Harley Davidson 2009 Dyna Models. Service manual — page 23
4
3
1
2
sm02580
1.
Console fastener, long (2)
2.
Console fastener, short (1)
3.
Console
4.
LED assembly
Figure 7-62. Indicator Lamps: FXDB
3
2
2
1
sm02655
1.
LED assembly
2.
Clips (2 pair)
3.
Connector [21]
Figure 7-63. FXDB Connector [21]
FXD Models
1.
. Remove LED assembly fasteners (4)
from LED assembly (3).
2.
Pull LED assembly from speedometer bracket.
FXDL Models
1.
Pull riser cover from between handlebar risers.
2.
See
. Squeeze clips (2) together and gently
pull LED assembly (1) from handlebar cover (3).
Table 7-9. FXDC, FXDF Connector [21] Pins
Function
Wire Color
Pin On [21]
left turn
Violet
1
high beam
White
2
oil pressure
Green/yellow
3
right turn
Brown
4
neutral
Tan
5
+12V
Orange
6
ground
Black
7
n/a
Not used
8
Table 7-10. FXDB Connector [21] Pins
Function
Wire Color
Pin On [21]
right turn
Brown
1
oil pressure
Green/yellow
2
high beam
White
3
left turn
Violet
4
ground
Black
5
+12V
Orange
6
neutral
Tan
7
+12V
Orange
8
ground
Black
9
ground
Black
10
Table 7-11. FXD, FXDL Connector [20] Pins
Wire Color
Pin On [20]
Brown
3
White
4
Violet
5
Orange
6
Tan
8
Green/yellow
9
Black
12
Table 7-12. LED Assembly Wiring
CONNECTION
INDICATOR LAMP
Ground through switch
Oil pressure
Ground through switch
Neutral
12V when active
High beam
12V when active
Right/left turn
7-52 2009 Dyna Service: Electrical
INSTALLATION
FXDC/FXDF Models
1.
. Install LED assembly (1) into console.
Make sure clips (2) engage to secure assembly in place.
2.
Connect connector (3) [21] to main wiring harness.
3.
. Place console (2) in position. Tighten
screws (1) to 18-24 in-lbs (2.0-2.7 Nm).
FXDB Models
1.
. Install LED assembly (1) into console.
2.
Engage clips (2) into tabs on LED assembly.
3.
Connect connector (3) [21] to main wiring harness.
4.
. Place console (3) in position.
5.
Install long console fasteners (1) and short console
fastener (2). Tighten fasteners to 18-24 in-lbs (2.0-2.7
Nm).
FXD Models
1.
See
. Install LED assembly (3) into speedo-
meter bracket.
2.
Install LED assembly fasteners (4) into LED assembly.
Tighten fasteners (1) to 18-24 in-lbs (2.0-2.7 Nm).
FXDL Models
1.
. Install LED assembly (1) into handlebar
cover.
2.
Engage clips (2) into tabs on LED assembly.
3.
Install riser cover between handlebar risers.
3
4
2
1
sm02653
1.
Trim plate
2.
Lens
3.
LED assembly
4.
LED assembly fasteners (2)
Figure 7-64. Indicator Lamps: FXD
1
3
2
2
sm02654
1.
LED assembly
2.
Clips (2 pair)
3.
Handlebar cover
Figure 7-65. FXDL LED Assembly
2009 Dyna Service: Electrical 7-53
7.26
NEUTRAL SWITCH
GENERAL
The neutral switch is located on the transmission case. The
two terminal switch is normally closed. When the transmission
shifter is in neutral and the ignition switch is in the IGNITION
position, the switch causes the NEUTRAL indicator light to
illuminate.
REMOVAL
1.
Verify that transmission is in NEUTRAL.
2.
. Remove two elbow connectors from
neutral switch posts.
3.
Remove neutral switch from transmission case.
INSTALLATION
1.
. Inspect O-ring for cuts, tears or general
deterioration. Replace as necessary. Lightly lubricate new
O-ring with clean transmission oil before installation.
2.
Verify that transmission is in NEUTRAL.
3.
Install neutral switch in transmission case and tighten to
120-180 in-lbs (13.6-20.3 Nm).
NOTE
The neutral switch is not polarity sensitive The elbow con-
nectors can be installed on either post.
4.
Install two elbow connectors onto neutral switch posts.
5.
Test neutral switch for proper operation as follows:
a.
Verify that transmission is in NEUTRAL.
b.
Turn Ignition/Light Key Switch to IGNITION.
c.
