completed Spokes: Top Flange Outer

Table 2-11. Spoke Nipple Torque Specification

MINIMUM TORQUE

RIM TYPE

55 in-lbs (6.2 Nm)

All

HOME

2009 Dyna Service: Chassis 2-27

2.9

WHEEL LACING: 21 INCH RIM

GENERAL

NOTE

Do not install incorrect spokes or spoke nipples on rim. Using
incorrect spokes can result in improper thread engagement
which could result in damage to rim, tubes or tire.

See

Figure 2-43

. Measure distance "A" to determine spoke

length. Refer to

Table 2-12

to determine correct spoke length

for type of rim used.

Table 2-12. 21 Inch Rim Spoke Length

IN.

RIM

239.3-240.3

9.42-9.46

Steel laced

241.8-242.8

9.52-9.56

Chrome aluminum profile
laced

sm02258

Figure 2-43. Measuring Spoke Length

PROCEDURE

NOTE

The primary brake disc side of the hub can be identified by
having one or two grooves cut into the disc mounting surface.

See

Figure 2-44

. Place the hub on table with primary brake

disc side down. Insert a spoke in each hole of the lower
row. Angle spokes clockwise.

Center the rim over the hub assembly with the valve stem
hole facing upward.

See

Figure 2-45

. Using any lower row spoke, place the

first spoke into the rim hole, angled to correctly accept the
spoke, on the upper half of the rim centerline.

sm03315

Figure 2-44. Spokes in Lower Row

sm003316

Figure 2-45. Lower Row into Rim

See

Figure 2-46

. Install the rest of lower row spokes in

every fourth hole.

See

Figure 2-47

. Place the first upper row spoke into the

hub as shown below. Angle the spoke counterclockwise
crossing four lower row spokes. The spoke must enter the
hole to the right of the valve stem hole.

HOME

2-28 2009 Dyna Service: Chassis

sm03317

Figure 2-46. Lower Row Spokes Spaced to Every 4th Hole

smo3318

Figure 2-47. Spokes into Hub Upper Row

See

Figure 2-48

. Install the remaining nine upper row

spokes into every fourth remaining hole above the rim
centerline. This completes spoke installation on this side.

sm03319

Figure 2-48. Upper Row Spokes Completed

See

Figure 2-49

. Turn rim over, primary brake disc side

up. Place any lower row spoke into hub. Angle spoke
clockwise and place into rim hole angled to accept it.

xx00000

Figure 2-49. Install Lower Spokes into Hub

See

Figure 2-50

. Place the remaining nine lower row

spokes, angled clockwise, into hub and rim.

HOME

2009 Dyna Service: Chassis 2-29

sm03321

Figure 2-50. Lower Row Spokes Completed

See

Figure 2-51

. Insert any upper row spoke into hub and

angle spoke counterclockwise into appropriate rim hole.
Install remaining upper row spokes.

sm03322

Figure 2-51. Upper Spoke Row Completed

10. Tighten spoke nipples to the torque specification listed in

Table 2-13

11. True wheel. See

2.10 TRUING LACED WHEELS

Table 2-13. Spoke Nipple Torque Specification

MINIMUM TORQUE

RIM TYPE

55 in-lbs (6.2 Nm)

All

HOME

2-30 2009 Dyna Service: Chassis

2.10

TRUING LACED WHEELS

GENERAL

The rim must be trued both laterally and radially. If new bear-
ings were installed, wheels may be trued with only the bearings
and center spacer installed.

LATERAL TRUING

TOOL NAME

PART NUMBER

SPOKE WRENCH

HD-94681-80

WHEEL TRUING STAND

HD-99500-80

Divide the wheel spokes into ten groups of four and mark
the center of each group with a piece of tape. The groups
should be directly across from one another and approxim-
ately 90 degrees apart. Tighten the spokes in these four
groups finger tight.

See

Figure 2-52

. Install truing arbor in wheel hub and

place wheel in WHEEL TRUING STAND (Part No. HD-
99500-80). Tighten arbor nuts so hub will turn on its
bearings.

