Harley Davidson 2009 Dyna Models. Service manual — page 27
2009 DYNA WIRING DIAGRAMS
Refer to the table below for wiring diagram information.
Wiring Diagram List
LOCATION
DIAGRAM
Figure B-2
Main Harness (1 of 3): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)
Figure B-3
Main Harness (2 of 3): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)
Figure B-4
Main Harness (3 of 3): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)
Figure B-5
Charging Circuit: 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)
Figure B-6
Starting Circuit: 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)
Figure B-7
Ignition Circuit: 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)
Figure B-8
Lights (1 of 2): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)
Figure B-9
Lights (2 of 2): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)
Figure B-10
Horn and Instruments Circuit: 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)
Figure B-11
Security (1 of 2): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)
Figure B-12
Security (2 of 2): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)
Figure B-13
Main Harness (1 of 3): 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)
Figure B-14
Main Harness (2 of 3): 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)
Figure B-15
Main Harness (3 of 3): 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)
Figure B-16
Charging Circuit: 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)
Figure B-17
Starting Circuit: 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)
Figure B-18
Ignition Circuit: 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)
Figure B-19
Lights (1 of 2): 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)
Figure B-20
Lights (2 of 2): 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)
Figure B-21
Horn and Instruments Circuit: 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)
Figure B-22
Security Circuit (1 of 2): 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)
Figure B-23
Security Circuit (2 of 2): 2009 All Dyna DOM. and INT. Models (FXDC, FXDF)
B-4 2009 Dyna Service: Appendix B Wiring
IGN - 15A
INSTR - 15A
Lights - 15A
ACCY - 15A
[31RA]
[91A]
(Gray)
Data
Link
Connector
Ignition
Switch
To
Headlamp
See Sheet 3
[7A]
[33A]
[33B]
[64B]
To
Front
Turn
Signals
See Sheet 3
[38A]
To Rear
Lighting
Harness
See
Sheet 3
Fuel Pump
& Sender
Assembly
See Sheet 2
Intake Air
Temp Sensor
Throttle
Position
Sensor
Engine
Temp
Sensor
Front
Injector
Rear
Injector
Idle Air
Control
System
Relay
Battery - 15A
Fuel Pump - 15A
ECM - 15A
T
ur
n
Signal
&
Secur
ity
Module
TSM/TSSM/HFSM
To
Left Hand
Controls
(Gray)
See Sheet 3
To
Right Hand
Controls
(Black)
See Sheet 3
Security
Siren
To Instrument
Assembly
See Sheet 3
Start
Relay
(Gray)
Fuel
Gauge
See
Sheet 2
(Optional)
2
1
4
3
6
5
8
7
10
9
12
11
2
1
4
3
6
5
8
7
10
9
12
11
B
A
C
B
A
C
[62B]
[90A]
Vehicle
Speed
Sensor
R/
Starter
Solenoid
[20A]
[117B]
[141B]
[90B]
[88A]
[88B]
Power
Signal
Ground
[30B]
[30A]
[84B]
[84A]
[85B]
[85A]
[128B]
Ignition
Coil
P & A
Battery
[160B]
P&A IGN - 15A
