Harley Davidson 2009 Dyna Models. Service manual — page 8
1.25
CRITICAL FASTENERS
INSPECTION
Inspect critical fasteners at the scheduled service intervals.
Replace any fasteners that are damaged or missing.
Checking Torques on Fasteners
Refer to
. Attempt to turn the fastener using a torque
wrench set to the minimum torque specification for that
fastener. If the fastener does not rotate, the fastener torque
has been maintained. If the fastener rotates, remove it to
determine if it has a locking agent.
If it has a locking agent, clean all locking material from the
threaded hole. Replace the fastener with a new one or clean
the original fastener threads and apply the appropriate locking
agent (see appropriate procedure). Install and tighten the
fastener to specification.
If the fastener does not have a locking agent, install and tighten
to specification.
Table 1-16. Critical Fasteners: Dyna
TORQUE
FASTENER
SYSTEM
3.9-5.1 Nm
35-45 in-lbs
Upper and lower switch housing screws
Hand controls
6.8-9.0 Nm
60-80 in-lbs
Clutch lever handlebar clamp screws
6.8-9.0 Nm
60-80 in-lbs
Master cylinder handlebar clamp screws
28.5-33.9 Nm
21-25 ft-lbs
Banjo bolts
Brakes
38.0-51.5 Nm
28-38 ft-lbs
Front brake caliper mounting bolts
20.3-22.6 Nm
15-16 ft-lbs
Front brake pad pin/bridge bolt
13.6-18.9 Nm
10-14 ft-lbs
Rear brake caliper mounting bolts
9.0-13.6 Nm
80-120 in-lbs
Rear brake pad pin
21.7-32.5 Nm
16-24 ft-lbs
Brake disc screws, front
40.7-61.0 Nm
30-45 ft-lbs
Brake disc screws, rear
0.7-0.9 Nm
6-8 in-lbs
Reservoir cover screws
40.7-54.2 Nm
30-40 ft-lbs
Rear master cylinder mounting nut
84.1-90.1 Nm
62-67 ft-lbs
Front axle
Axle nuts
128.1-142.4 Nm
95-105 ft-lbs
Rear axle
40.7-47.5 Nm
30-35 ft-lbs
Lower fork pinch bolts
Front fork
13.6-19.0 Nm
10-14 ft-lbs
Axle cap fasteners
40.7-47.5 Nm
30-35 ft-lbs
Upper bracket pinch bolts
16.3-21.7 Nm
12-16 ft-lbs
Handlebar clamp mounting screw
2009 Dyna Service: Maintenance 1-49
1.26
ENGINE MOUNTS
INSPECTION
1.
. Check for cracks or tears in the isolator
rubber.
2.
Check stabilizer links for wear.
3.
Check that all engine mount bolts are tight.
4.
Check that all engine mount rivets are not sheared.
5.
Check that the mounts are supporting the weight of the
motor.
17
18
12
6
8
1
17
6
16
10
3
14
6
7
2
4
5
15
21
13
19
9
11
20
sm02288
12.
1.
Bolt
Bolt
2.
13.
Lockwasher
Lockwasher
14.
3.
Washer
Washer
4.
15.
Front isolator
Bolt
16.
5.
Spacer
Bolt
6.
17.
Flange nut
Washer (3)
18.
7.
Stabilizer link
Washer
8.
19.
Rear isolator
Washer
20.
9.
Bolt
Bolt
10.
21.
Flange nut
Bolt
11. Washer
Figure 1-49. Engine Mounts
1-50 2009 Dyna Service: Maintenance
1.27
STORAGE
GENERAL
If the motorcycle will not be operated for several months, such
as during the winter season, there are several things which
should be done to protect parts against corrosion, to preserve
the battery and to prevent the buildup of gum and varnish in
the fuel system.
This work should be performed following Service Manual pro-
cedures.
PLACING IN STORAGE
TOOL NAME
PART NUMBER
STORAGE COVER
98716-87A
Do not store motorcycle with gasoline in tank within the
home or garage where open flames, pilot lights, sparks or
electric motors are present. Gasoline is extremely flam-
mable and highly explosive, which could result in death
or serious injury. (00003a)
Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)
Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)
1.
Prepare the fuel system by filling fuel tank and adding a
gasoline stabilizer. Use one of the commercially available
gasoline stabilizers following the manufacturer's instruc-
tions.
2.
Run motorcycle until engine is at normal operating temper-
ature. Stop the engine then drain the oil pan, install a new
oil filter, and fill oil pan with the proper grade oil. Check
the transmission lubricant level.
3.
Remove the spark plugs, inject a few squirts of engine oil
into each cylinder and crank the engine 5-6 revolutions.
Install spark plugs.
4.
Inspect rear belt deflection. See
.
5.
Inspect rear belt and sprockets. See
6.
Inspect air cleaner filter. See
7.
