Harley Davidson 2009 Dyna Models. Service manual — page 3

Perform the service and maintenance operations as
indicated in the regular service interval table. Lack of
regular maintenance at the recommended intervals can
affect the safe operation of your motorcycle, which could
result in death or serious injury. (00010a)

Service operations to be performed before customer delivery
are specified in the applicable model year predelivery and set-
up instructions.

The performance of new motorcycle initial service is required
to keep warranty in force and to verify proper emissions sys-
tems operation. See

1.3 MAINTENANCE SCHEDULE

SAFE OPERATING MAINTENANCE

NOTES

•

Do not attempt to retighten engine head bolts. Retightening
can cause engine damage.

•

During the initial break-in period, use only Harley-Davidson
20W50 engine oil. Failure to use the recommended oil will
result in improper break-in of the engine cylinders and
piston rings.

A careful check of certain equipment is necessary after periods
of storage, and frequently between regular service intervals,
to determine if additional maintenance is required.

Check:

Tires for abrasions, cuts and correct pressure.

Secondary drive belt for proper tension and condition.

Brakes, steering and throttle for responsiveness.

Brake fluid level and condition. Hydraulic lines and fittings
for leaks. Also, check brake pads and rotors for wear.

Cables for fraying, crimping and free operation.

Engine oil and transmission fluid levels.

Headlamp, auxiliary lamp, tail lamp, brake lamp, horn and
turn signal operation.

SHOP PRACTICES

Repair Notes

General maintenance practices are given in this section.

NOTES

•

Repair = Disassembly/Assembly.

•

Replacement = Substitute a new part for existing com-
ponent.

All special tools and torque values are noted at the point of
use.

All required parts or materials can be found in the appropriate
PARTS CATALOG.

Safety

Safety is always the most important consideration when per-
forming any job. Be sure you have a complete understanding
of the task to be performed. Use common sense. Use the
proper tools. Protect yourself and bystanders with approved
eye protection. Don't just do the job - do the job safely.

Removing Parts

Always consider the weight of a part when lifting. Use a hoist
whenever necessary. Do not lift heavy parts by hand. A hoist
and adjustable lifting beam or sling are needed to remove some
parts. The lengths of chains or cables from the hoist to the part
should be equal and parallel and should be positioned directly
over the center of the part. Be sure that no obstructions will
interfere with the lifting operation. Never leave a part suspended
in mid-air.

Be sure to check capacity rating and condition of hoists,
slings, chains and cables before use. Exceeding capacity
ratings or using lifting devices that are in poor condition
can lead to an accident, which could result in death or
serious injury. (00466c)

Always use blocking or proper stands to support the part that
has been hoisted. If a part cannot be removed, verify that all
bolts and attaching hardware have been removed. Check to
see if any parts are in the way of the part being removed.

When removing hoses, wiring or tubes, always tag each part
to verify proper installation.

Cleaning

If you intend to reuse parts, follow good shop practice and
thoroughly clean the parts before assembly. Keep all dirt out
of parts; the unit will perform better and last longer. Seals, filters
and covers are used in this vehicle to keep out environmental
dirt and dust. These items must be kept in good condition to
guarantee satisfactory operation.

When you are instructed in a step to clean fastener threads or
threaded holes, proceed as follows: Clean all LOCTITE material
from fastener threads and threaded holes. Use a wire brush
to clean fastener threads. Use a thread chaser or other suitable
tool to clean threaded holes. Use PJ-1 cleaner or equivalent
to remove all traces of oil and contaminants from threads. Blow
out all threaded holes with low pressure compressed air.

Clean and inspect all parts as they are removed. Be sure all
holes and passages are clean and open. After cleaning, cover
all parts with clean lint-free cloth, paper or other material. Be
sure the part is clean when it is installed.

Always clean around lines or covers before they are removed.
Plug, tape or cap holes and openings to keep out dirt, dust and
debris.

Always verify cleanliness of blind holes before assembly.
Tightening a screw with dirt, water or oil in the hole can cause
castings to crack or break.