[5]
40 Amp
MAXIFUSE
A
B
See Figure B-5
For Further
Connections
To Charging
System
[GND1]
Rear Ground
Stud Under
Electrical Center
Rear
Stop Lamp
Switch
[121]
1 2 3 4 5 6
1 2 3 4 5 6 7 8
A B
A B
1
4
3
2
5 6
C
B
A
C
B
A
Manifold
Absolute
Pressure
Sensor
2
3
4
R
BK
Crank Position Sensor
3
2
1
4
2
1
2
1
B
A
B
A
B
A
B
A
Battery
System Relay
Active Exhaust Feedback (HDI)
Serial Data
Engine Temperature
Intake Air Temperature
Oxygen Sensor (A)
Jiffy Stand Sensor (HDI)
Ground
Coil Rear
Crank POS Sensor (-)
Switched Power
5V Sensor Power
Idle Air Control (A) Hi
Idle Air Control (B) Low
Injector Rear
Active Exhaust (HDI)
Injector Front
Active Intake Solenoid (HDI)
Oxygen Sensor (B)
Throttle POS Sensor Input
Map Sensor Input
5V Sensor Ground
Ion Sense
Ground
Coil Front
Crank POS Sensor (+)
Battery
Vehicle Speed Sensor Input
Idle Air Control (A) Low
Idle Air Control (B) Hi
Ignition
Serial Data
Neutral Switch
Left Turn Feed
Right Turn Feed
Right Turn Switch Input
Left Turn Switch Input
Start Relay Control
Clutch Switch
Alarm Signal
Ground
1 2
4
A
B
C
D
A
B
C
D
Power
Ion Sense
Coil Rear
Coil Front
1 2
1 2
B A
B A
1
A B C D
A B C D
ECM
1
4
5
6
7
8
9
10
11
12
13
14
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
33
35
36
1
4
5
6
7
8
9
10
11
12
13
14
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
33
35
36
A
B
C
A B C D
12
1 2 3 4 5 6 7 8 9 10
[131]
Neutral
Switch
[120]
[62]
[64]
Oil Pressure
Sending Unit
[31LA]
1
2
3
3
2
1
A
B
C
[122]
Horn
Customer
Accessory
Connector
4
3
2
1
CUST ACCY - 15A
Spare - 15A
ENG CTL - 15A
See
Sheet
2
2
1
3
2
1
3
See Sheet 2
2
1
2
1
[4A]
7 8
See Sheet 2
See Sheet 2
See Sheet 2
See Sheet 2
See
Sheet 2
A
B
[GND2]
B
A
1
See Sheet 4 For Hands
Free Security Antenna
ACC − C
BATT − B
IGN − A
GN/BN
BK/PK
GN/GY
BE/GY
BE/GN
GYBE
LGN/V
GY/BE
BK/GN
BK/GN
BK/GN
LGN/V
LGN/Y
V/BE
GN/O
W/BN
BK/R
PK/Y
PK/O
GY/O
BK/O
W/GN
BE/O
GY/V
Y/BE
W/BK
BK/W
W/GN
BN/R
Y/GN
Y/BE
BE/O
GY
TN
BN
BK
BK
W/V
R/W
V
BN/GY
BN/GY
LGN/BN
LGN/BN
TN/GN
LGN/V
V/W
R/W
V/O
W/Y
R
PK/GN
BN
BK
TN
TN
BK
BK
BK
BE
BE
BN
BK
BE
GY
GN
GN
BK
BK
BK
BK
BE
GY
BK
BK
BK
BE
BK
BN
BK
GY
W/Y
Y/W
Y/W
Y/W
R/W
V/W
O/W
O/R
O/R
O/R
R/Y
O/W
O/W
O/W
O/W
R/Y
O/W
W/V
R/Y
R/Y
R/W
O
R
O
V
W
V
R
R
R
R
R
R
O
V
Y
Y
W
W
LGN/V
BN/GY
GN/GY
BK/GN
BK/GN
BK/GN
BN/GY
TN/GN
BE/GY
BE/GY
LGN/R
BK/PK
BE/GN
LGN/Y
GN/Y
GN/Y
O/W
BK/W
Y/GN
Y/GN
O/GY
Y/GN
R/BK
R/BK
R/BK
R/BK
R/BK
R/GY
R/BK
R/GY
R/GY
R/BK
BK/R
W/BK
Y/GN
O/GY
GN/O
Y/BK
Y/BK
W/BK
W/BN
BK/R
BK/R
GY/V
BK/W
LGN/Y
BK/W
BK/W
BN/R
BK/O
BK/W
PK/Y
BK/GN
BK/GN
BK/GN
BK/GN
Fuseblocks
Accessories
Lights
Ignition
Instruments
Top View
Top View
F
E
D
C
B
A
L
K
J
I
H
G
U
S
R
P
O
M
B
A
H
G
O
M
C
I
Q P
R
E
K
T S
U
Fuel Pump
Start Relay System Relay
ECM
P&A IGN
Battery
Spare
Spare
Eng CTL
Cust ACCY
[80A]
[80B]
[79A]
[79B]
[142B]
[142A]
[78B]
[78A]
[83B]
[83A]
[65B]
[89B
[89C]
[89D
[89A]
[87B]
[87A]
[24B]
[22B]
86
85
30
87A
87
1
2
3
4
5
R
P
C
Q
I
86
85
30
87A
87
1
2
3
4
5
U
S
E
T
K
F
E
S
U
D
C
G
H
A
B
M
O
P
R
I
J
O
M
A
B
G
H
et00168
Figure B-2. Main Harness (1 of 3): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)
Figure B-2.