Lubricate controls. See
8.
Inspect operation of all electrical equipment and switches.
9.
Check tire inflation and inspect tires for wear and/or
damage. See
. If the motorcycle
will be stored for an extended period of time, securely
support the motorcycle under the frame so that all weight
is off the tires.
10. Wash painted and chrome-plated surfaces. Apply a light
film of oil to exposed unpainted surfaces.
Unplug or turn OFF battery charger before connecting
charger cables to battery. Connecting cables with charger
ON can cause a spark and battery explosion, which could
result in death or serious injury. (00066a)
Explosive hydrogen gas, which escapes during charging,
could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks
and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)
11. Remove battery from vehicle. Charge battery until the
correct voltage is obtained. Charge the battery every other
month if it is stored at temperatures below 60° F (16° C).
Charge battery once a month if it is stored at temperatures
above 60° F (16° C). See
Unplug or turn OFF battery charger before disconnecting
charger cables from battery. Disconnecting clamps with
charger ON can cause a spark and battery explosion, which
could result in death or serious injury. (00067a)
12. If the motorcycle is to be covered, use a material that will
breathe, such as STORAGE COVER (Part No. 98716-
87A) or light canvas. Plastic materials that do not breathe
promote the formation of condensation, which leads to
corrosion.
REMOVAL FROM STORAGE
The clutch failing to disengage can cause loss of control,
which could result in death or serious injury. Prior to
starting after extended periods of storage, place transmis-
sion in gear and push vehicle back and forth several times
to assure proper clutch disengagement. (00075a)
1.
Charge and install the battery.
2.
Remove and inspect the spark plugs. Replace if neces-
sary.
3.
Clean the air cleaner element.
4.
If fuel tank was drained, fill fuel tank with fresh gasoline.
2009 Dyna Service: Maintenance 1-51
5.
Start the engine and run until it reaches normal operating
temperature.
6.
Check engine oil level. Check the transmission lubricant
level. Fill to proper levels with correct fluids, if required.
7.
Perform all of the checks in the PRE-RIDING CHECKLIST
in the Owner's Manual.
1-52 2009 Dyna Service: Maintenance
1.28
TROUBLESHOOTING
GENERAL
The Troubleshooting section of this manual is a guide to
diagnose problems. Read the appropriate sections of this
manual before performing any work. Improper repair and/or
maintenance could result in death or serious injury.
(00528b)
The following check list of possible operating troubles and their
probable causes will be helpful in keeping a motorcycle in good
operating condition. More than one of these conditions may
be causing the trouble and all should be carefully checked.
NOTE
For further troubleshooting information, see the ELECTRICAL
DIAGNOSTIC MANUAL.
ENGINE
Starter Motor Does Not Operate or Does Not
Turn Engine Over
1.
Ignition switch not in ON position.
2.
Engine run switch in OFF position.
3.
Discharged battery, loose or corroded connections
(solenoid chatters).
4.
Starter control circuit, relay, or solenoid faulty.
5.
Electric starter shaft pinion gear not engaging or overrun-
ning clutch slipping.
6.
TSM/TSSM/HFSM Bank Angle Sensor tripped and ignition
switch not cycled OFF then ON.
Engine Turns Over But Does Not Start
1.
Fuel tank empty.
2.
Fouled spark plugs.
3.
Discharged battery, loose or broken battery terminal con-
nections.
4.
Engine lubricant too heavy (winter operation).
NOTE
For cold weather starts, always disengage clutch.
5.
Spark plug cables in bad condition and shorting, cable
connections loose or cables connected to incorrect cylin-
ders.
6.
Loose wire connection at coil, battery or ECM connector.
7.
Ignition timing incorrect due to faulty coil, ECM or sensors
(MAP, CKP and/or TSM/TSSM/HFSM).
Starts Hard
1.
Spark plugs in bad condition or have improper gap or are
partially fouled.
2.
Spark plug cables in bad condition.
3.
Battery nearly discharged.
4.
Loose wire connection at one of the battery terminals, coil
or ECM connector.
5.
Water or dirt in fuel system.
6.
Intake air leak.
7.
Fuel tank vent hose and vapor valve plugged.
8.
Engine lubricant too heavy (winter operation).
NOTE
For cold weather starts, always disengage clutch.
9.
Ignition not functioning properly (possible sensor failure).
10. Faulty ignition coil.
11. Valves sticking.
Starts But Runs Irregularly or Misses
1.
Spark plugs in bad condition or partially fouled.
2.
Spark plug cables in bad condition and leaking.
3.
Spark plug gap too close or too wide.
4.
Faulty ignition coil, ECM, or sensor.
5.
Battery nearly discharged.
6.
Damaged wire or loose connection at battery terminals,
coil or ECM connector.
7.
Intermittent short circuit due to damaged wire insulation.
8.
Water or dirt in fuel system.
9.
