Harley Davidson 2009 Dyna Models. Service manual — page 1
Fastener Torque Values in this Chapter. . . . . . . ..1-1
Repair and Replacement Procedures. . . . . . . . 1-4
Cleaning. . . . . . . . . . . . . . . . . . . .1-5
Tool Safety. . . . . . . . . . . . . . . . . . ..1-5
General. . . . . . . . . . . . . . . . . . . ...1-7
Checking and Adding Oil. . . . . . . . . . . . ..1-12
Changing Oil and Filter. . . . . . . . . . . . . .1-13
General. . . . . . . . . . . . . . . . . . . .1-15
1.8 AIR CLEANER AND EXHAUST SYSTEM
Changing Transmission Lubricant. . . . . . . . . .1-24
Adjustment. . . . . . . . . . . . . . . . . ...1-25
Sprockets. . . . . . . . . . . . . . . . ..1-27
Rear Belt. . . . . . . . . . . . . . . . ...1-27
Cable Inspection, Lubrication and Adjustment. . . . .1-31
Inspection and Lubrication. . . . . . . . . . 1-31
Adjustment. . . . . . . . . . . . . . . . 1-31
Inspection. . . . . . . . . . . . . . . . . . .1-33
Brake Pads. . . . . . . . . . . . . . . . 1-33
Brake Disc. . . . . . . . . . . . . . . . .1-33
Brake Pad Replacement. . . . . . . . . . . . ...1-33
Rear Brake Caliper. . . . . . . . . . . . . 1-33
Front Brake Caliper. . . . . . . . . . . . ...1-34
Voltmeter Test. . . . . . . . . . . . . . . 1-37
Charging Battery. . . . . . . . . . . . . . . ..1-37
Safety Precautions. . . . . . . . . . . . . 1-37
Using a Battery Charger. . . . . . . . . . . 1-37
III
T
ABLE OF CONTENTS
Rear Shock Preload Adjustment. . . . . . . . . ..1-41
Adjustment. . . . . . . . . . . . . . . . . ...1-44
Bearing Adjustment (Fall Away). . . . . . . . 1-44
Lubrication. . . . . . . . . . . . . . . . . . 1-44
Replacing Fork Oil. . . . . . . . . . . . . . . 1-45
1.23 CABLE AND CHASSIS LUBRICATION
All Models. . . . . . . . . . . . . . . . ..1-47
Inspection. . . . . . . . . . . . . . . . . . .1-49
Checking Torques on Fasteners. . . . . . . . 1-49
Inspection. . . . . . . . . . . . . . . . . . .1-50
Lubrication System. . . . . . . . . . . . . . ...1-54
Electrical System. . . . . . . . . . . . . . . ..1-54
Alternator Does Not Charge. . . . . . . . . ..1-54
Transmission. . . . . . . . . . . . . . . . . .1-55
Handling. . . . . . . . . . . . . . . . . . ...1-55
Irregularities. . . . . . . . . . . . . . . ..1-55
Brakes. . . . . . . . . . . . . . . . . . . ..1-55
Brake Does Not Hold Normally. . . . . . . . .1-55
Fastener Torque Values in this Chapter. . . . . . . ..2-1
Specifications. . . . . . . . . . . . . . . . . .2-4
2.3 VEHICLE IDENTIFICATION NUMBER
(V.I.N.)
General. . . . . . . . . . . . . . . . . . . ...2-7
Cast Wheel. . . . . . . . . . . . . . . . 2-13
Laced Wheel. . . . . . . . . . . . . . . .2-13
Installation. . . . . . . . . . . . . . . . . . 2-13
Procedure. . . . . . . . . . . . . . . . . . .2-24
General. . . . . . . . . . . . . . . . . . . .2-28
IV TABLE OF CONTENTS
TABLE OF CONTENTS
Procedure. . . . . . . . . . . . . . . . . . .2-28
2.11 CHECKING CAST WHEEL RUNOUT
Inspection. . . . . . . . . . . . . . . . . . .2-35
2.13 FRONT BRAKE MASTER CYLINDER
2.15 REAR BRAKE MASTER CYLINDER
Tube Type Tires. . . . . . . . . . . . . . .2-56
Tubeless Tires. . . . . . . . . . . . . . ...2-57
Removal. . . . . . . . . . . . . . . . . . ...2-63
Steering Head Bearing Race Removal . . . . . 2-64
2.26 HANDLEBARS: ALL BUT FXDB/FXDF
Removal. . . . . . . . . . . . . . . . . . ...2-74
Installation. . . . . . . . . . . . . . . . . . 2-75
Removal. . . . . . . . . . . . . . . . . . ...2-77
FXDB. . . . . . . . . . . . . . . . . . .2-77
FXDF. . . . . . . . . . . . . . . . . . .2-77
Installation. . . . . . . . . . . . . . . . . . 2-78
General. . . . . . . . . . . . . . . . . . . .2-81
Removal. . . . . . . . . . . . . . . . . 2-81
TABLE OF CONTENTS V
TABLE OF CONTENTS
FXDF. . . . . . . . . . . . . . . . . . . . 2-82
Removal. . . . . . . . . . . . . . . . . 2-82
Installation. . . . . . . . . . . . . . . . .2-82
FXD, FXDC, and FXDL Models. . . . . . . . . . 2-82
Removal. . . . . . . . . . . . . . . . . 2-82
Installation. . . . . . . . . . . . . . . . .2-82
FXDB Models. . . . . . . . . . . . . . . . ...2-82
Removal. . . . . . . . . . . . . . . . . 2-82
Installation. . . . . . . . . . . . . . . . .2-83
Removal. . . . . . . . . . . . . . . . . . ...2-88
Front Isolator. . . . . . . . . . . . . . . .2-88
Rear Isolator. . . . . . . . . . . . . . . ..2-88