Figure B-2.
Main Harness (1 of 3): 2009 All Dyna DOM. and INT. Models
(Except FXDC, FXDF)
Main Harness (1 of 3): 2009 All Dyna DOM. and INT. Models
(Except FXDC, FXDF)
S
U
IGN - 15A
INSTR - 15A
Lights - 15A
ACCY - 15A
[64B]
[62B]
Battery - 15A
Fuel Pump - 15A
ECM - 15A
A
G
I
P
M
A
G
B
H
J
R
O
B
H
P & A
Battery
P&A IGN - 15A
C
[5]
40A
MAXIFUSE
A
B
1
Cust ACCY - 15A
ENG CTL - 15A M
O
2
1
2
1
2
1
1 2
BK
BK
GY/O
LGN/R
2
1
2 3
1
2 3
1
2 1
BK
BK
Rear O
2
Sensor
Front O
2
Sensor
Active Exhaust Feedback (HDI)
Oxygen Sensor (A)
Jiffy Stand Sensor (HDI)
Ground
5V Sensor Power
Active Exhaust (HDI)
Active Intake Solenoid (HDI)
Oxygen Sensor (B)
5V Sensor Ground
Ground
Battery
Ignition
Switch
ACC − C
BATT − B
IGN − A
A
B
C
ECM
1
8
9
10
14
20
22
23
26
28
31
1
8
9
10
14
20
22
23
26
28
31
Domestic Only
HDI Only
Active Intake Solenoid
4
4
3
3
2
2
1
1
R
W
BK
5
HDI Only
Rear Ground
Stud Under
Electrical
Center
HDI Only
D
Exhaust Actuator
[GND1]
Jiffy Stand Sensor
BE
GY
BK
BK
BK
BK
BK
O/R
O/W
V/O
R/W
R/W
V/O
R
R
R
R
R
O
R
W
LGN/R
BN/GY
BE/GY
LGN/R
BK/GN
BK/GN
BK/GN
GN/BN
LGN/R
GN/BN
PK/GN
BE/GY
R/BK
R/BK
R/BK
R/BK
R/BK
R/GY
R/BK
R/GY
R/GY
Y/GN
O/GY
V/BE
GY/O
V/BE
PK/O
GY/O
BK/W
BE
GY/BK
BE
GY/BK
PK/GN
BK/W
BK/W
PK/O
BK/GN
BK/GN
P
o
w
er
Signal
Ground
Fuel Gauge
4
2
1
Full: 39.5 / 27.5
1/2 : 118.0 / 97.0
Empty: 260.0 / 240.0
A B C D
[86]
BK
BK
BK
Y/W
Y/W
O
O/GY
Fuel Pump & Sender In Tank [141A]
[138A]
[138B]
[137A]
[137B]
[33B]
[33A]
[160B]
[78B]
[78A]
[117A]
[179B]
[179A]
[133B]
[133A]
[178B]
[178A]
et01126
Figure B-3. Main Harness (2 of 3): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)
Figure B-3.
Figure B-3.