Fuel tank vent system plugged.
10. Air leak at intake manifold or air cleaner.
11. Loose or dirty ECM connector.
12. Faulty Sensor(s): Manifold Absolute Pressure (MAP),
Crank Position (CKP) or Oxygen (O2).
13. Incorrect valve timing.
14. Weak or broken valve springs.
15. Damaged intake or exhaust valve.
Spark Plug Fouls Repeatedly
1.
Fuel mixture too rich.
2.
Incorrect spark plug for the kind of service.
3.
Piston rings badly worn or broken.
4.
Valve guides or seals badly worn.
Pre-Ignition or Detonation (Knocks or Pings)
1.
Fuel octane rating too low.
2.
Faulty spark plugs.
3.
Incorrect spark plug for the kind of service.
4.
Excessive carbon deposit on piston head or in combustion
chamber.
2009 Dyna Service: Maintenance 1-53
5.
Ignition timing advanced due to faulty sensors (MAP and/or
CKP).
Overheating
1.
Insufficient oil supply or oil not circulating.
2.
Insufficient air flow over engine.
3.
Heavy carbon deposit.
4.
Ignition timing retarded due to faulty sensor(s): Manifold
Absolute Pressure (MAP) and/or Crank Position (CKP).
5.
Leaking valve.
Valve Train Noise
1.
Low oil pressure caused by oil feed pump not functioning
properly or oil passages obstructed.
2.
Faulty hydraulic lifters.
3.
Bent push rod(s).
4.
Incorrect push rod length.
5.
Rocker arm binding on shaft.
6.
Valve sticking in guide.
7.
Chain tensioner or shoe worn.
Excessive Vibration
1.
Wheels and/or tires worn or damaged.
2.
Engine/transmission/rear wheel not aligned properly.
3.
Primary chain badly worn or links tight as a result of
insufficient lubrication or misalignment.
4.
Engine to transmission mounting bolts loose.
5.
Upper engine mounting bracket loose.
6.
Ignition timing advanced due to faulty sensor inputs (MAP
and/or CKP)/poorly tuned engine.
7.
Internal engine problem.
8.
Broken frame.
Check Engine Light Illuminates During
Operation
Fault detected. For diagnostic information see the Electrical
Diagnostic Manual.
LUBRICATION SYSTEM
Oil Does Not Return To Oil Pan
1.
Oil pan empty.
2.
Oil pump not functioning.
3.
Restricted oil lines or fittings.
4.
Restricted oil filter.
5.
Oil pump misaligned or in poor condition.
6.
O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).
Engine Uses Too Much Oil Or Smokes
Excessively
1.
Oil pan overfilled.
2.
Restricted oil return line to pan.
3.
Restricted breather operation.
4.
Restricted oil filter.
5.
Oil pump misaligned or in poor condition.
6.
Piston rings badly worn or broken.
7.
Valve guides or seals worn.
8.
O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).
9.
Plugged crankcase scavenge port.
Engine Leaks Oil From Cases, Push Rods,
Hoses, Etc.
1.
Loose parts.
2.
Imperfect seal at gaskets, push rod cover, washers, etc.
3.
Restricted breather hose to air cleaner.
4.
Restricted oil filter.
5.
Oil pan overfilled.
6.
Lower rocker housing gasket installed incorrectly (upside
down).
7.
Restricted oil return line to tank.
Low Oil Pressure
1.
Oil pan underfilled.
2.
Faulty low oil pressure switch.
3.
Oil pump O-ring damaged or missing.
4.
Bypass valve stuck in open position.
5.
Ball missing or leaking in cam support plate.
High Oil Pressure
1.
Oil pan overfilled.
2.
Bypass valve stuck in closed position.
ELECTRICAL SYSTEM
NOTE
For diagnostic information see the ELECTRICAL DIAGNOSTIC
MANUAL.
Alternator Does Not Charge
1.
Voltage regulator module not grounded.
2.
Engine ground wire loose or broken.
3.
Faulty voltage regulator module.
4.
Loose or broken wires in charging circuit.
5.
Faulty stator and/or rotor.
1-54 2009 Dyna Service: Maintenance
Alternator Charge Rate Is Below Normal
1.
Weak or damaged battery.
2.
Loose connections.
3.
Faulty voltage regulator module.
4.
Faulty stator and/or rotor.
Speedometer Operates Erratically
1.
Contaminated vehicle speed sensor (remove sensor and
clean off metal particles).
2.
Loose connections.
TRANSMISSION
Shifts Hard
1.
Primary chaincase overfilled with lubricant.
2.
Clutch not fully disengaging.
3.
Transmission lubricant too heavy (winter operation).
4.
Shifter return spring (inside transmission) bent or broken.
5.
Bent shifter rod.
6.
Shifter forks (inside transmission) sprung.
7.
Corners worn off shifter clutch dog rings (inside transmis-
sion).
