Harley Davidson 2009 Dyna Models. Service manual — page 6

1.12

CLUTCH

ADJUSTMENT

NOTE

Perform the clutch adjustment with the motorcycle at room
temperature. The clearance at the adjuster screw will increase
as the powertrain temperature increases. If adjuster screw is
adjusted with powertrain hot, clearance at push rod bearing
could be insufficient with powertrain cold and clutch slippage
could occur.

1.

Stand motorcycle upright and level.

2.

Remove five TORX screws with captive washers to detach
clutch inspection cover from primary chaincase cover.

3.

Remove and discard clutch inspection cover seal.

4.

See

Figure 1-20

. Add freeplay to cable.

a.

Slide rubber boot (1) off cable adjuster.

b.

Holding cable adjuster (2) with 1/2 in. wrench, loosen
jam nut (3) using a 9/16 in. wrench.

c.

Turn cable adjuster (2) until there is a large amount
of freeplay at clutch hand lever.

5.

See

Figure 1-21

. Loosen jam nut (1) on clutch adjuster

screw (2). To take up all freeplay, turn screw inward
(clockwise) until lightly seated. Activate the clutch lever to
verify the balls are seated in the ramps.

6.

Back out adjusting screw (counterclockwise) 1/2 to 1 full
turn. Tighten jam nut to 72-120 in-lbs (8.1-13.6 Nm), while
holding adjusting screw with an Allen wrench.

7.

Squeeze clutch lever to maximum limit three times, to set
ball and ramp release mechanism.

8.

Check freeplay.

a.

Turn cable adjuster away from jam nut until slack is
eliminated at hand lever.

b.

See

Figure 1-22

. Pull clutch cable ferrule (2) away

from clutch lever bracket (3) to check freeplay. Turn
cable adjuster as necessary to obtain 1/16-1/8 in.
(1.6-3.2 mm) freeplay between end of cable ferrule
and clutch lever bracket.

9.

Hold adjuster with 1/2 in. wrench. Using 9/16 in. wrench,
tighten jam nut against cable adjuster. Cover cable
adjuster mechanism with rubber boot.

10. Install clutch inspection cover and seal. Install seal as fol-

lows:

a.

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

b.

See

Figure 1-15

. Position seal (1) in groove in primary

chaincase 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

3

2

1

sm02219

1.

Rubber boot

2.

Cable adjuster

3.

Jam nut

4.

Cable end

Figure 1-20. Clutch Cable Adjuster

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2009 Dyna Service: Maintenance 1-25

1

2

sm02220

1.

Jam nut

2.

Clutch adjuster screw

Figure 1-21. Clutch Adjuster Screw

1

4

2

3

pd00059

1.

Clutch cable

2.

Cable ferrule

3.

Clutch lever bracket

4.

1/16-1/8 in. (1.6-3.2 mm)

Figure 1-22. Clutch Hand Lever

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1-26 2009 Dyna Service: Maintenance

1.13

REAR BELT AND SPROCKETS

GENERAL

When a drive belt is replaced for any reason other than stone
damage, it is recommended that the transmission and rear
sprockets also be replaced to increase the longevity of the new
drive belt. In the case of stone damage, inspect sprockets for
damage and replace as required.

Never bend belt forward into a loop smaller than the drive
sprocket diameter. Never bend belt into a reverse loop.
Over bending can damage belt resulting in premature
failure, which could cause loss of control and death or
serious injury. (00339a)

CLEANING

Keep dirt, grease, oil, and debris off the belt and sprockets.
Clean the belt with a rag slightly dampened with a light cleaning
agent.

INSPECTION

Sprockets

NOTE

If chrome chips or gouges to rear sprocket are large enough
to be harmful, they will leave a pattern on the belt face.

1.

See

Figure 1-23

. Inspect each tooth (1) of rear sprocket

for:

a.

Major tooth damage.

b.

Large chrome chips with sharp edges.

c.

Gouges caused by hard objects.

d.

Excessive loss of chrome plating (see next step).

2.

To check if chrome plating has worn off, drag a scribe or
sharp knife point across the bottom of a groove (2)
(between two teeth) with medium pressure.

a.

If scribe or knife point slides across groove without
digging in or leaving a visible mark, chrome plating
is still good.

b.

If scribe or knife points digs in and leaves a visible
mark, it is cutting the bare aluminum. A knife point
will not penetrate the chrome plating.

3.

Replace rear sprocket if major tooth damage or loss of
chrome exists.

1

2

sm02222

1.

Tooth

2.

