Harley Davidson 2009 Dyna Models. Service manual — page 31
4.
Replace the sprocket if teeth are cracked or worn. See
5.7 TRANSMISSION SPROCKET, Cleaning and Inspec-
tion
for more information.
5.
Inspect the needle bearings on the inside of the main drive
gear. If mainshaft race surface appears pitted or grooved,
replace these bearings.
NOTE
If the main drive gear needle bearings and/or seal need to be
replaced, continue as follows. Otherwise, proceed to
6.8 TRANSMISSION CASE, Assembly
.
Needle Bearing Replacement
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
NOTES
•
. When replacing needle bearings, discard
original retaining rings (1) and install replacement retaining
rings (2).
•
To install the inner main drive gear needle bearings and
mainshaft seal, use MAIN DRIVE GEAR BEARING AND
SEAL INSTALLATION TOOL (Part No. HD-47932).
1.
See
. Remove mainshaft seal (6). Remove
retaining rings (1), needle bearings (2) and spacer (5) from
main drive gear (3). Discard retaining rings.
2.
Remove and discard o-ring (4).
1
2
3
4
2
1
6
5
sm03036
1.
Retaining ring (2)
2.
Needle bearing (2)
3.
Main drive gear
4.
O-ring
5.
Spacer
6.
Mainshaft seal
Figure 6-37. Main Drive Gear Assembly
1
2
sm03038
1.
Original retaining ring
2.
Replacement retaining ring
Figure 6-38. Main Drive Gear Retaining Rings
3.
See
. Install clutch side needle bearing using
an arbor press and the 0.400 in. step end of tool as shown.
Press until tool contacts gear.
sm03040
Figure 6-39. Installing Clutch Side Needle Bearing in Main
Drive Gear
NOTE
An alternative method is provided which allows the mainshaft
seal to be pressed into place after installation of the main drive
gear. See
6.7 MAIN DRIVE GEAR AND BEARING, Removal
4.
. Turn over tool and press in mainshaft
seal using the 0.090 in. step with garter spring side down.
5.
Install spacer.
6.
See
. Turn over the main drive gear in the arbor
press. With the tool at the 0.188 in. step, press inner
bearing until tool contacts gear.
6-22 2009 Dyna Service: Transmission
1
2
8
7
4
3
6
5
sm03051
1.
12 in. bolt
2.
Cross plate
3.
Screw (2)
4.
Main drive gear bearing
5.
Bearing driver
6.
Nice bearing
7.
Flat washer
8.
Nut
Figure 6-42. Installing Main Drive Gear Bearing (Typical)
Installing Main Drive Gear
NOTE
See
. Make sure new o-ring (4) is installed onto
main drive gear (3). Lubricate o-ring with clean engine oil before
installing drive gear into transmission case.
1.
. Apply a light coat of graphite lubricant
to the threads of 8 IN. BOLT (Part No. HD-35316-4A) (1)
and insert through WASHER (Part No. HD-35316-7) (2)
and main drive gear (3). Insert assembly into transmission
case, through main drive gear bearing.
2.
At outside of case, place INSTALLER CUP (Part No. HD-
35316-12) (5), NICE BEARING (6), FLAT WASHER (7)
and NUT (8) over end of bolt.
3.
Tighten nut until main drive gear contacts main drive gear
bearing.
NOTE
See
. In next step, bearing retaining ring must be
installed with the flat side facing the bearing and the opening
in the ninety degree range shown.
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
4.
. Install new retaining ring (2).
6
7
8
5
4
2
1
3
sm03052
1.
8 in. bolt
2.
Washer
3.
Main drive gear
4.
O-ring
5.
Installer cup
6.
Nice bearing
7.
Flat washer
8.
Nut
Figure 6-43. Installing Main Drive Gear (Typical)
sm03053
Figure 6-44. Retaining Ring Opening
Installing Main Drive Gear Large Seal
1.
. From outside of crankcase, install
PILOT (Part No. HD-47856-2) over end of main drive gear
bearing inner race.