Verify that neutral indicator light illuminates.
sm05247
Figure 7-66. Neutral Switch
sm05246
Figure 7-67. Neutral Switch O-Ring
7-54 2009 Dyna Service: Electrical
7.27
OIL PRESSURE SWITCH
GENERAL
The oil pressure switch monitors oil pressure in the crankcase.
If the oil pressure drops below 3 psi (20.6 kPa) the oil pressure
switch is tripped and illuminates the low oil pressure indicator
light.
See
. The oil pressure switch is located on the right
side of the crankcase.
REMOVAL
1.
See
. Remove connector (2) from oil pressure
switch (1).
2.
Using a 15/16 in. open end wrench, remove switch from
crankcase.
2
1
sm02650
1.
Oil pressure switch
2.
Connector
Figure 7-68. Oil Pressure Switch
INSTALLATION
NOTE
Perform step 1 only if original switch is being re-installed. New
switches have a sealant contact patch on the threads. If new
switch is being installed, begin at step 2.
1.
Coat threads of oil pressure switch with LOCTITE PIPE
SEALANT WITH TEFLON (PST).
2.
See
. Install oil pressure switch (1) to crank-
case. Tighten switch to 96-144 in-lbs (10.8-16.3 Nm).
3.
Attach connector (2) to oil pressure switch.
4.
Test oil pressure switch for proper operation.
NOTE
If connector (2) requires replacement, see
.
2009 Dyna Service: Electrical 7-55
7.28
REAR STOPLIGHT SWITCH
GENERAL
See
. The rear stoplight switch monitors brake fluid
pressure in the rear brake line. When pressure in the line
reaches a preset level, the rear stoplight switch is tripped and
illuminates the tail light/stoplight.
REMOVAL
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)
1.
. Remove both connectors (2) from rear
stoplight switch (1).
2.
Place a clean container under the rear stoplight switch
and brake line to catch escaping fluid.
3.
Remove rear stoplight switch.
INSTALLATION
1.
Coat threads of stoplight switch with LOCTITE 565 (thread
sealant) perpendicular to the threads. Do not allow thread
sealant to make contact with end of switch.
2.
See
. Install rear stoplight switch (1). Tighten
switch to 12-15 ft-lbs (16.3-20.3 Nm).
3.
Install both switch connectors (2).
After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)
4.
Bleed brake system. See
.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
5.
Check stoplight for proper operation.
2
1
3
sm04050
1.
Stoplight switch
2.
Connectors
3.
Master cylinder
Figure 7-69. Rear Stoplight Switch
7-56 2009 Dyna Service: Electrical
7.29
HORN
INSPECTION
If the horn fails to sound or does not sound satisfactorily, check
for loose, frayed or damaged wires leading to horn terminal,
discharged battery or corroded ground.
The horn is permanently sealed and non-repairable. Only the
mounting hardware is replaceable.
NOTE
No tonal adjustments may be made to this horn.
REPLACEMENT
1.
. Remove nut (4) and washer (5) to detach
horn bracket (6) from vehicle.
2.
See
. Disconnect wires from posts (1, 2) on
back side of horn.
3.
. Remove screws (8) and nut (10) to
detach horn from bracket. Free wires from clamp (9).
4.
Install new horn on bracket. Secure with screws (8), push
nuts (3) and nut (10). Fold wires under clamp (9).
5.
. Attach wiring.
a.
Connect Y/BK wire to gold post (1).
b.
Connect BK wire to silver post (2).
6.
. Attach horn to vehicle using washer (5)
and nut (4). Tighten nut to 10-15 ft-lbs (13.6-20.3 Nm).
When tightening fasteners, be sure the horn does not
contact the horn cover or other parts.
7
2
9
4
5
6
8
10
1
3
sm02647
1.
Horn
2.
Cover
3.
Push nut (2)
4.
Acorn nut
5.
Washer
6.
Bracket
7.
Rubber mount
8.
Screw (2)
9.
Clamp
10. Nut
Figure 7-70. Horn
2
1
is03886
1.
Gold post and Y/BK wire
2.
Silver post and BK wire
Figure 7-71. Horn Wiring
2009 Dyna Service: Electrical 7-57
7.30
ACTIVE EXHAUST
GENERAL
The active exhaust system utilizes an actuator valve located
in the rear exhaust pipe which is connected to a servo motor
via a cable. The valve position automatically adjusts to enhance
engine performance.