NOTE

The primary brake disc side of the hub can be identified by
having one or two grooves cut into the disc mounting surface.

Lay a straightedge across primary brake disc mounting
surface of hub and one of the marked spoke groups.

See

Figure 2-53

and

Table 2-14

. Measure distance "A"

from the straightedge to the location as shown.

NOTES

•

Tighten or loosen spoke, one flat at a time, and recheck
measurement.

•

Always loosen the appropriate spokes before tightening
the other two. Reversing this procedure will cause the rim
to become out-of-round.

If the dimension is not correct, tighten the four spokes
accordingly. Use SPOKE WRENCH (Part No. HD-94681-
80). For example, If the measurement on the right rim
edge side is less than it should be, loosen the two spokes
attached to the hub right side and tighten the two spokes
attached to the hub left side. Turn all four spokes an equal
number of turns until offset dimension is correct.

Repeat the previous step for all ten groups on the wheel.

sm02463

Figure 2-52. Front Wheel Hub Offset Dimension

Table 2-14. Laced Wheel Hub Offset Dimensions

OFFSET (A)

WHEEL SIZE

LACED WHEEL TYPE

IN.

15.62-16.38

0.615-0.645

17"

Steel (1)

28.83-29.59

1.135-1.165

19"

38.74-39.50

1.525-1.555

21"

9.78-10.54

0.385-0.415

17"

Chrome aluminum profile (2)

22.48-23.24

0.885-0.915

19"

39.48-40.26

1.555-1.585

21"

HOME

2009 Dyna Service: Chassis 2-31

17"

19"

21"

19"

21"

sm03331

Steel rim

Chrome aluminum profile rim

Figure 2-53. Laced Wheel Hub Offset Dimensions

RADIAL TRUING

See

Figure 2-54

. Adjust truing stand gauge to the rim's

tire bead seat as shown. The rim should be trued within
0.030 in. (0.76 mm).

NOTES

•

Tighten or loosen spoke one flat at a time and recheck
measurement.

•

Always loosen the appropriate spokes before tightening
the other two. Reversing this procedure will cause the rim
to become out-of-round.

Spin the rim slowly.

If the rim contacts the gauge on or near a marked
group of spokes, loosen the spokes in the marked
group on the opposite side of the rim. Now tighten
the spokes in the group where the rim makes contact.
Loosen and tighten spokes an equal number of turns.

If the rim contacts the gauge between two marked
groups, loosen the spokes in both opposite groups
and tighten the spoke groups on the side of the rim
that makes contact.

HOME

2-32 2009 Dyna Service: Chassis

When the wheel is centered and trued, start at the valve
hole and tighten the rest of the spoke nipples one turn at
a time until they are snug.

Seat each spoke head in the hub flange using a flat nose
punch and mallet. Then check wheel trueness again and
tighten the nipples accordingly.

Spokes that are too tight can draw nipples through the rim
or distort hub flanges. Spokes that are too loose can
continue to loosen when put in service. Either condition
can adversely affect stability and handling, which could
result in death or serious injury. (00286a)

Verify spokes are tightened to specification listed in

Table 2-15

File or grind off ends of spokes protruding through nipples
to prevent puncturing tube when tire is mounted.

NOTE

After installation of front wheel, visually check the relationship
of the front wheel to the fork fender bosses. The front wheel
should be approximately centered between the bosses.

sm02464

Figure 2-54. Truing Rim Radially

Table 2-15. Spoke Nipple Torque Specification

MINIMUM TORQUE

RIM TYPE

55 in-lbs (6.2 Nm)

All

HOME

2009 Dyna Service: Chassis 2-33

2.11

CHECKING CAST WHEEL RUNOUT

GENERAL

The die-cast wheels should be checked for lateral and radial
runout before installing a new tire or tube.