2.
Coat lips of new main drive gear seal with FORMULA+
TRANSMISSION AND PRIMARY CHAINCASE LUB-
RICANT (Part No. 99851-05, qt).
3.
. Place seal over pilot with garter spring
facing bearing, and position seal squarely in end of
crankcase bore.
6-24 2009 Dyna Service: Transmission
1
2
sm03061
1.
Installer
2.
Nut
Figure 6-48. Installer and Nut
1
3
2
sm03062
1.
Crow's foot wrench
2.
1/2 inch breaker bar
3.
Adjustable wrench
Figure 6-49. Press Seal Into Crankcase
6-26 2009 Dyna Service: Transmission
6.8
TRANSMISSION CASE
REMOVAL
Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)
1.
Disconnect battery, negative (-) cable first.
2.
Drain engine oil. See
3.
Drain transmission lubricant. See
LUBRICANT, Changing Transmission Lubricant
4.
Remove starter. See
5.
Remove transmission assembly. See
6.
Remove oil pan. See
When lifting a motorcycle using a jack, be sure jack con-
tacts frame tubes only. Never lift by jacking on cross-
members, oil pan, or other housings. Failure to comply
can cause serious damage resulting in the need to perform
major repair work. (00586b)
7.
Position jack across lower frame to support rear of
motorcycle. Slide wooden blocks beneath the crankcase
to support the weight of the engine and transmission
assembly.
8.
Remove rear fork. See
9.
Disconnect vehicle speed sensor (VSS). See
7.24 VEHICLE SPEED SENSOR (VSS), Removal
.
10. Disconnect neutral switch. See
11. Remove fastener from ground post at top of transmission
case and remove battery negative ring terminal.
12. Move O2 sensor, starter solenoid, neutral switch and VSS
harness out of the way.
13. Mark splines on shift arm and shift shaft to assist in
assembly. Remove shift arm from shift shaft.
14. In a crosswise pattern, remove four fasteners that connect
transmission to engine.
NOTE
. Do not use a hammer to remove transmission.
If the transmission sticks or binds on the ring dowels, gently
pry away from crankcase using the indent.
15. Move transmission rearward until two ring dowels in lower
flange are free of crankcase. Remove transmission case
from left side of the motorcycle.
2009 Dyna Service: Transmission 6-27
1
2
22
21
20
3
4
19
17
14
15
18
16
5
6
7
12
10
13
11
9
8
sm03063
12.
1.
Allen screws
Main drive gear
2.
13.
O-ring
Bearing, inner race
14.
3.
Screw
Transmission case
4.
15.
Bearing
Shifter rod lever
16.
5.
Retaining ring
Bearing
6.
17.
Bevelled retaining ring
Washer
18.
7.
Seal
Oil seal
8.
19.
Sprocket
Sleeve (inside transmission case)
20.
9.
Shifter lever centering spring
Sprocket nut
10.
21.
Oil seal, sixth gear
Shifter pawl lever assembly
22.
11.
Shifter shaft lever spring
Lockplate
Figure 6-50. Transmission Case, Sprocket and Main Drive Gear
INSTALLATION
1.
Install new ground post at top of transmission case.
Tighten ground post until snug.
NOTE
A new transmission case comes with the shifter shaft sleeve
and seal, centering screw, countershaft needle bearing and
main drive gear bearing and seal installed.
2.
Thoroughly wipe all engine oil from pockets in crankcase
flange.
3.
Install new engine-to-transmission gasket engaging two
index pins in holes of transmission flange.
4.
Verify that transmission dowels are seated. Place trans-
mission case into position behind crankcase. Mate engine
and transmission flanges.
5.
Install and tighten fasteners.
a.
Shorter bolts are installed at the top, longer fasteners
are installed at the bottom. Using a crosswise pattern,
hand tighten fasteners.
b.
. Tighten bolts in the sequence shown
to 15 ft-lbs (20.3 Nm) in the same crosswise pattern.
c.