Jumps Out Of Gear
1.
Shifter rod improperly adjusted.
2.
Shifter drum (inside transmission) improperly adjusted or
damaged/worn.
3.
Shifter engaging parts (inside transmission) badly worn
and rounded.
4.
Shifter forks bent.
5.
Damaged gears.
Clutch Slips
1.
Clutch controls improperly adjusted.
2.
Insufficient clutch spring tension.
3.
Worn friction discs.
Clutch Drags Or Does Not Release
1.
Lubricant level too high in primary chaincase.
2.
Clutch controls improperly adjusted.
3.
Primary chain badly misaligned or too tight.
4.
Insufficient clutch spring tension.
5.
Clutch discs warped.
Clutch Chatters
Friction discs or steel discs worn or warped.
HANDLING
Irregularities
1.
Improperly loaded motorcycle. Non-standard equipment
on the front end such as heavy radio receivers, extra
lighting equipment or luggage tends to cause unstable
handling.
2.
Damaged tire(s) or improper front-rear tire combination.
3.
Irregular or peaked front tire tread wear.
4.
Incorrect tire pressure.
5.
Shock absorber not functioning normally.
6.
Loose wheel axle nuts. Tighten to recommended torque
specification.
7.
Excessive wheel hub bearing play.
8.
Rear wheel out of alignment with frame and front wheel.
9.
Steering head bearings improperly adjusted. Correct
adjustment and replace pitted or worn bearings and races.
10. Loose spokes (laced wheel vehicles only).
11. Tire and wheel unbalanced.
12. Rims and tires out-of-round or eccentric with hub.
13. Rims and tires out-of-true sideways.
14. Rear fork pivot.
BRAKES
Brake Does Not Hold Normally
1.
Master cylinder reservoir low on fluid, system leaking or
pads worn.
2.
Brake system contains air bubbles.
3.
Master cylinder or caliper piston seals worn or parts
damaged.
4.
Brake pads contaminated with grease or oil.
5.
Brake pads badly worn.
6.
Brake disc badly worn or warped.
7.
Brake drags - insufficient brake pedal or hand lever free-
play, caliper piston worn or damaged, or excessive brake
fluid in reservoir.
8.
Brake fades due to heat build up - brake pads dragging
or excessive braking.
9.
Brake fluid leak when under pressure.
2009 Dyna Service: Maintenance 1-55
4.1
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
4.5 AIR CLEANER ASSEMBLY, Installation
4.5-6.8 Nm
40-60 in-lbs
Air cleaner cover bracket screw
4.5 AIR CLEANER ASSEMBLY, Installation
4.1-6.8 Nm
36-60 in-lbs
Air cleaner cover screw
4.5 AIR CLEANER ASSEMBLY, Installation/metric
29.8-32.5 Nm
22-24 ft-lbs
Breather bolts
4.9 ENGINE TEMPERATURE SENSOR
(ET), Installation/Hand start 2-3 turns
13.6-20.3 Nm
10-15 ft-lbs
Engine temperature sensor
4.17 EXHAUST SYSTEM, Installation: All but FXDF
11.3-13.6 Nm
100-120 in-lbs
Exhaust flange nut (lower front cylinder)
4.17 EXHAUST SYSTEM, Installation: FXDF
11.3-13.6 Nm
100-120 in-lbs
Exhaust flange nut (lower front cylinder)
4.17 EXHAUST SYSTEM, Installation: All but FXDF
11.3-13.6 Nm
100-120 in-lbs
Exhaust flange nut (lower rear cylinder)
4.17 EXHAUST SYSTEM, Installation: FXDF
11.3-13.6 Nm
100-120 in-lbs
Exhaust flange nut (lower rear cylinder)
4.17 EXHAUST SYSTEM, Installation: All but FXDF
11.3-13.6 Nm
100-120 in-lbs
Exhaust flange nut (upper front cylinder,
final torque)
4.17 EXHAUST SYSTEM, Installation: FXDF
11.3-13.6 Nm
100-120 in-lbs
Exhaust flange nut (upper front cylinder,
final torque)
4.17 EXHAUST SYSTEM, Installation: All but FXDF