LATERAL RUNOUT

See

Figure 2-55

. Install arbor in the wheel hub and place wheel

in the truing stand. To check rim lateral runout, place a gauge
rod or dial indicator near the rim bead. If lateral runout exceeds
0.030 in. (0.76 mm), replace the wheel.

sm02465

Figure 2-55. Checking Lateral Runout

RADIAL RUNOUT

TOOL NAME

PART NUMBER

WHEEL TRUING AND BALANCING
STAND

HD-99500-80

See

Figure 2-56

. Using WHEEL TRUING AND BALANCING

STAND (Part No. HD-99500-80), check for radial runout as
shown. Replace the wheel if runout exceeds 0.030 in. (0.76
mm).

sm03726

Wheel truing and balancing stand

Radial runout

Gauge rod

Figure 2-56. Checking Cast Wheel Radial Runout

HOME

2-34 2009 Dyna Service: Chassis

2.12

VEHICLE ALIGNMENT

INSPECTION

TOOL NAME

PART NUMBER

AXLE ALIGNMENT PLUG SET

HD-48856

Only a Harley-Davidson dealer should perform vehicle
alignment. Improper alignment can adversely affect sta-
bility and handling, which could result in death or serious
injury. (00060a)

Check vehicle alignment according to following proced-
ures. Incorrect alignment can adversely affect stability and
handling, which could result in death or serious injury.
(00287a)

Verify wheels are true to specifications. See

2.10 TRUING

LACED WHEELS

2.11 CHECKING CAST WHEEL

RUNOUT

Check steering head bearing adjustment and adjust if
necessary. See

2.19 STEERING HEAD

See

Figure 2-59

. To ensure accurate measurements,

obtain a piece of 1/8 in. (3.2 mm) aluminum welding rod
12.25 in. (311 mm) long. Grind one end down to a blunt
point. With a pliers, bend the rod 90° as shown. Place a
snug fitting O-ring or cable strap on the rod to act as a
slide measurement indicator.

Obtain AXLE ALIGNMENT PLUG SET (Part No. HD-
48856). See

Figure 2-57

. Insert axle alignment plugs (1,

2) into left and right ends of rear axle.

See

Figure 2-58

. With the blunt point of the alignment tool

inserted in the rear fork pilot hole, slide the O-ring along
the tool until it is aligned with the center of the alignment
plug as shown. Measure and record distance from end of
tool to O-ring. Repeat for the other side of the motorcycle.

sm03937

Alignment plug (left side)

Alignment plug (right side)

Alignment hole

Figure 2-57. Axle Alignment Plugs

sm03771

Figure 2-58. Measuring Alignment

sm02240

O-ring

2.25 in (57 mm)

10.0 in (254 mm)

Figure 2-59. Alignment Tool

See

Figure 2-60

. The measurement between the center

of the rear axle and the rear fork hole must be equal to
within 1/32 in. (0.8 mm) on both sides of the motorcycle.
If it is not, adjust the rear wheel with the axle adjusters to
accomplish the equal measurement. It is extremely
important that this adjustment be made as accurately as
possible in order to make the remaining adjustments
accurate.

Raise the rear of the motorcycle so that the rear wheel
spins freely. Do this by placing a center stand or blocking
under the frame.

See

Figure 2-61

. Remove the bolt (2) which attaches the

top stabilizer link (1) to the engine mounting bracket.

Position front wheel so brake disc is vertical using an
inclinometer. If possible, use a digital inclinometer for the
best accuracy.

HOME

2009 Dyna Service: Chassis 2-35

;sm02839

Chassis

Powertrain

Rear fork hole

Rear axle center

Figure 2-60. Adjust Axle Adjusters until A = A

NOTES

•

The exhaust system must be in place while performing
the following steps.

•

Motorcycle must be upright and level before performing
this procedure.

•

Stabilizer link should only be loosened/adjusted on end
with threads showing. Adjusting or loosening other end
will tear the isolator.

•

There should be 0.25 in. (6.4 mm) minimum clearance
between the fuel tank tunnel and the head of the left sta-
bilizer link mounting bolt.