Final tighten bolts to 34-39 ft-lbs (46.1-52.9 Nm).
6-28 2009 Dyna Service: Transmission
6.
Install oil pan. See
7.
Install rear fork. See
8.
Install shift arm on shift shaft. Align marks made during
disassembly.
9.
Install transmission and side door assembly. See
6.6 TRANSMISSION ASSEMBLY, Installation
10. Connect battery ground (-) cable to ground post at top of
transmission case. Tighten securely.
11. Adjust drive belt tension. See
.
12. Install primary chaincase. See
13. Install drive components. See
NOTE
The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.
14. Install primary chaincase cover. See
.
15. Install neutral switch and tighten to 120-180 in-lbs (13.6-
20.3 Nm).
16. Install VSS and tighten screw to 84-132 in-lbs (9.5-14.9
Nm)
17. Mate VSS, O2 sensors, starter solenoid and neutral switch
connectors to main harness.
18. Install starter. See
19. Install the exhaust system. See
20. Clean transmission drain plug and install. Tighten to 14-
21 ft-lbs (19.0-28.5 Nm). Place motorcycle in an upright
position. Fill transmission to proper level with fresh trans-
mission fluid. See
Do not overfill the primary chaincase with lubricant.
Overfilling can cause rough clutch engagement, incom-
plete disengagement, clutch drag and/or difficulty in
finding neutral at engine idle. (00199b)
21. Fill primary. See
1.10 PRIMARY CHAIN, Changing Primary
22. Fill engine oil. See
1.5 ENGINE OIL AND FILTER, Chan-
.
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)
23. Connect battery cables.
4
2
1
3
sm02180
Figure 6-51. Transmission Housing to Crankcase Torque
Sequence
DISASSEMBLY
Shifter Arm Assembly
1.
. After removing door assembly, remove
screw (8) and shifter rod lever (9) from the shifter pawl
lever assembly (1).
2.
Remove retaining ring (7), washer (6) and seal (5). Discard
retaining ring and seal. Pull shifter pawl lever assembly
out of the transmission case.
3.
Inspect sleeve (2) inside transmission case.
CLEANING AND INSPECTION
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
1.
Clean all parts in solvent except the case and main drive
gear needle bearings. Blow parts dry with low pressure
compressed air.
NOTE
Never wash the transmission case and needle bearings with
solvent. Normal cleaning methods will wash dirt or other con-
taminants into the bearing case (behind the needles) leading
to bearing failure.
2.
. Inspect the shifter pawl lever assembly
(1) for wear. Replace assembly if pawl ends are damaged.
Replace centering spring (3) if elongated.
2009 Dyna Service: Transmission 6-29
3.
Inspect the shifter spring (4). Replace if the spring fails to
hold the pawl on the cam pins.
4.
Thoroughly clean the oil pan with solvent.
5.
Inspect preformed transmission top cover vent hose for
nicks, cuts or general deterioration. Replace as necessary.
Use low-pressure compressed air to verify that hose and
fitting are unobstructed.
4
1
2
3
5
7
8
11
9
6
10
sm03066
1.
Shifter pawl lever assembly
2.
Sleeve (inside transmission case)
3.
Shift lever centering spring
4.
Shifter shaft lever spring
5.
Seal
6.
Washer
7.
Retaining ring
8.
Screw
9.
Shifter rod lever
10. Washer
11. Screw
Figure 6-52. Shifter Arm Assembly
ASSEMBLY
Countershaft Needle Bearing Replacement
1.
Find a suitable bearing driver 1.25 in. (31.75 mm) in dia-
meter.
2.
From the outside of the transmission case place the needle
bearing open end first next to the bearing bore. Hold the
driver squarely against the closed end of the bearing and
tap the bearing into place. The bearing is properly posi-
tioned when it is driven inward flush with the outside sur-
face of the case or to a maximum depth of 0.030 in. (0.76
mm).
3.
Lubricate the bearing with transmission lubricant.