1-2 Nm
9-18 in-lbs
Exhaust flange nut (upper front cylinder,
initial torque)
4.17 EXHAUST SYSTEM, Installation: FXDF
1-2 Nm
9-18 in-lbs
Exhaust flange nut (upper front cylinder,
initial torque)
4.17 EXHAUST SYSTEM, Installation: All but FXDF
11.3-13.6 Nm
100-120 in-lbs
Exhaust flange nut (upper rear cylinder,
final torque)
4.17 EXHAUST SYSTEM, Installation: FXDF
11.3-13.6 Nm
100-120 in-lbs
Exhaust flange nut (upper rear cylinder,
final torque)
4.17 EXHAUST SYSTEM, Installation: All but FXDF
1-2 Nm
9-18 in-lbs
Exhaust flange nut (upper rear cylinder,
initial torque)
4.17 EXHAUST SYSTEM, Installation: FXDF
1-2 Nm
9-18 in-lbs
Exhaust flange nut (upper rear cylinder,
initial torque)
4.14 FUEL INJECTORS, Installation
10.2-12.4 Nm
90-110 in-lbs
Fuel supply tube fastener
4.6 FUEL TANK, Installation/Front and rear
20.3-27.1 Nm
15-20 ft-lbs
Fuel tank mounting fasteners
4.8 INTAKE AIR TEMPERATURE SENSOR
(IAT), Installation
1.7-2.3 Nm
15-20 in-lbs
Intake air temperature sensor fastener
4.10 INDUCTION MODULE, Installation
10.8-16.3 Nm
96-144 in-lbs
Intake manifold mounting screws
4.17 EXHAUST SYSTEM, Installation: FXDF
20.3-25.8 Nm
15-19 ft-lbs
Muffler bracket bolt
4.17 EXHAUST SYSTEM, Installation: FXDF
20.3-25.8 Nm
15-19 ft-lbs
Muffler bracket flange nuts
4.17 EXHAUST SYSTEM, Installation: All but FXDF
51.6-58.4 Nm
38-43 ft-lbs
Muffler clamp nuts
4.17 EXHAUST SYSTEM, Installation: FXDF
51.6-58.4 Nm
38-43 ft-lbs
Muffler clamp nuts
4.17 EXHAUST SYSTEM, Installation: FXDF
20.3-25.8 Nm
15-19 ft-lbs
Muffler mounting bolt
4.17 EXHAUST SYSTEM, Installation: All but FXDF
20.3-25.8 Nm
15-19 ft-lbs
Muffler support bracket nuts
4.13 OXYGEN SENSOR, Installation
39.3-59.7 Nm
29-44 ft-lbs
Oxygen sensor
4.11 IDLE AIR CONTROL (IAC), Installation
2.3-4.0 Nm
20-35 in-lbs
Throttle cable bracket fasteners
4.12 MANIFOLD ABSOLUTE PRESSURE
SENSOR (MAP), Installation/Use new screws
2.3-4.0 Nm
20-35 in-lbs
Throttle cable bracket fasteners
4.7 THROTTLE POSITION SENSOR
(TPS), Installation
2.0 Nm
18 in-lbs
Throttle position sensor fasteners
2009 Dyna Service: Fuel System 4-1
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
CHASSIS
4.2
SPECIFICATIONS: FUEL SYSTEM
SPECIFICATIONS
Table 4-1. Fuel Capacity
FXDC
FXDF
FXD
FXDL
FXDB
CAPACITY
5.1
4.8
Total (gallons)
19.3
18.5
Total (liters)
2009 Dyna Service: Fuel System 4-3
2.1
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
2.4 FRONT WHEEL, Installation
13.6-19.0 Nm
10-14 ft-lbs
Axle cap fastener
2.4 FRONT WHEEL, Installation
13.6-19.0 Nm
10-14 ft-lbs
Axle cap fastener
2.20 BELT GUARD, Installation
13.6-20.3 Nm
10-15 ft-lbs
Belt guard fastener
2.20 BELT GUARD, Installation
13.6-20.3 Nm
10-15 ft-lbs
Belt guard fastener
2.5 REAR WHEEL, Assembly
74.6-88.1 Nm
55-65 ft-lbs
Belt sprocket screws
2.14 FRONT BRAKE CALIPER, Assembly
20.3-22.6 Nm
15-16 ft-lbs
Brake bridge bolt/pad pin, front caliper
2.13 FRONT BRAKE MASTER CYL-
INDER, Assembly and Installation
23.1-29.9 Nm
17-22 ft-lbs
Brake caliper/master cylinder banjo bolt
2.14 FRONT BRAKE CALIPER, Assembly
9.0-11.3 Nm
80-100 in-lbs
Brake caliper bleeder valve
2.16 REAR BRAKE CALIPER, Assembly
9.0-11.3 Nm
80-100 in-lbs
Brake caliper bleeder valve
2.14 FRONT BRAKE CALIPER, Assembly
38.0-51.5 Nm
28-38 ft-lbs
Brake caliper bridge bolt, front
2.4 FRONT WHEEL, Installation
38.0-51.5 Nm