10. Loosen jam nut (3) on stabilizer link. Adjust the stabilizer

so that the bolt removed in previous step can be reinstalled
without pushing the engine to the right or left. Tighten jam
nut.

11. Check the rear brake disc with the inclinometer to ensure

that it is parallel to the front brake disc.

12. If the rear brake disc is not parallel to the front brake disc,

adjust the top stabilizer link until the rear brake is parallel
to within 1 degree of the front brake disc's position.

13. If you cannot adjust the front and rear brake discs to within

1°, inspect the frame, front fork and/or rear fork for
damage.

To prevent damage to fuel tank and possible fire or
explosion, which could cause death or serious injury,
maintain clearance specified in service manual between
fuel tank and head of left stabilizing link mounting bolt.
(00262a)

14. If you have to adjust the top stabilizer link more than five

full turns to bring the brake discs to specification, again
inspect the frame, front fork and/or rear fork for damage.

15. Tighten the stabilizer jam nut (3).

NOTE

If the stabilizer link has been adjusted more than five full turns,
the vehicle's vibration will very likely have reached an unaccept-
able level. Adjust the vehicle's vibration level as follows:

16. Be sure the transmission is in neutral.

17. Loosen, but do not remove, ALL the mounting bolts on

the engine isolators and start the engine. Let the engine
run for approximately 5 seconds. This will center the
mounts on the frame and power train assembly.

18. Tighten isolator mounting bolts to 25 ft-lbs (33.9 Nm).

sm02469

Top stabilizer link

Bolt

Jam nut

Adjusting stud (nut)

Figure 2-61. Top Stabilizer

HOME

2-36 2009 Dyna Service: Chassis

2.13

FRONT BRAKE MASTER CYLINDER

GENERAL

Do not use parts from single caliper repair kits (9/16 inch
bore) on dual caliper models. Likewise, do not use parts
from dual caliper repair kits (11/16 inch bore) on single
caliper models. Using incorrect parts can cause brake
failure, which could result in death or serious injury.
(00278a)

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

Do not allow dirt or debris to enter the master cylinder
reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)

See

Figure 2-62

. Master cylinders designed for single disc (one

caliper) operation have a 9/16 in. (14.3 mm) bore. The bore
size is stamped on the master cylinder assembly inboard of
the handlebar clamp bracket.

sm02242

Single disc master cylinder

Bore stamp size

Figure 2-62. Bore Size

REMOVAL AND DISASSEMBLY

Drain brake fluid.

Open bleeder nipple cap on front brake caliper.

Install end of a length of clear plastic tubing over cal-
iper bleeder valve, while placing free end in a suitable
container.

Open bleeder valve about 1/2-turn.

Pump brake hand lever to drain brake fluid.

Close bleeder valve.

Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and master cylinder bore are clean and undamaged before
assembly. (00322a)

Remove bolt and two steel/rubber washers to disconnect
fitting of hydraulic brake line from master cylinder. Discard
washers.

Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and
plunger on the front stoplight switch. (00324a)

HOME

2009 Dyna Service: Chassis 2-37

sm03169

12.

Site glass

Lubricant

13.

Wiper

Screw (2)

14.

Master cylinder reservoir

Piston cap

15.

O-ring

Pivot pin

16.

Bushing

Piston

17.

Primary cup

Brake hand lever

18.

Retaining ring

Spring

19.

Handlebar clamp

Flat side

20.

Shoulder

T27 TORX screw and washer (2)

10.

21.

Gasket

Pin

22.

11.

O-ring groove

Cover

Figure 2-63. Front Brake Master Cylinder

See

Figure 2-64

. Place the cardboard insert between the

brake lever and lever bracket.

See

Figure 2-63

. Loosen both switch housing clamp

screws. Remove the two T27 TORX screws with flat

washers (9) to detach the handlebar clamp (8) from the
master cylinder reservoir (14).

Remove retaining ring (18) from pivot pin groove at bottom
of master cylinder bracket.

HOME

2-38 2009 Dyna Service: Chassis

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Harley Davidson 2009 Dyna Models. Service manual — page 10

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