Shifter Pawl Lever Assembly
1.
. Verify that sleeve (2) is inside transmis-
sion case.
2.
See
. Slide shifter lever centering spring (3)
over shaft of shifter pawl lever assembly (2). Align opening
on spring with tab on lever.
3.
Place shifter shaft lever spring (4) on shifter pawl lever
assembly.
NOTE
Do not bend shifter shaft lever spring more than necessary for
assembly.
4.
See
. Insert the assembly into the transmission
case.
5.
. Verify that pin sits inside shifter shaft
lever spring.
6.
See
. Install a new seal. Install washer (1) and
a new retaining ring (2).
NOTE
In next step, shifter rod lever must be installed so angle of lever
is toward front of vehicle, one spline from vertical.
7.
See
. Install shifter rod lever (9) on the shifter
pawl lever assembly shaft end using screw (8). Tighten
to 18-22 ft-lbs (24.4-29.8 Nm).
2
1
4
3
sm03067
1.
Pawl (part of shifter pawl lever assembly)
2.
Shifter pawl lever assembly
3.
Shifter lever centering spring
4.
Shifter shaft lever spring
Figure 6-53. Shifter Pawl Lever Assembly
6-30 2009 Dyna Service: Transmission
4
2
1
3
sm03068
1.
Washer (with seal behind)
2.
Retaining ring
3.
Shifter shaft lever
4.
Pin
Figure 6-54. Shifter Shaft Lever, Exterior View
sm03069
Figure 6-55. Shifter Shaft Lever Spring
2009 Dyna Service: Transmission 6-31
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
ELECTRICAL
7.1
FASTENER TORQUE VALUES
FASTENER TORQUE VALUES IN THIS
CHAPTER
The table below lists torque values for all fasteners presented
in this chapter.
NOTES
TORQUE VALUE
FASTENER
7.30 ACTIVE EXHAUST, Installation
4.1-6.8 Nm
36-60 in-lbs
Active exhaust module fasteners
7.9 BATTERY TRAY AND BATTERY
CABLES, Battery Tray
10.8-13.6 Nm
96-120 in-lbs
Battery tray screws
7.17 CRANK POSITION SENSOR (CKP), Installa-
tion
10.2-13.6 Nm
90-120 in-lbs
CKP sensor screw
7.19 FUEL GAUGE, FXD Models
2.0-2.7 Nm
18-24 in-lbs
Console mounting screws
7.25 INDICATOR LAMPS, Installation
2.0-2.7 Nm
18-24 in-lbs
Console mounting screws (FXDB)
7.8 IGNITION SWITCH/FORK LOCK, FXDC, FXDF
Models (Ignition Switch Only)
2.0-2.7 Nm
18-24 in-lbs
Console mounting screws (FXDC, FXDF)
7.21 INSTRUMENTS: FXDC/FXDF, Installation
2.0-2.7 Nm
18-24 in-lbs
Console mounting screws (FXDC/FXDF)
7.25 INDICATOR LAMPS, Installation
2.0-2.7 Nm
18-24 in-lbs
Console mounting screws (FXDC/FXDF)
7.22 INSTRUMENTS: FXDB/FXDL, Installation
2.0-2.7 Nm
18-24 in-lbs
Console to fuel tank fasteners
7.22 INSTRUMENTS: FXDB/FXDL, Installation
2.0-2.7 Nm
18-24 in-lbs
Console to fuel tank fasteners
7.3 ELECTRICAL CADDY, Installation
4.5-6.8 Nm
40-60 in-lbs
Electrical caddy fasteners, front
7.3 ELECTRICAL CADDY, Installation
10.2-12.4 Nm
90-110 in-lbs
Electrical caddy fasteners, top
7.19 FUEL GAUGE, FXD Models
2.03-2.49 Nm
18-22 in-lbs
Fuel gauge trim ring screws
7.21 INSTRUMENTS: FXDC/FXDF, Installation
2.03-2.71 Nm
18-24 in-lbs
Fuel tank trim screws
