Harley Davidson 2009 Dyna Models. Service manual — page 5

om00846

Figure 1-12. Tire Sidewall Wear Bar Locator

om00845

Figure 1-13. Wear Bar Appearance (Typical)

WHEEL BEARINGS

1.

Replace when bearings exceed end play service wear
limit of 0.002 in. (0.051 mm).

2.

Inspect any time the wheels are removed.

a.

Inspect the play of the wheel bearings by finger while
they are in the wheel.

b.

Rotate the inner bearing race and check for abnormal
noise.

c.

Make sure bearing rotates smoothly.

3.

Check wheel bearings and axle spacers for wear and
corrosion. Excessive play or roughness indicates worn
bearings. Replace bearings in sets only. See

2.6 SEALED

WHEEL BEARINGS, Inspection

.

WHEEL SPOKES

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)

If nipples require more than one full turn to tighten spoke,
remove tire to check that spoke protrusion has not dam-
aged tube. (00526b)

1.

Raise motorcycle wheel off the ground.

NOTE

Perform the entire procedure for each spoke, one at a time.

2.

Mark one of the spokes with a reference mark to the rim.

3.

Loosen spoke 1/4 turn.

NOTES

•

Use a spoke torque wrench to tighten spokes.

•

Do not tighten spoke more than 1/4 turn past reference
mark. If more tension is needed, label spoke and check
after completing rest of wheel.

4.

Tighten spoke to reference mark. If torque is less then the
value listed in

Table 1-8

, continue to tighten spoke until it

reaches the listed torque.

5.

Once the entire wheel has been checked, repeat pro-
cedure for each labeled spoke.

6.

If more than a few spokes were loose, true the entire wheel
following procedure under

2.10 TRUING LACED WHEELS

.

Table 1-8. Spoke Nipple Torque Specification

MINIMUM TORQUE

RIM TYPE

55 in-lbs (6.2 Nm)

All

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2009 Dyna Service: Maintenance 1-21

1.10

PRIMARY CHAIN

GENERAL

All models have an automatic chain tensioner. For primary
chain service procedures, see

5.4 DRIVE COMPONENTS

.

CHANGING PRIMARY CHAINCASE
LUBRICANT

1.

Run motorcycle until engine is warmed up to normal
operating temperature.

When draining or adding lubricant, do not allow dirt, debris
or other contaminants to enter the engine. (00198a)

Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)

2.

See

Figure 1-14

. Remove magnetic drain plug at bottom

of primary chaincase. Drain lubricant into suitable con-
tainer.

NOTE

Dispose of lubricant in accordance with local regulations.

3.

Clean drain plug. If plug has accumulated a lot of debris,
inspect the condition of chaincase components.

4.

Install new o-ring on drain plug.

5.

Install drain plug back into primary chaincase cover.
Tighten plug to 14-21 ft-lbs (19.0-28.5 Nm).

6.

See

Figure 1-15

. Remove five TORX screws with captive

washers (3) to detach clutch inspection cover (2) from
primary chaincase cover.

7.

Remove the seal (1). Wipe oil from groove in chaincase
cover and mounting surface.

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)

8.

Refer to

Table 1-9

. Pour the specified amount of GENUINE

Harley-Davidson FORMULA+ TRANSMISSION AND
PRIMARY CHAINCASE LUBRICANT (Part No. 99851-05
quart) in through the clutch inspection cover opening.

Table 1-9. Primary Chaincase Lubricant Refill Capacity

CAPACITY

ITEM

32 oz (0.95 L) wet

Primary chaincase lubricant

40 oz (1.18 L) dry

om00114a

Figure 1-14. Removal/Installation of Chaincase Drain Plug

3

2

1

om00709

1.

Seal

2.

Clutch inspection cover

3.

Screws with captive washer

Figure 1-15. Clutch Cover

HOME

1-22 2009 Dyna Service: Maintenance

9.

Install clutch inspection cover and new seal as follows:

a.

Thoroughly wipe all lubricant from cover mounting
surface and groove in chaincase.

b.

See

Figure 1-15

. Position new seal (1) in groove in

clutch inspection cover and press each of the nubs
on seal into the groove. The nubs will retain seal in
position.

c.

See

Figure 1-16

. Insert screw (with captive washer)

through clutch inspection cover and carefully thread
it into the top cover screw hole.

d.

Start the remaining four screws (with captive
washers).

e.

Alternately tighten screws to 84-108 in-lbs (9.5-12.2
Nm) following torque sequence shown in

Figure 1-16

.