Main Harness (2 of 3): 2009 All Dyna DOM. and INT. Models
(Except FXDC, FXDF)
Main Harness (2 of 3): 2009 All Dyna DOM. and INT. Models
(Except FXDC, FXDF)
Front
Right
Turn
[31R]
Front
Left
Turn
Running
Lamp
(DOM
Only)
To Main
Harness
[38A]
To Main
Harness
[31L&R]
FXDL
To Main
Harness
To Main
Harness
To Main
Harness
[7A]
Right
Rear
Turn
[31R]
Right
Rear
Turn
To Main
Harness
[7A]
[31R]
Left
Rear
Turn
[31L]
Left
Rear
Turn
[31L]
Front Lighting
Rear Lighting
Position Lamp
(HDI Only)
[29]
1
2
3
Headlamp
[38]
1
2
3
4
[31L]
1
2
3
4
5
6
7
8
9
10
11
12
Trip Odometer
Reset Switch
1
2
3
4
5
6
7
8
9
10
11
12
Trip Odometer
Reset Switch
Taillamp
Taillamp
1
2
1
2
3
1
2
3
4
1
2
3
4
5
6
1
2
1
2
1
2
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
[20A]
[20A]
1
2
3
[18A]
[19A]
High
Low
Running
Light (HDI)
Running
Light (DOM)
Brake Light
FXD
FXD, FXDL
FXDB
FXDB
To Main
Harness
1
2
3
4
5
6
7
8
9
10
11
12
Trip Odometer
Reset Switch
1
1
2
2
7
7
8
8
3
4
5
6
9
10
3
4
5
6
9
10
[20A]
Speedometer
Tachometer
Serial Data
Security LP
Battery
Accessory
Ground
Trip Odometer Reset Switch
Fuel Level
Trip Odometer Reset Switch
RPM x 100
Ignition
Serial Data
Battery
Accessory
Ground
2
4
5
6
7
8
9
11
2
Ignition
1
1
4
5
6
7
8
9
11
Speedometer
Ignition
Serial Data
Security LP
Battery
Accessory
Ground
Trip Odometer Reset Switch
Fuel Level
Trip Odometer Reset Switch
1
2
4
5
6
7
8
9
11
1
2
4
5
6
7
8
9
11
Speedometer
Ignition
Serial Data
Security LP
Battery 12V
Accessory
Ground
Trip Odometer Reset Switch
Fuel Level
Trip Odometer Reset Switch
1
2
4
5
6
7
8
9
11
1
2
4
5
6
7
8
9
11
1
2
5
6
7
1
2
5
6
7
Horn Switch
Headlamp Hi/Lo Switch
Left Turn Switch
[163]
Left Hand
Controls
1 2 3 4 5 6 7 8
Clutch Switch
1
2
3
4
5
6
Right Turn Switch
Engine Stop Switch
Start Switch
Front Stop Lamp Switch
[162]
Right Hand
Controls
BN
TN
BK
BK
GY
BK
GY
GY
BK
BK
BK
BK
BK
BK
BK
BN
BN
TN
TN
BK
BK
BK
BK
BN
TN
GY
O/W
Y/W
Y/W
O/W
O/W
O/W
O/W
O/W
O
V
W
W
V
O
O
O
O
BN/GY
LGN/V
BN/GY
BN/GY
LGN/V
LGN/V
GN/Y
BN/V
GN/Y
BN/V
Y/W
Y/W
Y/W
O
W
W
V
V
O
O
O
O
BN/GY
BN/GY
BN/GY
LGN/V
LGN/V
LGN/V
GN/Y
GN/Y
BN/V
BN/V
BN/V
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BN
BE
BK
BK
BE
BE
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BN
BN
BN
TN
TN
O/W
Y/W
O
O
O
V
V
V
V
W
W
BN/GY
LGN/V
BN/V
GN/Y
GN/Y
R/Y
R/Y
O/W
BN
BN
BN
BE
BE
BE
BE
BE
BE
BE
V
V
V
W
W
Y
Y
R/Y
R/Y
O/W
O/W
O/W
BE
GY
W/V
O/W
O/W
R/Y
W
Y
Y/BK
W/BK
W/BN
BK/R
BK/R
BN/W
BN/W
O/W
BN
BK
BK
BK
BE
R/Y
V
O/W
BN
BN
BK
BK
BK
BK
BK
BE
R/Y
O/W
V/W
V/W
BK
BK
BK
BE
R/Y
V
V
R
R
O/W
BN
BK
BK
BK
BE
BN
BK
BE
BE
R/Y
O/W
BK
R/Y
V
BK
BE
V
[7B]
2
3
4
5
6
7
8
1
Converter Module
2
3
2
3
4
1
2
3
1
2
3
2
3
4
1
2
3
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
[20B]
[39B]
[39A]
[108A]
[108B]
[24A]
[22A]
[94B]
[94A]
[20B]
[21A]
[21B]
[18B]
[19B]
[20B]
[7B]
[38B]
[31RB]
[31LB]
[39B]
[39A]
[39B]
[39A]
[94B]
[94A]
[94B]
[94A]
[19A]
[19B]
[233A]
[233B]
[18A]
[18B]
et00160
Figure B-4. Main Harness (3 of 3): 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)
Figure B-4.
Figure B-4.