Groove

Figure 1-23. Rear Sprocket

Rear Belt

See

Figure 1-24

. Inspect drive belt for:

•

Cuts or unusual wear patterns.

•

Outside edge bevelling (8). Some bevelling is common,
but it indicates that sprockets are misaligned.

•

Outside ribbed surface for signs of stone puncture (7). If
cracks/damage exists near edge of belt, replace belt
immediately. Damage to center of belt will require belt
replacement eventually, but when cracks extend to edge
of belt, belt failure is imminent.

•

Inside (toothed portion) of belt for exposed tensile cords
(normally covered by nylon layer and polyethylene layer).
This condition will result in belt failure and indicates worn
transmission sprocket teeth. Replace belt and transmission
sprocket.

•

Signs of puncture or cracking at the base of the belt teeth.
Replace belt if either condition exists.

•

Replace belt if conditions 2, 3, 6 or 7 (on edge of belt)
exist.

NOTE

Condition 1 may develop into 2 or 3 over time. Condition 1 is
not grounds for replacing the belt, but it should be watched
closely before condition 2 develops which will require belt
replacement.

HOME

2009 Dyna Service: Maintenance 1-27

1

3

5

7

2

4

6

8

Stone

Belt cross-section

Sprocket side
of belt

sm01390

Figure 1-24. Drive Belt Wear Patterns

Table 1-10. Drive Belt Wear Analysis

REQUIRED ACTION

CONDITION

PATTERN

OK to run, but monitor condition.

Internal tooth cracks (hairline)

1

Replace belt.

External tooth cracks

2

Replace belt.

Missing teeth

3

OK to run, but monitor condition.

Chipping (not serious)

4

OK to run, but monitor condition.

Fuzzy edge cord

5

Replace belt and sprocket.

Hook wear

6

Replace belt if damage is on the edge.

Stone damage

7

OK to run, but monitor condition.

Bevel wear (outboard edge only)

8

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1-28 2009 Dyna Service: Maintenance

sm02568

Figure 7-39. HFSM Antenna Connector [208]

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7-36 2009 Dyna Service: Electrical

7.17

CRANK POSITION SENSOR (CKP)

GENERAL

The crank position sensor is a variable reluctance (VR) sensor
that generates an AC signal by sensing the passing of the 30
teeth machined in the left side flywheel. Two consecutive teeth
are missing in the flywheel to establish a reference point. The
crank position sensor sends a signal to the electronic control
module which is used to reference engine position (TDC) and
engine speed.

NOTE

CKP sensor connector is not serviceable. If connector or sensor
fails, the entire assembly must be replaced.

REMOVAL

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)

1.

Disconnect negative battery cable.

NOTE

Before removing wiring, carefully note wire routing.

2.

Depress upper front electrical caddy cover tabs to open
cover.

3.

See

Figure 7-40

. Remove CKP sensor connector (2) from

front electrical caddy.

4.

Disconnect CKP sensor connector.

5.

See

Figure 7-41

. Remove screw and captive washer (2)

to detach CKP sensor (1) and O-ring from crankcase.
Carefully remove crank position sensor.

2

1

sm03722

1.

O2 sensor connector

2.

CKP sensor connector

Figure 7-40. Front Electrical Caddy and Connectors

1

2

sm02184

1.

CKP sensor

2.

Screw and captive washer

Figure 7-41. Crank Position Sensor

INSTALLATION

1.

See

Figure 7-42

. Lubricate CKP sensor O-ring (1) with

clean engine oil.

2.

Install new CKP sensor with screw and captive washer.
Tighten screw to 90-120 in-lbs (10.2-13.6 Nm).

3.

Connect CKP sensor connector.

a.

Mate connector halves.

b.

Install connector on front electrical caddy.

4.

Close and latch front electrical caddy cover.

5.

Connect negative battery cable.

sm02543

Figure 7-42. CKP Sensor O-Ring

HOME

2009 Dyna Service: Electrical 7-37

1.14

REAR BELT DEFLECTION

INSPECTION

TOOL NAME

PART NUMBER

H-D BELT TENSION GAUGE

HD-35381-B

Check rear belt deflection:

•

As part of the pre-ride inspection.

•

At every scheduled service interval.

When checking belt deflection:

•

Set belt tension at loosest point in belt.

•

Measure belt deflection with motorcycle cold and on jiffy
stand, or with rear wheel in the air.

•

Shift transmission into NEUTRAL.

1.

See

Figure 1-25

. Obtain H-D BELT TENSION

GAUGE (Part No. HD-35381-B).