The active exhaust module is located in front of the battery
box. The attached cable is routed to a bellcrank located on the
rear exhaust pipe.
REMOVAL
1.
. Remove active exhaust cable housing
(1) from notch in shroud (2). Remove ferrule (3) from active
exhaust module to free cable (4).
2.
See
. Remove module fasteners (4) and
washers (3) from battery box (1).
3
4
1
2
5
sm02645
1.
Active exhaust cable housing
2.
Shroud
3.
Ferrule
4.
Active exhaust cable
5.
Active exhaust module connector [179]
Figure 7-72. Active Exhaust Module
7
4
1
5
8
7
3
2
6
sm02643
1.
Battery box
2.
Active exhaust module
3.
Washer (2)
4.
Module fastener (2)
5.
Rear exhaust pipe, all but FXDF
6.
Cable
7.
Clip
8.
Head pipe, FXDF
Figure 7-73. Active Exhaust
REPAIR
NOTE
. Active exhaust module shroud (2) can be
replaced. Replace shroud if active exhaust cable housing (1)
is a loose fit in shroud.
1.
Remove fasteners securing shroud.
2.
Replace shroud. Replace fasteners and tighten securely.
INSTALLATION
1.
. Install ferrule (3) into slot shown. Wrap
cable counterclockwise around active exhaust module
shroud as shown.
2.
Clip cable housing into active exhaust module housing
(2).
3.
Place active exhaust module into position in front of battery
box.
4.
Install fasteners (4) and washers (3). Tighten to 36-60 in-
lbs (4.1-6.8 Nm).
5.
. After installation, be sure
active exhaust cable is routed correctly and does not
7-58 2009 Dyna Service: Electrical
contact the exhaust pipe, battery cover or transmission
case.
3
5
4
1
2
sm02642
1.
Active exhaust module
2.
Active exhaust cable
3.
Clamp
4.
Bellcrank
5.
Cable tie
Figure 7-74. Active Exhaust Cable: All but FXDF
1
4
2
3
sm03818
1.
Active exhaust module
2.
Active exhaust cable
3.
Clamp (2)
4.
Bellcrank
Figure 7-75. Active Exhaust Cable: FXDF
2009 Dyna Service: Electrical 7-59
7.31
MAIN WIRING HARNESS
GENERAL
The main wiring harness is routed through the frame backbone
and has enough slack designed into it so that it can be pulled
out of the front end of the backbone to access the connectors
located inside the frame.
NOTE
B.1 CONNECTORS, Connector Locations
for a description
of all connector locations.
REMOVAL
1.
Remove seat.
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)
NOTE
Disarm HFSM or TSSM before removal.
2.
Disconnect battery cables, negative cable first.
3.
Remove battery.
4.
Remove battery tray. See
5.
Remove instrument console.
a.
For FXDC/FXDF models, see
.
b.
For FXDL, FXDB models, see
c.
For FXD models, see
NOTE
To verify proper installation, make note of all wire routing and
connector locations before removal. In particular, pay close
attention to the locations of cable straps and anchors which
must be replaced.
6.
See
. Disconnect fuel pump/sender connector
[141].
7.
For FXDC/FXDF models, remove the remaining three
main harness connectors. The three are:
a.
Key switch [33].
b.
Indicator lamps [21] (8-Place Mini-Deutsch).
c.
Speedometer [39] (NOTE: Reset boot and switch
must be removed from console).
8.
Remove fuel tank. See
. This includes
detaching fuel gauge connector [117].
9.
Remove exhaust. See
10. Remove rear brake master cylinder. See
.
11. On HDI vehicles, remove active exhaust module connector
[179] located in front of electrical caddy.
12. Remove electrical caddy and ignition coil. See
ed02966
Figure 7-76. Fuel Pump Connector [141] (Typical)
13. See
. Remove harness shield by pushing both
tabs of shield in at the same time.
14. Pull harness connectors from inside frame.
15. Disconnect the following connectors:
a.
Right handlebar controls [22] (6-place Deutsch).
b.
Left handlebar controls [24] (6-Place Deutsch).
c.
Instruments [20].
d.
Turn signals [31].
e.
(FXDL/FXDB models) Instruments [21].
f.
Headlamp [38].
NOTE
In next step, note location of ground wires before removal to
verify proper installation.
16. See
. Remove ground wires from studs on
frame.
7-60 2009 Dyna Service: Electrical
17. Disconnect connectors located under seat:
a.
Accessory connector [4].
b.
Tail lamp harness connector [7].
c.