7.33 RIGHT HANDLEBAR SWITCH, Installation
6.8-9.0 Nm
60-80 in-lbs
Handlebar switch clamp screws
7.34 LEFT HANDLEBAR SWITCH, Installation
6.8-9.0 Nm
60-80 in-lbs
Handlebar switch clamp screws
7.33 RIGHT HANDLEBAR SWITCH, Installation
4.0-5.1 Nm
35-45 in-lbs
Handlebar switch housing screws
7.34 LEFT HANDLEBAR SWITCH, Installation
4.0-5.1 Nm
35-45 in-lbs
Handlebar switch housing screws
7.12 HEADLAMP, Headlamp Assembly Installation
33.9-40.7 Nm
25-30 ft-lbs
Headlight horizontal adjusting bolt
7.29 HORN, Replacement
13.6-20.3 Nm
10-15 ft-lbs
Horn mounting nut
7.25 INDICATOR LAMPS, Installation
2.0-2.7 Nm
18-24 in-lbs
LED assembly fasteners
7.11 STARTER SOLENOID, Solenoid Contacts
7.3-9.0 Nm
65-80 in-lbs
Long post jam nut
7.26 NEUTRAL SWITCH, Installation
13.6-20.3 Nm
120-180 in-lbs
Neutral switch
7.27 OIL PRESSURE SWITCH, Installation
10.8-16.3 Nm
96-144 in-lbs
Oil pressure switch
7.28 REAR STOPLIGHT SWITCH, Installation
16.3-20.3 Nm
12-15 ft-lbs
Rear stoplight switch
7.14 TURN SIGNALS AND RUNNING
LIGHTS, Rear Lamp Housing Replacement
16.3-21.7 Nm
12-16 ft-lbs
Rear turn signal lamp fastener
7.10 STARTER, Field Coil Assembly
7.9-10.2 Nm
70-90 in-lbs
Solenoid ring terminal nut
7.24 VEHICLE SPEED SENSOR (VSS), Installation
9.5-12.2 Nm
84-108 in-lbs
Speedometer sensor mounting bolt
7.10 STARTER, Field Coil Assembly
10.2-12.4 Nm
90-110 in-lbs
Starter end cover screw
7.10 STARTER, Installation
33.9-36.6 Nm
25-27 ft-lbs
Starter mounting bolts
7.9 BATTERY TRAY AND BATTERY
CABLES, Battery Cables/metric
7.3-9.6 Nm
65-85 in-lbs
Starter positive terminal nut
7.10 STARTER, Installation
7.3-9.6 Nm
65-85 in-lbs
Starter positive terminal nut
7.10 STARTER, Field Coil Assembly
4.4-7.3 Nm
39-65 in-lbs
Starter thru bolts
7.18 ALTERNATOR AND STATOR, Installation/T27
TORX, use only once
6.2-8.4 Nm
55-75 in-lbs
Stator screws
2009 Dyna Service: Electrical 7-1
NOTES
TORQUE VALUE
FASTENER
7.13 TAIL LAMP, Base Replacement: All But FXDB
4.5-5.4 Nm
40-48 in-lbs
Tail lamp base screws: all but FXDB
7.13 TAIL LAMP, Base Replacement: FXDB
9.5-12.2 Nm
84-108 in-lbs
Tail lamp base screws: FXDB
7.13 TAIL LAMP, Tail Lamp Bulb Replacement:
Standard Style
2.3-2.7 Nm
20-24 in-lbs
Tail lamp lens screws
7.13 TAIL LAMP, Base Replacement: All But FXDB
2.3-2.7 Nm
20-24 in-lbs
Tail lamp lens screws: all but FXDB
7.20 FUEL GAUGE SENDER, Installation
3.1-3.7 Nm
27-33 in-lbs
Top plate fasteners (all but FXD)
7.20 FUEL GAUGE SENDER, Installation
1.7-2.4 Nm
15-21 in-lbs
Top plate fasteners (FXD)
7.9 BATTERY TRAY AND BATTERY
CABLES, Battery Cables
17.6-27.1 Nm
13-20 ft-lbs
Transmission ground stud nut
7.6 VOLTAGE REGULATOR, Installation
6.8-9.0 Nm
60-80 in-lbs
Voltage regulator fasteners
7-2 2009 Dyna Service: Electrical
7.2
SPECIFICATIONS: ELECTRICAL
SPECIFICATIONS
Table 7-1. Ignition
DATA
IGNITION
1000 ± 50 RPM
Idle speed
12 mm
Spark plug size
0.038-0.043 in.