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2009 Dyna Service: Maintenance 1-3

Disassembly and Assembly

Always assemble or disassemble one part at a time. Do not
work on two assemblies simultaneously. Be sure to make all
necessary adjustments. Recheck your work when finished. Be
sure that everything is done.

Operate the vehicle to perform any final check or adjustments.
If all is correct, the vehicle is ready to go back to the customer.

Checking Torques on Fasteners

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 is a lock-patch
type.

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 Loctite
product (see appropriate procedure). Install and tighten the
fastener to specification.

If the fastener is not lock-patch type, install and tighten to
specification.

Magnetic Parts Trays

Magnetic parts trays are becoming common in the service
facility because they are convenient and can keep parts from
becoming lost during a repair procedure.

However, hardened steel parts can become magnetized when
held in magnetic parts trays. Metal fragments that would
ordinarily be washed away in the oil and trapped in the oil filter
or magnetic drain plug during vehicle operation could be cap-
tured by magnetized parts in the engine, potentially causing
accelerated engine wear and damage.

Parts that will be returned to service inside the vehicle's
powertrain such as gears, thrust washers and especially
bearings should never be kept in magnetic parts trays.

REPAIR AND REPLACEMENT
PROCEDURES

Hardware and Threaded Parts

Install helical thread inserts when inside threads in castings
are stripped, damaged or not capable of withstanding specified
torque.

Replace bolts, nuts, studs, washers, spacers and small
common hardware if missing or in any way damaged. Clean
up or repair minor thread damage with a suitable tap or die.

Replace all damaged or missing lubrication fittings.

Use Teflon pipe sealant or LOCTITE 565 THREAD SEALANT
on pipe fitting threads.

Threadlocking Agents

Always follow specific service manual procedures when working
with fasteners containing preapplied threadlocking agents when
fastener replacement is recommended. When re-using
fasteners containing threadlocking agents, be sure to com-
pletely remove all existing threadlocking agent from fastener
threads with a wire brush or wire wheel. Also, be sure to
remove residual threadlocking agent from fastener hole using
an appropriate thread chasing device and compressed air when

using new or existing fasteners. Always use the recommended
threadlocking agent for your specific procedure.

Wiring, Hoses and Lines

Hoses, clamps, electrical wiring, electrical switches or fuel lines
if they do not meet specifications.

Instruments and Gauges

Replace broken or defective instruments and gauges. Replace
dials and glass that are so scratched or discolored that reading
is difficult.

Bearings

Anti-friction bearings must be handled in a special way. To
keep out dirt and abrasives, cover the bearings as soon as
they are removed from the package.

Wash bearings in a non-flammable cleaning solution. Knock
out packed lubricant inside by tapping the bearing against a
wooden block. Wash bearings again. Cover bearings with clean
material after setting them down to dry. Never use compressed
air to dry bearings.

Coat bearings with clean oil. Wrap bearings in clean paper.

When bearings are installed against shoulders, be sure that
the chamfered side of the bearing always faces the shoulder.
Lubricate bearings and all metal contact surfaces before
pressing into place. Only apply pressure on the part of the
bearing that makes direct contact with the mating part. Install
bearings with numbered side facing out.

Always use the proper tools and fixtures for removing and
installing bearings.

Bearings do not usually need to be removed. Only remove
bearings if necessary.

Bushings

Do not remove a bushing unless damaged, excessively worn
or loose in its bore. Press out bushings that must be replaced.

When pressing or driving bushings, be sure to apply pressure
in line with the bushing bore. Use a bearing/bushing driver or
a bar with a smooth, flat end. Never use a hammer to drive
bushings.

Inspect the bushing and the mated part for oil holes. Be sure
all oil holes are properly aligned.

Gaskets

Always discard gaskets after removal. Replace with new gas-
kets. Never use the same gasket twice. Be sure that gasket
holes match up with holes in the mating part. But be aware
that sections of a gasket may be used to seal passages.

If a gasket must be made, be sure to cut holes that match up
with the mating part. Serious damage can occur if any flange
holes are blocked by the gasket. Use material that is the right
type and thickness.

Lip Type Seals

Lip seals are used to seal oil or grease and are usually installed
with the sealing lip facing the contained lubricant. Seal orient-
ation, however, may vary under different applications.