Rear oxygen sensor [137].
d.
Security siren connector [142] if security siren
installed.
e.
B+ connector [160].
18. Disconnect starter solenoid [128].
19. Disconnect two neutral switch post terminals located on
top of transmission.
sm02641
Figure 7-77. Harness Shield
sm02216
Figure 7-78. Vehicle Ground Studs
20. Remove rear stop light switch terminals. See
21. Remove starter post nut, positive battery cable and main
wiring harness ring terminal from starter post.
22. Disconnect rear fender extension from fender.
23. See
. Slide wire harness retainer up frame
tubes. Remove harness retainer from frame and harness.
24. Remove the following connectors located in fuel tank area:
a.
MAP sensor connector [80].
b.
Horn wires.
c.
IAT sensor connector [89].
d.
ET sensor connector [90].
e.
IAC connector [87].
f.
TP sensor connector [88].
g.
Front [84] and rear [85] fuel injector connectors.
25. Disconnect voltage regulator connector [77], crank position
sensor connector [79], stator connector [46] and front
oxygen sensor [138]. See
26. Disconnect oil pressure switch connector [120].
27. On HDI vehicles, remove intake solenoid connector [178]
from air cleaner backing plate.
28. Disassemble voltage regulator connector.
NOTE
The upper portion of the wiring harness is now free. Be careful
to note routing before pulling harness out of position.
29. Attach a long thin wire to the top end of the wiring harness
before pulling harness through frame backbone.This guide
wire will aid in pulling the new harness back through the
backbone.
30. Gently pull wiring harness out of rear of frame tube.
2009 Dyna Service: Electrical 7-61
5
1
3
2
4
sm02639
1.
Wire harness retainer
2.
Vent line
3.
To front of vehicle
4.
Rear brake light switch
5.
Front engine harness
Figure 7-79. Main Wire Harness (Typical)
INSTALLATION
NOTES
•
Be sure to replace all cable straps and anchors.
•
Do not remove factory installed wire harness tape securing
connectors to harness unless necessary.
1.
Guide wiring harness back into frame backbone. Pull the
front of the harness through using the guide wire while
pushing the harness through the frame tube opening.
2.
Connect the following connectors.
a.
Right handlebar controls [22] (6-place Deutsch).
b.
Left handlebar controls [24] (6-Place Deutsch).
c.
Instruments [20].
d.
Turn signals [31].
e.
(FXDL/FXDB models) Instruments [21].
f.
Headlamp [38].
NOTE
Be sure to leave enough slack in harness at front of vehicle so
when front wheel is turned, harness does not bind.
3.
Install connectors into frame. Install harness shield.
4.
To ease installation, wrap voltage regulator terminals with
electrical tape.
5.
. Route engine harness (which contains
voltage regulator connector [77], crank position sensor
connector [79], stator connector [46] and front oxygen
sensor [138] wiring to front of vehicle as shown. Install the
oxygen sensor and crank position sensor connectors in
front electrical caddy (see
). Connect the engine harness and stator
connectors to the voltage regulator.
6.
Route rear brake switch wiring (4) as shown and connect
to rear brake switch.
7.
Route neutral switch wiring and connect to neutral switch.
8.
Route starter solenoid wiring and connect to starter
solenoid.
9.
Install rear brake master cylinder and rear brake control.
See
2.15 REAR BRAKE MASTER CYLINDER
10. Secure front engine harness with harness clamps.
11. Install wire harness retainer (1).
12. Connect rear fender extension to rear fender.
NOTES
•
See
. To prevent contact with rear fork, front
engine harness (5) and rear brake switch wiring must be
secured in wire harness retainer (1).
•
If equipped with jiffy stand sensor (HDI models only), route
the sensor harness up along the vent line (2) and secure
in the same retainer cavity as the vent line.
13. Connect oil pressure switch [120].
14. See
. Connect vehicle speed sensor connector
[65].
15. See
. Secure harness grounds to studs.
16. Route top engine harness to fuel tank area.
17. Connect:
a.
MAP sensor connector [80].
b.
Horn wires.
c.
IAT sensor connector [89].
d.
ET sensor connector [90].
e.
IAC connector [87].
f.
TP sensor connector [88].
g.
Front [84] and rear [85] fuel injector connectors.
18. Install electrical caddy and wiring. See
7-62 2009 Dyna Service: Electrical
19. See
. Mate connectors located under seat:
a.
Accessory connector [4].
b.
Tail lamp harness connector [7].
c.