NOTE

Customers may purchase gauge from an authorized Harley-
Davidson dealer.

2.

To use the belt tension gauge:

a.

Slide o-ring (4) toward 0 lbs (0 kg) mark (3).

b.

Fit belt cradle (2) against bottom of drive belt half-way
between drive pulleys (point 3 in

Figure 1-26

.)

c.

Press upward on knob (6) until o-ring slides down to
10 lbs (4.5 kg) mark (5).

3.

See

Figure 1-27

. Measure belt deflection as viewed

through deflection viewing window (2) while holding gauge
steady. Deflection graduations (3) are 1/8 in. (3.2 mm)
apart.

4.

Measure belt deflection several times, each time with belt
moved (by rotating rear wheel) to a different position on
sprockets.

5.

Refer to

Table 1-11

. Compare drive belt deflection with

specifications listed in the table.

NOTE

Do not rely on "feel" for the proper deflection as this typically
results in belts which are under tensioned. Always use H-D
BELT TENSION GAUGE (Part No. HD-35381-B) to determine
the 10 lb. (4.5 kg) deflection force. Loose belts will fail due to
"ratcheting" (jumping a tooth) with resultant tensile cord
crimping and breakage.

Table 1-11. Rear Belt Deflection

FXDB/FXDL

FXDF/FXD/

FXDC

MM

IN.

MM

IN.

6.4-7.9

1/4-5/16

7.9-9.5

5/16-3/8

With motorcycle on
jiffy stand without
rider or luggage

7.9-9.5

5/16-3/8

12.7-14.3

1/2-9/16

Vehicle upright with
rear wheel in air

10

0

3

6

1

2

4

5

sm02452

1.

Belt tension gauge

2.

Belt cradle

3.

0 lbs (0 kg) mark

4.

O-ring

5.

10 lbs (4.5 kg) mark

6.

Knob

Figure 1-25. Belt Tension Gauge (Part No. HD-35381-B)

HOME

2009 Dyna Service: Maintenance 1-29

1

2

3

4

om00156

1.

Transmission sprocket

2.

Rear wheel sprocket

3.

Force

4.

Deflection of belt

Figure 1-26. Check Belt Deflection

2

4

1

3

sm01441

1.

Debris deflector

2.

Belt deflection viewing window

3.

Drive belt deflection graduations

4.

Drive belt

Figure 1-27. Belt Deflection Window

ADJUSTMENT

If belt adjustment is necessary, perform the following procedure:

1.

See

Figure 1-28

. Remove retaining ring (3) and loosen

axle nut (2).

2.

Adjust belt tension by turning the axle adjusters (1) an
equal number of turns to keep the wheel aligned until the
specification in

Table 1-11

is achieved.

3.

Tighten axle nut (2) to 95-105 ft-lbs (128.8-142.4 Nm).

4.

Install retaining ring (3).

5.

Tighten adjuster screws to 96-120 in-lbs (10.8-13.6 Nm).

6.

Verify rear wheel alignment. See

2.12 VEHICLE ALIGN-

MENT

.

Check wheel bearing end play after tightening axle nut to
specified torque. Excessive end play can adversely affect
stability and handling. Insufficient end play can cause
bearing seizure. Either condition can cause loss of control,
which could result in death or serious injury. (00285a)

7.

Check wheel bearing end play. See

2.6 SEALED WHEEL

BEARINGS, Inspection

2

3

1

sm03754

1.

Axle adjuster

2.

Axle nut

3.

Retaining ring

Figure 1-28. Axle Adjusters (Left Side Shown)

HOME

1-30 2009 Dyna Service: Maintenance

1.15

THROTTLE CABLES

CABLE INSPECTION, LUBRICATION AND
ADJUSTMENT

Inspection and Lubrication

1.

See

Figure 1-29

. Remove two screws (1) to separate the

upper handlebar housing from the lower housing.

2.

Unhook each ferrule and cable from the throttle grip and
remove the throttle sleeve.

3.

Apply a light coat of graphite to the handlebar and replace
throttle grip.

4.

Put one or two drops of SUPER OIL (Part No. HD-94968-
85TV) into the housing of each cable.

5.

When assembling the handlebar housing, tighten both
screws (1) to 35-45 in-lbs (4.0-5.1 Nm).

Adjustment

The throttle control must operate freely without binding. With
the throttle friction adjustment screw backed off, the throttle
grip must freely return to the closed (idle) position. The throttle
control also must open and close freely when the front wheel
is turned to both the right and left fork stops. If the throttle grip
does not return to the idle position freely, check the throttle
friction adjustment screw tension. If the adjuster screw is
backed off, inspect the cables for short bends.