Main Harness (3 of 3): 2009 All Dyna DOM. and INT. Models
(Except FXDC, FXDF)
Main Harness (3 of 3): 2009 All Dyna DOM. and INT. Models
(Except FXDC, FXDF)
See sheet 1
for further
connections
Starter solenoid
connection
Starter
Battery
A
B
Red Band
[5B]
BK
BK
BK
BK
[47B]
[47A]
Voltage
Regulator
Front ground
stud under
electrical center
40A
MAXIFUSE
[77B]
[GND3]
Stator
[77A]
[128A]
+
–
+
–
1
3
1
3
2
2
BK
BK
BK
R
R
R
et01131
Figure B-5. Charging Circuit: 2009 All Dyna DOM. and INT. Models (Except FXDC, FXDF)
4.17
EXHAUST SYSTEM
REMOVAL: ALL BUT FXDF
NOTE
If removing exhaust as an assembly and not removing mufflers,
skip muffler removal steps.
1.
Remove seat.
2.
See
. Disconnect rear O2 sensor connector
[137]. Note wire routing for proper installation.
3.
See
. Open front electrical caddy cover and
disconnect front O2 sensor connector [138] (1). Remove
connector housing from caddy.
4.
. On models with an active exhaust
module, remove active exhaust cable (1):
a.
Remove cable (1) and retainer (2) from exhaust pipe.
b.
Remove ferrule (3) from bellcrank (4).
5.
. Remove muffler support bracket nuts
(29) from bolts (30). Remove muffler support bracket (28).
6.
Loosen nuts (17) on muffler clamps (19) to exhaust pipes.
Remove mufflers (16, 27).
7.
Loosen or remove heat shields (1, 8) by opening worm
drive clamps (2).
8.
Remove flange nuts (35) from front and rear cylinder head
exhaust studs.
9.
Remove locknut (3) and bolt (41) attaching front exhaust
pipe clamp (4) to front exhaust bracket (40).
10. Remove bolt (13) and washer (14) attaching rear exhaust
pipe clamp (10) to rear exhaust bracket (23). Remove
bracket (15) if equipped.
11. Remove exhaust system as an assembly.
sm02191
Figure 4-60. Rear O2 Connector and Harness
2
1
sm03722
1.
O2 sensor connector
2.
CKP sensor connector
Figure 4-61. Front Electrical Caddy and Connectors
1
2
3
4
sm02197
1.
Active exhaust cable
2.
Cable retainer
3.
Ferrule
4.
Bellcrank
Figure 4-62. Bellcrank
2009 Dyna Service: Fuel System 4-33
18
34
33
31
32
29
28
27
30
19
23
24
25
26
22
21
20
9
7
8
2
6
3
2
1
4
5
42
7
35
36
37
38
39
40
41
22
43
35
36
37
38
2
2
16
11
17
18
19
15
14
13
17
12
10
sm02366
31.
16.
1.
Active exhaust cable
Rear muffler
Front heat shield
2.
32.
17.
Worm drive clamp (6)
Active exhaust module
Locknut (2)
18.
3.
33.
Washer
Locknut
Washer
34.
19.
4.
Active exhaust module
fastener
Muffler clamp (2)
Exhaust pipe front clamp
5.
20.
Interconnect gasket
Cable retainer
35.
21.
6.
Flange nut (4)
Active exhaust cable clip
Rear crossover pipe heat
shield
36.
22.
Exhaust manifold flange (2)
Oxygen sensor (2, DOM only)
7.
23.
Worm drive clamp (4)
37.
Rear exhaust bracket
Retaining ring (2)
38.
24.
8.
Exhaust gasket (2)
Washer
Rear heat shield
9.
39.
25.
Rear exhaust pipe
Screw (3)
Rear exhaust bracket fastener
26.
10.
40.
Nut (2)
Rear exhaust pipe clamp
Front exhaust bracket
41.
27.
11.
Bolt
Front muffler
Muffler heat shield (2)
12.
42.
28.
Worm drive clamp (4)
Front crossover pipe heat
shield
Muffler support bracket
29.
13.
Nut
Bolt
43.
14.
Front exhaust pipe
30.
Washer
Bolt
15. Bracket (active exhaust
equipped models only)
Figure 4-63. Exhaust System: All But FXDF
4-34 2009 Dyna Service: Fuel System
DISASSEMBLY: ALL BUT FXDF
1.