28-38 ft-lbs
Brake caliper mounting bolt, front
2.4 FRONT WHEEL, Installation
38.0-51.5 Nm
28-38 ft-lbs
Brake caliper mounting bolt, front
2.16 REAR BRAKE CALIPER, Installation
13.6-18.9 Nm
10-14 ft-lbs
Brake caliper mounting bolt, rear
2.4 FRONT WHEEL, Assembly
21.7-32.5 Nm
16-24 ft-lbs
Brake disc screws, front
2.4 FRONT WHEEL, Assembly
21.7-32.5 Nm
16-24 ft-lbs
Brake disc screws, front
2.4 FRONT WHEEL, Assembly
21.7-32.5 Nm
16-24 ft-lbs
Brake disc screws, front
2.5 REAR WHEEL, Assembly
40.7-61.0 Nm
30-45 ft-lbs
Brake disc screws, rear
2.13 FRONT BRAKE MASTER CYL-
INDER, Assembly and Installation
0.7-0.9 Nm
6-8 in-lbs
Brake master cylinder reservoir cover
screws
2.16 REAR BRAKE CALIPER, Assembly
9.0-13.6 Nm
80-120 in-lbs
Brake pad pin, rear caliper
2.14 FRONT BRAKE CALIPER, Installation
0.7-0.9 Nm
6-8 in-lbs
Brake reservoir cover screws, front
2.15 REAR BRAKE MASTER CYLINDER, Installa-
tion
0.7-0.9 Nm
6-8 in-lbs
Brake reservoir cover screws, rear
2.5 REAR WHEEL, Installation
4.5-6.8 Nm
40-60 in-lbs
Debris deflector screws
2.21 DEBRIS DEFLECTOR, Installation
4.5-6.8 Nm
40-60 in-lbs
Debris deflector screws
2.32 ENGINE MOUNTS, Installation
28-36 Nm
21-27 ft-lbs
Engine mount bolt
2.32 ENGINE MOUNTS, Installation
28-36 Nm
21-27 ft-lbs
Engine mount flange nut
2.32 ENGINE MOUNTS, Installation
28-36 Nm
21-27 ft-lbs
Engine mount flange nut
2.32 ENGINE MOUNTS, Installation
28-36 Nm
21-27 ft-lbs
Engine mount flange nut
2.19 STEERING HEAD, Installation/Anti-seize
94.9-108.4 Nm
70-80 ft-lbs
Fork stem nut
2.18 FRONT FORK, Assembly
22-58 Nm
16-43 ft-lbs
Fork tube caps
2.4 FRONT WHEEL, Installation
81.3-88.1 Nm
60-65 ft-lbs
Front axle nut
2.14 FRONT BRAKE CALIPER, Installation
38.0-51.5 Nm
28-38 ft-lbs
Front brake caliper lower mounting bolt
2.14 FRONT BRAKE CALIPER, Installation
38.0-51.5 Nm
28-38 ft-lbs
Front brake caliper upper mounting bolt
2.14 FRONT BRAKE CALIPER, Installation
23.1-29.9 Nm
17-22 ft-lbs
Front caliper banjo bolt
2.28 FRONT FENDER, Installation
20.3-28.5 Nm
15-21 ft-lbs
Front fender nuts
2.18 FRONT FORK, Assembly
12-18 Nm
106-159 in-lbs
Front fork seat pipe screw
2009 Dyna Service: Chassis 2-1
NOTES
TORQUE VALUE
FASTENER
2.13 FRONT BRAKE MASTER CYL-
INDER, Assembly and Installation
6.8-9.0 Nm
60-80 in-lbs
Handlebar switch clamp screw
2.13 FRONT BRAKE MASTER CYL-
INDER, Assembly and Installation
4.0-5.1 Nm
35-45 in-lbs
Handlebar switch housing screw
2.12 VEHICLE ALIGNMENT, Inspection
33.9 Nm
25 ft-lbs
Isolator mounting bolts
2.31 JIFFY STAND, Cleaning
25.8 Nm
19 ft-lbs
Jiffy stand bolt
2.31 JIFFY STAND, Sensor (HDI Models)
10.8-16.3 Nm
96-144 in-lbs
Jiffy stand sensor screw
2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation
40.7-54.2 Nm
30-40 ft-lbs
Lower handlebar clamp fastener
2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation
40.7-54.2 Nm
30-40 ft-lbs
Lower handlebar clamp fastener
2.27 HANDLEBARS: FXDB/FXDF, Installation
40.7-54.2 Nm
30-40 ft-lbs
Lower handlebar clamp fastener
2.15 REAR BRAKE MASTER CYLINDER, Installa-
tion
28.5-33.9 Nm
21-25 ft-lbs
Master cylinder banjo bolt, rear
2.15 REAR BRAKE MASTER CYLINDER, Installa-
tion
40.7-54.2 Nm
30-40 ft-lbs
Master cylinder mounting nut, rear
2.18 FRONT FORK, Installation
41-48 Nm
30-35 ft-lbs
Pinch bolts
2.24 REAR FORK, Installation
96.3-101.7 Nm
71-75 ft-lbs
Pivot shaft nut