Before starting engine, be sure throttle control will snap
back to idle position when released. A throttle control that
prevents engine from automatically returning to idle can
lead to loss of control, which could result in death or ser-
ious injury. (00390a)

Do not tighten throttle friction adjustment screw to the
point where the engine will not return to idle automatically.
Over-tightening can lead to loss of vehicle control, which
could result in death or serious injury. (00031b)

Adjust throttle cables:

1.

See

Figure 1-29

. Slide rubber boot off throttle cable

adjuster mechanism (2).

2.

Holding cable adjuster with a 3/8 inch wrench, loosen jam
nut turning in a clockwise direction.

3.

Back jam nut (3) away from cable adjuster until it stops.
Turn cable adjuster clockwise until it contacts jam nut.
Repeat procedure on idle cable adjuster.

4.

See

Figure 1-30

. Point the front wheel straight ahead.

Gently turn the throttle grip so that the throttle is wide open
(fully counterclockwise) and then hold in position. Now
turn the throttle cable adjuster counterclockwise until the
throttle cam (2) just touches the cam stop (5) on the
induction module.

5.

Release the throttle grip, turn throttle cable adjuster
counterclockwise an additional 1/2-1 full turn, and then

tighten the jam nut against the cable adjuster. Cover cable
adjuster mechanism with rubber boot.

6.

Turn the front wheel full right. Turn the idle cable adjuster
counterclockwise until the cable housing (4) just touches
the spring (6) in the cable guide (as seen through slot).

7.

Work the throttle grip to verify that the throttle cable returns
to the idle position when released. If the cable does not
return to idle, turn the cable adjuster clockwise slightly
until the correct response is achieved.

8.

Tighten jam nut against the cable adjuster and cover cable
adjuster mechanism with rubber boot.

2

1

4

3

sm02225

1.

Screw (2)

2.

Throttle cable adjuster

3.

Jam nut (2)

4.

Idle cable adjuster

Figure 1-29. Throttle Cable Adjusters

2

5

1

6

4

3

sm02226

1.

Throttle cable

2.

Throttle cam

3.

Idle cable

4.

Idle cable housing

5.

Cam stop

6.

Spring

Figure 1-30. Induction Module Cable Connection

HOME

2009 Dyna Service: Maintenance 1-31

1.16

BLEEDING BRAKES

GENERAL

Use denatured alcohol to clean brake system components.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even
after assembly. Deterioration of these components can
cause brake failure, which could result in death or serious
injury. (00291a)

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)

Front brake hand lever and rear brake foot pedal must have a
firm feel when brakes are applied. If not, bleed system as
described.

PROCEDURE

NOTE

Hydraulic brake fluid bladder-type pressure equipment can be
used to fill brake master cylinder through the bleeder valve.
Remove master cylinder reservoir cover so that system cannot
pressurize. Do not use pressure bleeding equipment when the
hydraulic system is sealed with master cylinder reservoir cover
and gasket in place.

1.

Remove bleeder valve cap. Install end of a length of clear
plastic tubing over caliper bleeder valve; place other end
in a clean container. Stand motorcycle upright.

a.

Front brake bleeder valve-see

Figure 1-31

.

b.

Rear brake bleeder valve-see

Figure 1-32

.

2.

Add D.O.T. 4 BRAKE FLUID to master cylinder reservoir.
Fluid level should be 1/8-1/4 in. (3.2-6.4 mm) below the
gasket surface. Depress and hold brake lever/pedal to
build up hydraulic pressure.

3.

Open bleeder valve slowly about 1/2-turn counterclock-
wise; brake fluid will flow from bleeder valve and through
tubing. When brake lever/pedal has moved its full range
of travel, close bleeder valve (clockwise). Allow brake
lever/pedal to return slowly to its released position.

4.

Repeat Steps 2-3 until all air bubbles are purged.

5.

Tighten bleeder valve to 80-100 in-lbs (9.0-11.3 Nm).
Install bleeder valve cap.

6.

Verify master cylinder fluid level as described in Step 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)

7.

Attach covers to master cylinder reservoirs. Tighten screws
on covers to 6-8 in-lbs (0.7-0.9 Nm).

sm03755

Figure 1-31. Front Brake Bleeder Valve

sm03756

Figure 1-32. Rear Brake Bleeder Valve

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1-32 2009 Dyna Service: Maintenance