Installation. . . . . . . . . . . . . . . . . . 2-88
Front Isolator. . . . . . . . . . . . . . . .2-88
Rear Isolator. . . . . . . . . . . . . . . ..2-88
Fastener Torque Values in this Chapter. . . . . . . ..3-1
Specifications. . . . . . . . . . . . . . . . . .3-3
General. . . . . . . . . . . . . . . . . . . ...3-5
General. . . . . . . . . . . . . . . . . . . .3-15
Diagnosing Valve Train Noise. . . . . . . . . . ...3-17
3.12 STRIPPING MOTORCYCLE FOR
SERVICE
Procedure. . . . . . . . . . . . . . . . . . .3-24
3.13 ASSEMBLING MOTORCYCLE AFTER
SERVICE
Procedure. . . . . . . . . . . . . . . . . . .3-25
3.14 REMOVING ENGINE FROM CHASSIS
Procedure. . . . . . . . . . . . . . . . . . .3-26
3.15 INSTALLING ENGINE IN CHASSIS
Procedure. . . . . . . . . . . . . . . . . . .3-27
3.16 TOP END OVERHAUL: DISASSEMBLY
3.17 TOP END OVERHAUL: ASSEMBLY
3.18 BOTTOM END OVERHAUL:
DISASSEMBLY
Crankcase. . . . . . . . . . . . . . . . . . 3-48
VI TABLE OF CONTENTS
TABLE OF CONTENTS
2
1
sm02295
1.
Cylinder
2.
Dowel pin
Figure 3-34. Cylinder Dowel Pins
3
4
2
1
4
3
1
2
sm02349
1.
Short bolt
2.
Short bolt
3.
Long bolt
4.
Long bolt
Figure 3-35. Cylinder Head Bolt Torque Sequence (Top:
Front Cylinder Head, Bottom: Rear Cylinder Head)
NOTE
Improperly tightened cylinder head bolts may result in gasket
leaks, stud failure and distortion of the cylinder and/or cylinder
head.
2009 Dyna Service: Engine 3-39
5.
Tighten the four cylinder head bolts.
a.
Following sequence shown, alternately turn each
cylinder head bolt until finger tight.
b.
Following the same sequence, tighten the cylinder
head bolts to 120-144 in-lbs (13.5-16.2 Nm).
c.
Continuing the same sequence, tighten each bolt to
15-17 ft-lbs (20.3-23.0 Nm).
d.
See
. Using a grease pencil, mark a
straight line on the cylinder head bolt continuing the
line over onto the cylinder head.
e.
Using the marks as a guide, turn each bolt 1/4 turn
or 90 degrees. Be sure to tighten the cylinder head
bolts in the sequence shown in
sm02395
Figure 3-36. Final Tightening for Cylinder Head Bolts
NOTES
•
For best results, use SNAP-ON TORQUE ANGLE GAUGE
TA360.
•
Even though all bolt holes (rocker housing, rocker arm
support plate and breather assembly) may appear to be
in alignment, the rocker housing gasket may be installed
upside down. An upside down gasket will result in an open
breather channel causing a major oil leak when the vehicle
is started, possibly resulting in engine and/or property
damage.
•
On front cylinder head, install side of gasket marked "front"
facing up. On rear cylinder head, install side of gasket
marked "rear" facing up.
6.
. Install a new rocker housing gasket on
the cylinder head. Verify that the rocker housing gasket
covers the breather channel.
3-40 2009 Dyna Service: Engine
2
1
sm02350
1.
CORRECT: Breather channel covered
2.
INCORRECT: Breather channel exposed
Figure 3-37. Install Rocker Housing Gasket (Rear Cylinder Shown)
7.
See
. With the indent (1) facing forward, place
the rocker housing into position aligning the holes in the
housing with those in the gasket.
8.
See
. Apply a small dab of LOCTITE
THREADLOCKER 243 (blue) to threads of six rocker
housing bolts. Loosely install the rocker housing bolts.
Place two long bolts on the left side of the engine and four
intermediate bolts in the interior. Alternately tighten the
bolts to 120-168 in-lbs (13.6-19.0 Nm) in the sequence
shown.
NOTES
•
If the engine was left in the chassis for service, final tighten
the rear left rocker housing bolt (rear cylinder) using a
torque wrench with a 1/4 in. drive.
•
O-rings that are missing, distorted, pinched or otherwise
damaged will result in either oil leakage or low oil pressure.
Use of the wrong o-ring will have the same results. Since
many o-rings are similar in size and appearance, always
use new o-rings, keeping them packaged until use to avoid
confusion.
9.
. Apply a very thin film of clean H-D 20W50
engine oil to new baffle hole o-ring (2). Install new o-ring
in groove around breather baffle hole in rocker housing.
NOTE
Do not confuse breather baffle hole o-ring (Part No. 11270,
large inner diameter) with the top push rod o-ring (Part No.
11293, small inner diameter).
2009 Dyna Service: Engine 3-41
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