2.5 REAR WHEEL, Installation
128.8-142.4 Nm
95-105 ft-lbs
Rear axle nut
2.16 REAR BRAKE CALIPER, Installation
28.5-33.9 Nm
21-25 ft-lbs
Rear caliper banjo bolt
2.29 REAR FENDER, FXDF
16.3-24.4 Nm
12-18 ft-lbs
Rear fender cover screw
2.29 REAR FENDER, FXD, FXDC, and FXDL
Models
16.3-24.4 Nm
12-18 ft-lbs
Rear fender screw
2.29 REAR FENDER, FXDB Models
16.3-24.4 Nm
12-18 ft-lbs
Rear fender screw
2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation
5.6-6.8 Nm
50-60 in-lbs
Riser cover fastener
2.30 SEAT, Installation
6.78-10.17 Nm
60-90 in-lbs
Seat strap nut
2.5 REAR WHEEL, Installation
40.7-54.2 Nm
30-40 ft-lbs
Shock mounting fastener, lower
2.23 REAR SHOCK ABSORBERS, Installation/Loc-
tite Threadlocker 343 (blue)
40.7-54.2 Nm
30-40 ft-lbs
Shock mounting fastener, lower
2.5 REAR WHEEL, Installation
40.7-54.2 Nm
30-40 ft-lbs
Shock mounting fastener, upper
2.23 REAR SHOCK ABSORBERS, Installation/Loc-
tite Threadlocker 343 (blue)
40.7-54.2 Nm
30-40 ft-lbs
Shock mounting fastener, upper
2.23 REAR SHOCK ABSORBERS, Installation
101.7-115.2 Nm
70-85 ft-lbs
Shock mounting stud nut, inner
2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation
5.6-6.8 Nm
50-60 in-lbs
Speedometer cover fastener
2.7 WHEEL LACING: 17 INCH RIM, Procedure
6.2 Nm
55 in-lbs
Spoke nipple
2.8 WHEEL LACING: 19 INCH RIM, Procedure
6.2 Nm
55 in-lbs
Spoke nipple
2.9 WHEEL LACING: 21 INCH RIM, Procedure
6.2 Nm
55 in-lbs
Spoke nipple
2.10 TRUING LACED WHEELS, Radial Truing
6.2 Nm
55 in-lbs
Spoke nipple
2.22 THROTTLE CONTROL, Assembly/Installation
4.0-5.1 Nm
35-45 in-lbs
Throttle housing screws
2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation
16.3-21.7 Nm
12-16 ft-lbs
Upper handlebar clamp fastener
2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation
16.3-21.7 Nm
12-16 ft-lbs
Upper handlebar clamp fastener
2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation
16.3-21.7 Nm
12-16 ft-lbs
Upper handlebar clamp fastener
2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation
16.3-21.7 Nm
12-16 ft-lbs
Upper handlebar clamp fastener
2-2 2009 Dyna Service: Chassis
NOTES
TORQUE VALUE
FASTENER
2.27 HANDLEBARS: FXDB/FXDF, Installation
16.3-21.7 Nm
12-16 ft-lbs
Upper handlebar clamp fastener
2.27 HANDLEBARS: FXDB/FXDF, Installation
16.3-21.7 Nm
12-16 ft-lbs
Upper handlebar clamp fastener
2.27 HANDLEBARS: FXDB/FXDF, Installation
16.3-21.7 Nm
12-16 ft-lbs
Upper handlebar clamp fastener
2.17 TIRES, Installation
1.4-1.7 Nm
12-15 in-lbs
Valve stem nut
2009 Dyna Service: Chassis 2-3
2.2
SPECIFICATIONS
SPECIFICATIONS
Chassis Specifications
Table 2-1. Dimensions: 2009 Dyna Models
FXDF
FXDB
FXDL
FXDC
FXD
ITEM
MM
IN.
MM
IN.
MM
IN.
MM
IN.
MM
IN.
1619.76
63.77
1630.68
64.20
1640.89
64.60
1630.68
64.20
1630.68
64.20
Wheel base
2329.94
91.73
2357.12
92.80
2364.74
93.10
2359.66
92.90
2357.12
92.80
Overall length
889.76
35.03
952.50
37.50
922.02
36.30
988.06
38.90
932.18
36.70
Overall width
124.99
4.92
124.97
4.92
124.97
4.92
135.13
5.32
135.13
5.32
Road clearance
1131.82
44.56
1280.16
50.40
1193.80
47.00
1211.58
47.70
1188.72
46.80
Overall height
662.94
26.10
649.22
25.56
655.32
25.80
680.72
26.80
675.64
26.60
Saddle height*
*With 180 lb. (81.6 kg) rider on seat.
Table 2-2. Capacities: 2009 Dyna Models
FXDF
FXDB
FXDL
FXDC
FXD
ITEM
LITERS
U.S.
LITERS
U.S.
LITERS
U.S.
LITERS
U.S.
LITERS
U.S.