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1-4 2009 Dyna Service: Maintenance

Seals should not be removed unless necessary. Only remove
seals if required to gain access to other parts or if seal damage
or wear dictates replacement.

Leaking oil or grease usually means that a seal is damaged.
Replace leaking seals to prevent overheated bearings.

Always discard seals after removal. Do not use the same seal
twice.

O-Rings (Preformed Packings)

Always discard o-rings after removal. Replace with new o-rings.
To prevent leaks, lubricate the o-rings before installation. Apply
the same type of lubricant as that being sealed. Be sure that
all gasket, o-ring and seal mating surfaces are thoroughly clean
before installation.

Gears

Always check gears for damaged or worn teeth.

Remove burrs and rough spots with a honing stone or crocus
cloth before installation.

Lubricate mating surfaces before pressing gears on shafts.

Shafts

If a shaft does not come out easily, check that all nuts, bolts
or retaining rings have been removed. Check to see if other
parts are in the way before using force.

Shafts fitted to tapered splines should be very tight. If shafts
are not tight, disassemble and inspect tapered splines. Discard
parts that are worn. Be sure tapered splines are clean, dry and
free of burrs before putting them in place. Press mating parts
together tightly.

Clean all rust from the machined surfaces of new parts.

Part Replacement

Always replace worn or damaged parts with new parts.

Exhaust System Leakage

In the event of an exhaust system leak at a muffler or header
pipe connection location, disassemble and clean all mating
surfaces. Replace any damaged components. If leak still exists,
disassemble and repair the leak by applying a bead of Harley-
Davidson High-Performance Sealant (Part No. 99650-02) (or
an equivalent 02 Sensor/Catalyst-safe alternative). Reassemble
components, wipe off any excess sealant and allow adequate
curing time following sealant product instructions before oper-
ating vehicle.

CLEANING

Part Protection

Before cleaning, protect rubber parts (such as hoses, boots
and electrical insulation) from cleaning solutions. Use a grease-
proof barrier material. Remove the rubber part if it cannot be
properly protected.

Cleaning Process

Any cleaning method may be used as long as it does not result
in parts damage. Thorough cleaning is necessary for proper
parts inspection. Strip rusted paint areas to bare metal before
priming and repainting.

Rust or Corrosion Removal

Remove rust and corrosion with a wire brush, abrasive cloth,
sand blasting, vapor blasting or rust remover. Use buffing
crocus cloth on highly polished parts that are rusted.

Bearings

Remove shields and seals from bearings before cleaning.
Clean bearings with permanent shields and seals in solution.

Using compressed air to "spin dry" bearings can cause
bearing to fly apart, which could result in death or serious
injury. (00505b)

Clean open bearings by soaking them in a petroleum cleaning
solution. Never use a solution that contains chlorine.

Let bearings stand and dry. Do not dry with compressed air.
Do not spin bearings while they are drying.

TOOL SAFETY

Air Tools

•

Always use approved eye protection equipment when
performing any task using air-operated tools.

•

On all power tools, use only recommended accessories
with proper capacity ratings.

•

Do not exceed air pressure ratings of any power tools.

•

Bits should be placed against work surface before air
hammers are operated.

•

Disconnect the air supply line to an air hammer before
attaching a bit.

•

Never point an air tool at yourself or another person.

•

Protect bystanders with approved eye protection.

Wrenches

•

Never use an extension on a wrench handle.

•

If possible, always pull on a wrench handle and adjust
your stance to prevent a fall if something lets go.

•

Never cock a wrench.

•

Never use a hammer on any wrench other than a
STRIKING FACE wrench.

•

Discard any wrench with broken or battered points.

•

Never use a pipe wrench to bend, raise or lift a pipe.

Pliers/Cutters/Pry bars

•

Plastic- or vinyl-covered pliers handles are not intended
to act as insulation. Do not use on live electrical circuits.

•

Do not use pliers or cutters for cutting hardened wire
unless they were designed for that purpose.

•

Always cut at right angles.

•

Do not use any pry bar as a chisel, punch or hammer.

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2009 Dyna Service: Maintenance 1-5

Hammers

•

Never strike a hammer against a hardened object, such
as another hammer.