Spark plug gap
0.97-1.09 mm
Harley-Davidson
No. 6R12
(no substitute)
Spark plug type
0.5-0.7 ohms
Ignition coil primary resistance
5500-7500 ohms
Ignition coil secondary resistance
Table 7-2. Fuses
AMPS
FUSE
40
Main fuse
15
Brakes
15
Accessory
15
P&A
15
Radio power/siren
15
ECM power
15
Ignition
15
Engine control: active exhaust (HDI only)
15
Lighting
15
Instruments
15
Headlamp
30
ABS
2
P&A ignition
15
Fuel pump
15
Battery
15
Radio memory
Table 7-3. Charging System
DATA
CHARGING SYSTEM
19 amp hour/270 CCA
Battery
16-23 VAC per 1000 RPM
Alternator AC voltage output
0.1-0.2 ohms
Alternator stator coil resistance
14.3-14.7
@
75° F (24° C)
Regulator voltage output @ 3600
RPM
35-50 amps
Regulator amperes @ 3000 RPM
Table 7-4. Starter Specifications
STARTER DATA
3000 RPM (min.) @ 11.5 V
Free speed
90 amp (max.) @ 11.5 V
Free current
200 amp (max.) @ 68°F
Cranking current
8.0 ft-lbs (10.8 Nm) @ 2.4 V
Stall torque
Table 7-5. Starter Service Wear Limits
MM.
IN.
ITEM
11.0
0.443
Brush length (minimum)
0.41
0.016
Commutator runout
28.98
1.141
Commutator diameter (minimum)
0.203
0.008
Commutator mica depth (minimum)
NOTE
The fuse labeled Security provides basic turn signal function-
ality on vehicles without a factory-installed security system. Do
not remove this fuse or use it as a replacement fuse for other
systems.
2009 Dyna Service: Electrical 7-3
7.3
ELECTRICAL CADDY
REMOVAL
NOTE
Security siren connector [142] is located under seat.
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.
. Firmly grasp both sides of electrical caddy
cover and pull outward to remove.
4.
See
. Remove relay and fuse panels from
electrical caddy.
a.
Insert small screwdriver into slot located under each
relay/fuse panel.
b.
Using screwdriver, disengage relay/fuse panel from
electrical caddy.
c.
Repeat for other relay/fuse panel.
5.
See
. Disconnect main fuse connector from
electrical caddy (1).
a.
Remove main fuse from connector.
b.
Insert small screwdrivers into slots (4) located on each
side of main fuse.
c.
Using screwdrivers depress tabs of main fuse con-
nector to disengage from electrical caddy.
6.
Depress tab located on electrical caddy securing
TSM/TSSM/HFSM. Pull TSM/TSSM/HFSM from electrical
caddy. Disconnect TSM/TSSM/HFSM connector (2) [30].
7.
Slide data link connector (3) [91] towards front of vehicle
to disengage from electrical caddy.
sm02029
Figure 7-1. Electrical Caddy Cover
sm02538
Figure 7-2. Removing Relay/Fuse Panels
3
2
1
4
sm02539
1.
Electrical caddy
2.
TSM/TSSM/HFSM connector [30]
3.
Data link connector
4.
Main fuse removal slots
Figure 7-3. Electrical Caddy Removal
8.
. Disconnect electronic control module
(ECM) connector (2) [78].