. Free front exhaust pipe (43) from rear
exhaust pipe (9) by twisting and separating at crossover
pipe.
2.
Examine exhaust gaskets (38) and retaining rings (37) in
cylinder head exhaust ports. Replace if necessary.
3.
Replace the front (42) and rear (6) crossover pipe heat
shields, if necessary.
4.
Remove interconnect gasket (5) from crossover pipe bell
on rear exhaust pipe.
ASSEMBLY: ALL BUT FXDF
1.
See
. If front (42) and rear (6) crossover pipes
heat shield were removed, install now.
2.
Insert new interconnect gasket (5) into crossover pipe bell
on rear exhaust pipe (9). Connect rear exhaust pipe to
front exhaust pipe (43) at crossover pipe.
INSTALLATION: ALL BUT FXDF
NOTES
•
. Replacement exhaust gaskets
(38) are tapered internally. Be sure the thin end goes over
the exhaust pipe. Also check condition of retaining ring
(37) before installation.
•
If mufflers were not removed, skip muffler installation
steps.
1.
Position ends of exhaust pipes into front and rear cylinder
head exhaust ports with holes in exhaust manifold flanges
(36) over cylinder head exhaust studs. Loosely thread on
flange nuts (35).
2.
Position front exhaust pipe clamp (4) on front exhaust
bracket (40). Install bolt (41) and locknut (3). Do not tighten
nut and bolt at this time.
3.
Position rear exhaust pipe clamp (10) and bracket (15) (if
equipped) on rear exhaust bracket (23). Install bolt (13)
and washer (14). Do not tighten bolt at this time.
NOTE
TORCA muffler clamps have eliminated the need for silicone
or graphite tape during assembly. To be sure of sealing integrity
of muffler clamps, and prevent the possibility of leakage,
Harley-Davidson recommends that the muffler clamp assem-
blies be discarded and replaced each time they are removed.
4.
Install front and rear mufflers (27, 16) on front and rear
exhaust pipes. Install muffler clamps (19) using nuts (17).
Do not tighten nuts at this time.
5.
Install muffler support bracket (28) and bracket (15) (if
equipped) using nuts (29) and bolts (30). Do not tighten
nuts at this time. Install exhaust system.
6.
Align exhaust system and tighten all nuts and bolts;
beginning at cylinder head exhaust ports and working
backwards.
7.
Tighten flange nuts (35), at front cylinder studs as follows:
a.
Install lower nut and tighten finger tight.
b.
Install upper nut and tighten to 9-18 in-lbs (1-2 Nm).
c.
Tighten lower nut to 100-120 in-lbs (11.3-13.6 Nm).
d.
Tighten upper nut to 100-120 in-lbs (11.3-13.6 Nm).
8.
Tighten flange nuts at rear cylinder studs as follows:
a.
Install upper nut and tighten finger tight.
b.
Install lower nut and tighten to 9-18 in-lbs (1-2 Nm).
c.
Tighten upper nut to 100-120 in-lbs (11.3-13.6 Nm).
d.
Tighten lower nut to 100-120 in-lbs (11.3-13.6 Nm).
9.
Open the worm drive clamps (2) and install heat shields
(1, 8).
10. Tighten nuts (29) to 15-19 ft-lbs (20.3-25.8 Nm).
11. Align mufflers. Tighten muffler clamp nuts (17) to 38-43
ft-lbs (51.6-58.4 Nm).
12. See
. On models with an active exhaust
module, install active exhaust cable (1) to bellcrank (4):
a.
Install ferrule (3) in bellcrank.
b.
Wrap cable around bellcrank.
c.
Install cable retainer (2) on exhaust pipe.
d.
See
. Ensure cable is properly routed and
secured.
13. See
. Connect rear O2 sensor connector [137].
NOTE
Connector halves must be clean and dry. Do not apply dielectric
grease to sealed connectors or terminals.
14. See
. Connect front O2 sensor connector [138].
Close front electrical caddy cover.
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)
15. Install seat.
2009 Dyna Service: Fuel System 4-35
1
2
3
5
6
4
sm02628
1.
Rear exhaust pipe
2.
Bellcrank
3.
Battery cover
4.
Active exhaust cable
5.
Cable end
6.