4

5

2

3

1

sm02844

Figure 1-16. Clutch Cover Torque Sequence

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2009 Dyna Service: Maintenance 1-23

1.11

TRANSMISSION LUBRICANT

CHANGING TRANSMISSION LUBRICANT

1.

See

Figure 1-17

. Remove transmission filler plug.

When draining or adding lubricant, do not allow dirt, debris
or other contaminants to enter the engine. (00198a)

Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)

2.

See

Figure 1-19

. Remove transmission drain plug and

drain lubricant into a suitable container.

NOTE

Dispose of transmission lubricant in accordance with local
regulations.

3.

Inspect o-ring on drain plug for tears or damage. Replace
as required. Wipe any foreign material from plug.

Do not over-tighten filler or drain plug. Doing so could
result in a lubricant leak. (00200b)

4.

Install o-ring and drain plug. Tighten to 14-21 ft-lbs (19.0-
28.5 Nm). Do not over-tighten.

5.

Fill the transmission with 32 oz. (0.95 liter) of GENUINE
Harley-Davidson FORMULA+ TRANSMISSION AND
PRIMARY CHAINCASE LUBRICANT (Part No. 99851-05)
(quart).

6.

With motorcycle on a level surface and resting on jiffy
stand, check lubricant level.

a.

Insert filler plug/dipstick into transmission fill hole but
do not thread in.

b.

See

Figure 1-18

. Remove filler plug/dipstick and

check lubricant level on dipstick. Lubricant level
should be between upper mark (2) and lower mark
(1). If necessary, add lubricant until level is correct.

7.

Install filler plug/dipstick and tighten to 25-75 in-lbs (2.8-
8.5 Nm).

sm02450

Figure 1-17. Transmission Filler Plug/Dipstick Location

3

2

1

sm02451

1.

Lower mark (add lubricant)

2.

Upper mark (full)

3.

Bottom edge of threaded section

Figure 1-18. Filler Plug/Dipstick

2

1

sm02174

1.

Engine oil drain plug and o-ring

2.

Transmission drain plug

Figure 1-19. Oil Pan

HOME

1-24 2009 Dyna Service: Maintenance

3

2

1

4

5

6

7

sm02565

1.

Lens

2.

Bulb

3.

Socket assembly

4.

Lamp housing

5.

Lamp support

6.

Washer

7.

Fastener

Figure 7-33. Rear Turn Signals

HOME

7-32 2009 Dyna Service: Electrical

3

4

5

2

1

3

3

4

4

5

5

2

2

1

1

sm02706a

1.

Conduit

2.

Right directional wire harness

3.

Left directional wire harness

4.

Tail lamp

5.

Tail lamp/turn signal wire harness

Figure 7-34. Rear Fender Harness Routing-viewed from underneath (Top: FXD, FXDC, FXDL; Middle: FXDF; Bottom:

FXDB)

HOME

2009 Dyna Service: Electrical 7-33

7.15

STOP-TAIL-TURN (STT) MODULE: FXDB
(DOMESTIC ONLY)

GENERAL

The domestic FXDB rear turn signal lamps also serve as tail
lamps and brake lamps. Dual filament bulbs provide these
features; one filament provides the tail lamp function while the
other filament provides the dual function of turn signal and
brake lamp.

The stop-tail-turn (STT) module is used to control the turn
signal lamps for all three functions (stop, tail, turn).

The STT module is located under the seat, next to the battery.

STT MODULE REPLACEMENT

1.

Remove seat. See

2.30 SEAT

.

2.

Remove battery and battery tray. See

1.18 BATTERY

MAINTENANCE, Disconnection and Removal

.

3.

See

Figure 7-35

. Disconnect STT module connectors (1)

from harness.

NOTES

•

The STT module is held onto the frame with a barb molded
to the STT module housing. When removing the module,
be careful not to break off the barb from the module.

•

If the barb from the module does break off, route a cable
tie through the tabs located on each side of the module
to secure it to the motorcycle frame.

4.

Replace STT module (2).

5.

Connect STT module connectors (1) to harness.

6.

Install battery tray and battery. See

1.18 BATTERY

MAINTENANCE, Installation and Connection

.

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)

7.

Install seat. See

2.30 SEAT

.

1

2

sm05849

1.

Connector (2)

2.

Module

Figure 7-35. Stop-Tail-Turn (STT) Module

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7-34 2009 Dyna Service: Electrical