Rear oxygen sensor [137].
d.
Security siren connector [142] if security siren
installed.
e.
B+ connector [160].
20. On HDI vehicles, install active exhaust module connector
[179] located in front of electrical caddy.
21. Install fuel tank. See
. This includes con-
necting fuel gauge connector [117].
22. Install instrument console.
a.
For FXDC/FXDF models, see
.
b.
For FXDL, FXDB models, see
c.
For FXD models, see
23. Install exhaust. See
.
sm02733
Figure 7-80. Vehicle Speed Sensor
sm02216
Figure 7-81. Vehicle Ground Studs
1
4
2
3
sm02638
1.
Tail lamp connector location
2.
B+ connector location
3.
Accessory connector location
4.
Unused
Figure 7-82. Under Seat Connector Mounting Locations
2009 Dyna Service: Electrical 7-63
2
1
5
3
4
6
7
sm02637
1.
Cable strap anchor
2.
Rear O2 sensor connector [137]
3.
IAT sensor connector [89]
4.
Tail lamp connector [7]
5.
Cable strap anchor
6.
HFSM antenna
7.
Cable strap anchor
Figure 7-83. Under Seat Wiring
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)
24. Install battery and battery tray.
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)
25. Install seat.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
26. Turn ignition ON. Test all electrical components for correct
operation.
7-64 2009 Dyna Service: Electrical
7.32
HANDLEBAR SWITCH ASSEMBLIES
GENERAL
The switches are of rugged construction and feature a superior
seal to protect electrical contacts and components from dirt
and moisture in harsh environments.
The left handlebar switches include the headlamp HI - LO
switch, horn and left turn signal switch. The right handlebar
switches include the engine start and RUN - OFF switch and
right turn signal switch. The individual switches are non-
repairable and must be replaced if they malfunction.
NOTES
•
On certain models, the turn signal wiring is routed through
the lower switch housings and handlebars.
•
To replace or repair individual switches in either the right
or left handlebar switch assemblies, see
REPAIR PROCEDURES
TOOL NAME
PART NUMBER
ROBINAIR HEAT GUN
HD-25070
ULTRA TORCH UT-100
HD-39969
HEAT SHIELD ATTACHMENT
HD-41183
. The removal and installation steps
listed apply when replacing the entire switch assembly, switch
housing or handlebars.
The information below is useful when repairing handlebar
switch assemblies.
1.
To better access wires and avoid damaging conduit with
radiant heating device, push conduit back and secure with
extra 7.0 in. (177.8 mm) cable strap in kit.
2.
Strip 0.5 in (12.7 mm) of insulation off switch wires. Twist
stripped ends of switch wires until all strands are tightly
coiled.
3.
Cut dual wall heat-shrink tubing, supplied in repair kit into
1.0 in. (25.4 mm) segments. Slide tubing over each wire
of new switch assembly.
4.
Splice existing and new switch wires, matching wire colors.
Solder the spliced connections. For best results, do one
wire at a time.
5.
Center the heat-shrink tubing over the soldered splices.
Be sure to follow manufacturer's instructions when using
the UltraTorch UT-100 or any other radiant heating device.
Failure to follow manufacturer's instructions can cause a
fire, which could result in death or serious injury. (00335a)
•
Avoid directing heat toward any fuel system component.
Extreme heat can cause fuel ignition/explosion resulting
in death or serious injury.
•
Avoid directing heat toward any electrical system com-
ponent other than the connectors on which heat shrink
work is being performed.
•
Always keep hands away from tool tip area and heat shrink
attachment.
6.
See
. Using the ULTRA TORCH UT-100 (Part
No. HD-39969) or ROBINAIR HEAT GUN (Part No. HD-
25070) with HEAT SHIELD ATTACHMENT (Part No. HD-
41183) or other suitable radiant heating device, uniformly
heat the heat-shrink tubing to insulate and seal the
soldered connections. Apply heat just until the meltable
sealant exudes out both ends of tubing and it assumes a
smooth cylindrical appearance.
7.
Inspect the melted sealant for solder beads. Excess solder
or heat may force some solder out with the melted sealant.
Use a small needle nose pliers to remove any solder
found. Briefly heat the connection to reseal the tubing if
solder beads were removed. Use less solder or reduce
heating time or intensity when doing subsequent splices.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
3
2
1
sm00082
1.
Ultra Torch UT-100
2.
Robinair Heat Gun
3.