18.93
5.00 gal
18.17
4.80 gal
18.17
4.80 gal
18.93
5.00 gal
18.17
4.80 gal
Fuel tank (total)
2.84
3.00 qt.
2.84
3.00 qt.
2.84
3.00 qt.
2.84
3.00 qt.
2.84
3.00 qt.
Oil tank with filter
0.95
1.00 qt.
0.95
1.00 qt.
0.95
1.00 qt.
0.95
1.00 qt.
0.95
1.00 qt.
Transmission
(approximate)
0.95
1.00 qt.
0.95
1.00 qt.
0.95
1.00 qt.
0.95
1.00 qt.
0.95
1.00 qt.
Primary chaincase
(approximate)
3.41
0.90 gal
3.41
0.90 gal
3.41
0.90 gal
3.41
0.90 gal
3.41
0.90 gal
Low fuel warning
light on
Table 2-3. Weights: 2009 Dyna Models
FXDF
FXDB
FXDL
FXDC
FXD
ITEM
KG
LB.
KG
LB.
KG
LB.
KG
LB.
KG
LB.
303.77
669.70
287.58
634.00
290.75
641.00
292.57
645.00
286.67
632.00
Weight (as shipped
from factory)
492.15
1085.00
492.15
1085.00
492.15
1085.00
492.15
1085.00
492.15
1085.00
GVWR
176.90
390.00
176.90
390.00
176.90
390.00
176.90
390.00
176.90
390.00
GAWR front
315.25
695.00
315.25
695.00
315.25
695.00
315.25
695.00
315.25
695.00
GAWR rear
NOTES
•
Gross vehicle weight rating (GVWR) (maximum allowable
loaded vehicle weight) and corresponding gross axle
weight rating (GAWR) are given on a label located on the
frame steering head.
•
For important information regarding tire data and tire
inflation, see
.
2-4 2009 Dyna Service: Chassis
Tire Specifications
Use only Harley-Davidson approved tires. See a Harley-
Davidson dealer. Using non-approved tires can adversely
affect stability, which could result in death or serious
injury. (00024a)
Tire sizes are molded on the sidewall. Refer to the tire fitment
tables below. Rim size and contour are cast or stamped into
the exterior surface of the rim.
Example: T19 x 2.15 MT DOT. "T" indicates that the rim con-
forms to Tire and Rim Association standards. The "19" is the
normal diameter of the rim in inches, measured at the bead
seat diameter. The "2.15" is the width of the bead seat meas-
ured in inches. "MT" designates the rim contour. "DOT" means
that the rim meets Department of Transportation Federal Motor
Vehicle Safety Standards.
Table 2-4. Tire Fitment - Tubeless Cast Wheels
Tire Size
Rim Valve Hole Dia.
Rim Size & Contour
Wheel Size & Position
Dunlop D427F
0.327 in.
E16 x 3.00 MT
16 in. - Front
130/90B16 73H
Dunlop D401F
0.327 in.
T19 x 2.5 MT
19 in. - Front
100/90-19 57H
Dunlop D427
0.333 in.
T16 x 5.0 MT
16 in. - Rear
180/70B16 77H
Dunlop K591
0.327 in.
T17 x 4.5 MT
17 in. - Rear
160/70B17 73V
Table 2-5. Tire Fitment - Tube Type Steel Laced Wheels
Tire Size
Tube Size
Center Valve Tube
Rim Size & Contour
Wheel Size & Position
Dunlop D401F
MJ/MM90-19
19M/C x MT2.5 T
19 in. - Front
100/90-19 57H
100/90-19
Dunlop D402F
MH90x21
21 M/C x MT2.15 T
21 in. - Front
MH90-21 54H
Dunlop K591
150-160/70-17
17M/C x MT4.5 T
17 in. - Rear
160/70B17 73V
Table 2-6. Tire Fitment - Tube Type Chrome Aluminum Profile Laced Wheels
Tire Size
Tube Size
Center Valve Tube
Rim Size & Contour
Wheel Size & Position
Dunlop D401F
MJ/MM90-19
T19 x 2.50 TLA
19 in. - Front
100/90-19 57H
100/90-19
Dunlop D402F
MH90x21
T21 x 2.15 TLA
21 in. - Front
MH90-21 54H
Dunlop K591
150-160/70-17
17M/C x MT4.5 T
17 in. - Rear
160/70B17 73V
2009 Dyna Service: Chassis 2-5
Table 2-7. Tire Pressures: 2009 Dyna Models
TIRE PRESSURE (COLD)
LOAD
MODEL
REAR
FRONT
kPa
PSI
kPa
PSI
248
36
206
30
Solo rider
All models except FXDF
275
40
206
30
Rider and passenger
248
36
248
36
Solo rider
FXDF
275
40
248
36
Rider and passenger
2-6 2009 Dyna Service: Chassis
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