Active exhaust module
Figure 4-64. Active Exhaust Bellcrank Location
REMOVAL: FXDF
NOTE
If removing exhaust as an assembly and not removing mufflers,
skip muffler removal steps.
1.
Remove seat.
2.
See
. Disconnect rear O2 sensor connector
[137]. Note wire routing for proper installation.
3.
See
. Open front electrical caddy cover and
disconnect front O2 sensor connector [138] (1). Remove
connector housing from caddy.
4.
. On models with an active exhaust
module, remove active exhaust cable (1):
a.
Remove cable and retainer (2) from exhaust pipe.
b.
Remove ferrule (3) from bellcrank (4).
5.
See
. Remove screw (1) attaching mufflers
together.
6.
Remove muffler support bracket bolt (4) and washer (3)
attaching mufflers (22, 23) to rear exhaust bracket (5).
7.
Loosen nuts on muffler clamps (21). Remove mufflers.
8.
Loosen or remove heat shields (16, 17, 18) by opening
worm drive clamps (15, 19).
9.
Remove flange nuts (12) from front and rear cylinder head
exhaust studs.
10. Remove head pipe assembly (14).
11. If necessary, remove flange locknuts (7) and bolt (8) to
remove muffler bracket (5).
sm02191
Figure 4-65. Rear O2 Connector and Harness
2
1
sm03722
1.
O2 sensor connector
2.
CKP sensor connector
Figure 4-66. Front Electrical Caddy and Connectors
1
2
4
3
sm03753
1.
Active exhaust cable
2.
Cable retainer
3.
Ferrule
4.
Bellcrank
Figure 4-67. Bellcrank: FXDF
4-36 2009 Dyna Service: Fuel System
27
26
24
25
4
9
1
23
6
3
5
7
10
11
12
15
13
14
8
16
15
17
18
19
21
22
20
7
2
sm03719a
19.
10.
1.
Worm drive clamp, large (3)
Retaining ring (2)
Screw, muffler-to-muffler
2.
20.
11.
Battery tray
Cable clamp (2)
Exhaust pipe flange
12.
3.
21.
Flange nut (4)
Washer
Muffler clamp (2)
22.
13.
4.
Front (lower) muffler
Front oxygen sensor
Bolt, muffler mounting
5.
23.
14.
Muffler bracket
Rear (upper) muffler
Head pipe assembly
15.
6.
24.
Worm drive clamp, small (4)
Rear oxygen sensor
Active exhaust cable
assembly
16.
7.
Rear heat shield
Flange locknut (2)
25.
8.
Active exhaust module
17.
Bolt
Front heat shield
18.
9.
26.
Collector heat shield
Exhaust gasket (2)
Washer
27. Active exhaust module
fastener
Figure 4-68. Exhaust System: FXDF
INSTALLATION: FXDF
NOTES
•
. Replacement exhaust gaskets
(9) are tapered internally. Be sure the thin end goes over
the exhaust pipe. Also check condition of retaining ring
(10) before installation.
•
If mufflers were not removed, skip muffler installation
steps.
2009 Dyna Service: Fuel System 4-37
1.
See
. If removed, install muffler bracket.
Tighten flange locknuts (7) to 15-19 ft-lbs (20.3-25.8 Nm).
Tighten bolt (8) to 15-19 ft-lbs (20.3-25.8 Nm).
2.
Position ends of head pipe assembly (14) into front and
rear cylinder head exhaust ports with holes in exhaust
manifold flanges (11) over cylinder head exhaust studs.
Loosely install flange nuts (12).
3.
Slide muffler clamps (21) onto exhaust pipes.
NOTE
TORCA muffler clamps have eliminated the need for silicone
or graphite tape during assembly. To be sure of sealing integrity
of muffler clamps, and prevent the possibility of leakage,
Harley-Davidson recommends that the muffler clamp assem-
blies be discarded and replaced each time they are removed.
4.
Install front and rear mufflers (22, 23) on exhaust pipes.
Install muffler clamps (21). Do not tighten nuts at this time.
5.
Install muffler-to-muffler screw (1). Do not tighten at this
time.
6.
Install muffler mounting bolt (4) and washer (3). Do not
tighten at this time.
NOTE
Align exhaust system and tighten all nuts and bolts, beginning
at cylinder head exhaust ports and working backwards.
7.