Heat Shield Attachment
Figure 7-84. Radiant Heating Devices
2009 Dyna Service: Electrical 7-65
7.33
RIGHT HANDLEBAR SWITCH
REMOVAL
NOTE
The removal and installation steps listed apply when replacing
the entire switch assembly, switch housing or handlebars.
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)
1.
Remove maxi-fuse.
2.
See
. Place the 5/32 in. (4 mm) thickness
cardboard insert between the brake lever and lever
bracket.
3.
Using a T25 TORX drive head, loosen but do not remove
the upper and lower switch housing screws.
4.
Using a T27 TORX drive head, remove the two screws
with flat washers securing the handlebar clamp to the
master cylinder housing. Remove the brake lever/master
cylinder assembly and clamp from the handlebar.
5.
Remove the upper and lower switch housing screws.
6.
Remove the friction shoe from the end of the tension
adjuster screw.
NOTE
The friction shoe is a loose fit and may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.
7.
Loosen cable adjusters. See
8.
Remove the brass ferrules from the notches on the inboard
side of the throttle control grip. Remove the ferrules from
the cable end fittings.
9.
Remove the throttle control grip from the end of the
handlebar.
10. Pull the crimped inserts at the end of the throttle and idle
control cable housings from the lower switch housing. For
best results, use a rocking motion while pulling. Place a
drop of light oil on the retaining rings, if necessary.
Remove the cables from the switch housing.
sm02635
Figure 7-85. Install 5/32 in. (4 mm) Thickness Cardboard
Insert
INSTALLATION
1.
. Push the throttle and idle control cables
into the lower switch housing until they snap in place. Note
the different diameter inserts crimped into the end of the
throttle and idle cable housings.
a.
Push the silver insert (2) of throttle cable housing into
the hole in front of tension adjuster screw (3).
b.
Push the gold insert (1) of idle cable housing into the
hole at the rear of tension adjuster screw (3).
NOTE
To aid assembly, place a drop of light oil on the retaining rings
of the crimped inserts. Always replace the retaining rings if
damaged or distorted.
2.
See
. Route the cable (2) to the upper switch
housing as shown.
3.
Slide the throttle control grip over the end of the right
handlebar until it bottoms against the closed end. Rotate
the grip so that the ferrule notches are at the top. To pre-
vent binding, pull the grip back about 1/8 in. (3.2 mm).
4.
With the concave side facing upward, install the friction
shoe so that the pin hole is over the point of the adjuster
screw.
NOTE
The friction shoe is a loose fit and may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.
7-66 2009 Dyna Service: Electrical
5.
. Position lower switch housing beneath
the throttle control grip. Install the brass ferrules (4) onto
the cable so that the end fittings seat in the ferrule recess.
Seat the ferrules in their respective notches (3) on the
throttle control grip. Verify that the cables are captured in
the grooves (2) molded into the grip.
6.
Position the upper switch housing over the handlebar and
lower switch housing.
7.
Verify that the wire harness conduit runs in the depression
at the bottom of the handlebar. Be sure that the upper
switch housing harness will not be pinched under the
handlebar when the switch housing screws are tightened.
8.
Start the upper and lower switch housing screws, but do
not tighten.
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)
1
3
2
sm02636
1.
Idle cable insert (gold insert, rear hole)
2.
Throttle cable insert (silver insert, front hole)
3.
Tension adjuster screw
Figure 7-86. Right Lower Switch Housing
1
1
2
sm02634
1.
End fittings
2.
Upper switch housing cable
Figure 7-87. Route Cable to Upper Switch Housing
5
4
3
2
1
sm01084
1.
Throttle cable (silver insert, front hole)
2.
Groove in throttle grip
3.
Notch
4.
Brass ferrule
5.
Idle cable (gold insert, rear hole)
Figure 7-88. Throttle Cable Attachment
9.
. Position the brake lever/master cylinder
assembly inboard of the switch housing assembly, enga-
ging the tab (2) on the lower switch housing in the groove
(3) at the top of the brake lever bracket.
10. Align the holes in the handlebar switch clamp with those
in the master cylinder housing and start the two screws
(with flat washers). Position for rider comfort. Beginning
with the top screw, tighten to specification using a T27
TORX drive head. Refer to
.
11. Using a T25 TORX drive head, tighten lower and upper
switch housing screws to specification. Refer to
.
NOTE
Always tighten the lower switch housing screw first so that any
gap between the upper and lower housings is at the front of
the switch.
2009 Dyna Service: Electrical 7-67
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