9.
Disconnect ignition coil connector [83].
10. Disconnect spark plug cables from coil.
11. Remove front electrical caddy fastener (4).
12. Remove top electrical caddy fasteners (3).
13. Remove wiring from electrical caddy.
14. Remove fasteners securing ECM and ground wire to
electrical caddy.
INSTALLATION
1.
Attach ECM and ground wire to electrical caddy.
2.
Install main fuse connector into rear of electrical caddy.
3.
Install relay and fuse panels into rear of electrical caddy.
4.
Route ECM and data link connector wiring through rear
of electrical caddy past ECM.
7-4 2009 Dyna Service: Electrical
5.
See
. Route TSM/TSSM/HFSM wiring through
rear of electrical caddy as shown.
6.
. Install but do not tighten electrical caddy
front fastener (4).
7.
Install electrical caddy top fasteners (3). Tighten to 90-110
in-lbs (10.2-12.4 Nm).
8.
Tighten electrical caddy front fastener to 40-60 in-lbs (4.5-
6.8 Nm).
9.
Connect electronic control module (ECM) connector [78].
10. See
. Connect TSM/TSSM/HFSM connector (2)
[30] to TSM/TSSM/HFSM. Slide TSM/TSSM/HFSM into
electrical caddy until tab of caddy engages
TSM/TSSM/HFSM.
11. Install data link connector (3) to electrical caddy as shown.
12. Install main fuse.
13. Attach coil connector [83].
14. Attach spark plug cables. Rear cable is installed on upper
coil tower.
15. Install electrical caddy cover.
16. 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)
17. Install seat.
4
2
1
3
sm02540
1.
Electrical caddy
2.
ECM connector [78]
3.
Top electrical caddy fasteners (2)
4.
Front electrical caddy fastener
Figure 7-4. Electrical Caddy Fasteners
sm02541
Figure 7-5. TSM/TSSM/HSFM Wiring
2009 Dyna Service: Electrical 7-5
7.4
ELECTRONIC CONTROL MODULE (ECM)
GENERAL
The electronic control module (ECM) is mounted in the elec-
trical caddy. Refer to the Electrical Diagnostic Manual for
information on the function and testing of the electronic control
module.
NOTE
The electronic control module cannot be repaired. Replace the
unit if it fails.
REPLACEMENT
1.
Follow removal instructions under
to remove the electronic control module.
NOTE
After installing ECM, the password learning procedure must
be performed. See the Electrical Diagnostic Manual for this
model.
2.
Follow installation instructions under
to install the electronic control module.
sm02542
Figure 7-6. ECM Location
7-6 2009 Dyna Service: Electrical
7.5
SPARK PLUG CABLES
REMOVAL
Disconnecting spark plug cable with engine running can
result in electric shock and death or serious injury.
(00464b)
NOTE
When disconnecting spark plug cable, grasp and pull on the
rubber boot at the end of the cable assembly. Do not pull on
the cable portion itself. Pulling on the cable will damage the
cable's carbon core.
1.
Disconnect spark plug cables from ignition coil and spark
plug terminals. Inspect all removed cables for damage.
2.
See
. Remove clips (1) on horn bracket for front
spark plug cable.
INSTALLATION
1.
See
. Connect spark plug cables to ignition coil
and spark plugs. Rear cylinder plug cable attaches to top
coil terminal (4). Fasten boots/caps securely. Tight con-
nections provide the necessary moisture-proof environ-
ment for the ignition coil and spark plug terminals.
2.
Secure front spark plug cable to horn bracket with clips
(1).
3.
Install cable retention clip (2) over spark plug cables. Be
sure clip is 1.5-2.0 in. (38.1-50.8 mm) from spark plug
boots (3).
4
3
3
2
1
sm02544
1.
Horn bracket clips
2.
Cable retention clip
3.
Spark plug boots
4.
Top coil terminal
Figure 7-7. Spark Plug Cable Routing
2009 Dyna Service: Electrical 7-7
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