Tighten flange nuts (12), at front cylinder studs as follows:
a.
Install lower nut and tighten finger tight.
b.
Install upper nut and tighten to 9-18 in-lbs (1-2 Nm).
c.
Tighten lower nut to 100-120 in-lbs (11.3-13.6 Nm).
d.
Tighten upper nut to 100-120 in-lbs (11.3-13.6 Nm).
8.
Tighten flange nuts at rear cylinder studs as follows:
a.
Install upper nut and tighten finger tight.
b.
Install lower nut and tighten to 9-18 in-lbs (1-2 Nm).
c.
Tighten upper nut to 100-120 in-lbs (11.3-13.6 Nm).
d.
Tighten lower nut to 100-120 in-lbs (11.3-13.6 Nm).
9.
Open the worm drive clamps (15, 19) and install heat
shields (16, 17, 18).
10. Tighten muffler mounting bolt (4) to 15-19 ft-lbs (20.3-25.8
Nm). Tighten muffler attaching bolt (1) securely.
11. Align mufflers. Tighten muffler clamp nuts to 38-43 ft-lbs
(51.6-58.4 Nm).
12. See
. On models with an active exhaust
module, install active exhaust cable (1):
a.
Install ferrule (3) in bellcrank (4).
b.
Wrap cable around bellcrank.
c.
Install cable and retainer (2) on exhaust pipe.
d.
. Make sure cable routing is correct
and secure with two camps (3).
NOTE
Connector halves must be clean and dry. Do not apply dielectric
grease to sealed connectors or terminals.
13. See
. Connect rear O2 sensor connector [137].
14. See
. Connect front O2 sensor connector [138].
Close front electrical caddy cover.
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)
15. Install seat.
1
4
2
3
sm03818
1.
Active exhaust module
2.
Active exhaust cable
3.
Clamp (2)
4.
Bellcrank
Figure 4-69. Active Exhaust Cable: FXDF
4-38 2009 Dyna Service: Fuel System
4.18
INTAKE LEAK TEST
GENERAL
Do not allow open flame or sparks near propane. Propane
is extremely flammable, which could cause death or ser-
ious injury. (00521b)
Read and follow warnings and directions on propane
bottle. Failure to follow warnings and directions can result
in death or serious injury. (00471b)
NOTES
•
To prevent false readings, keep air cleaner cover installed
when performing test.
•
Do not direct propane into air cleaner; false readings will
result.
•
Be careful when testing vehicle with Screamin' Eagle air
cleaner assembly. This type of air cleaner has an open
backing plate. Even with air cleaner cover on, directing
nozzle too close to backing plate can give false readings.
LEAK TESTER
TOOL NAME
PART NUMBER
PROPANE ENRICHMENT KIT
HD-41417
Parts List
•
Standard 14 oz. propane cylinder.
•
PROPANE ENRICHMENT KIT (Part No. HD-41417).
Tester Assembly
1.
See
. Make sure valve knob (6) is closed (fully
clockwise).
2.
Screw valve assembly (5) onto propane bottle (1).
Tester Adjustment
1.
. Press and hold trigger button (8).
2.
Slowly open valve knob (6) until pellet in flow gauge (7)
rises to between 5 and 10 SCFH on gauge.
3.
Release trigger button.
1
8
5
9
3
2
7
4
6
sm02629
1.
Propane bottle
2.
Nozzle
3.
Copper tube
4.
Hose
5.
Valve assembly
6.
Valve knob
7.
Flow gauge
8.
Trigger button
9.
Hanger
Figure 4-70. Leak Tester
PROCEDURE
1.
Start engine.
2.
Warm up engine to operating temperature.
NOTE
Do not direct propane stream toward air cleaner. If propane
enters air cleaner, a false reading will be obtained.
3.
See
. Aim nozzle (3) toward possible sources
of leak such as intake manifold mating surfaces.
4.
Press and release trigger button (2) to dispense propane.
Tone of engine will change when propane enters source
of leak. Repeat as necessary to detect leak.
2009 Dyna Service: Fuel System 4-39
5.
When test is finished, close valve knob (turn knob fully
clockwise).
3
1
2
sm02630
1.
Propane bottle
2.
Trigger button
3.
Nozzle
Figure 4-71. Checking for Leaks
4-40 2009 Dyna Service: Fuel System
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