•

Always grasp a hammer handle firmly, close to the end.

•

Strike the object with the full face of the hammer.

•

Never work with a hammer which has a loose head.

•

Discard hammer if face is chipped or mushroomed.

•

Wear approved eye protection when using striking tools.

•

Protect bystanders with approved eye protection.

Punches/Chisels

•

Never use a punch or chisel with a chipped or mush-
roomed end; dress mushroomed chisels and punches with
a file.

•

Hold a chisel or a punch with a tool holder if possible.

•

When using a chisel on a small piece, clamp the piece
firmly in a vise and chip toward the stationary jaw.

•

Wear approved eye protection when using these tools.

•

Protect bystanders with approved eye protection.

Screwdrivers

•

Do not use a screwdriver for prying, punching, chiseling,
scoring or scraping.

•

Use the right type of screwdriver for the job; match the tip
to the fastener.

•

Do not interchange POZIDRIV, PHILLIPS or REED AND
PRINCE screwdrivers.

•

Screwdriver handles are not intended to act as insulation.
Do not use on live electrical circuits.

•

Do not use a screwdriver with rounded edges because it
will slip. Redress with a file.

Ratchets and Handles

•

Periodically clean and lubricate ratchet mechanisms with
a light grade oil. Do not replace parts individually; ratchets
should be rebuilt with the entire contents of service kit.

•

Never hammer or put a pipe extension on a ratchet or
handle for added leverage.

•

Always support the ratchet head when using socket
extensions, but do not put your hand on the head or you
may interfere with the action of its reversing mechanism.

•

When breaking loose a fastener, apply a small amount of
pressure as a test to be sure the ratchet's gear wheel is
engaged with the pawl.

Sockets

•

Never use hand sockets on power or impact wrenches.

•

Select the right size socket for the job.

•

Never cock any wrench or socket.

•

Select only impact sockets for use with air or electric
impact wrenches.

•

Replace sockets showing cracks or wear.

•

Keep sockets clean.

•

Always use approved eye protection when using power
or impact sockets.

Storage Units

•

Do not open more than one loaded drawer at a time. Close
each drawer before opening up another.

•

Close lids and lock drawers and doors before moving
storage units.

•

Do not pull on a tool cabinet; push it in front of you.

•

Set the brakes on the locking casters after the cabinet has
been rolled to your workspace.

HOME

1-6 2009 Dyna Service: Maintenance

1.3

MAINTENANCE SCHEDULE

GENERAL

The table below lists the periodic maintenance requirements
for Dyna model motorcycles. If you are familiar with the proced-
ures, just refer to the table for the recommended service
interval. If necessary, see the quick reference table (

Table 1-2

)

for the required specifications.

If more detailed information is needed, turn to the sections
which follow for step-by-step instructions.

Also, throughout this manual, you will be instructed to use
various lubricants, greases and sealants. Refer to

Table 1-3

for the correct part numbers of these items.

Table 1-1. Regular Service Intervals: 2009 Dyna Models

NOTES

25,000 MI.

40,000 KM

20,000 MI.

32,000 KM

15,000 MI.

24,000 KM

10,000 MI.

16,000 KM

5000 MI.

8000 KM

1000 MI.

1600 KM

PROCEDURE

ITEM SERVICED

Replace

Engine oil and filter

Inspect for leaks

Oil lines and brake system

Inspect, service as required

Air cleaner

Check pressure, inspect tread

Tires

1, 4

Check tightness

Wheel spokes

Replace

Primary chaincase lubricant

Replace

Transmission lubricant

Check adjustment

Clutch

Inspect, adjust belt

Rear belt and sprockets

Check, adjust and lubricate

Throttle, brake and clutch controls

Inspect and lubricate

Jiffy stand

Inspect for leaks

Fuel, lines and fittings

Replace

Fuel pump filter

Check levels and condition

Brake fluid

Inspect for wear

Brake pads and discs

Inspect

Spark plugs

Replace

Check operation

Electrical equipment and switches

1, 6

Replace

Front fork oil

1, 2

Adjust

Steering head bearings

Inspect every 30,000 miles (48,000 kilometers)

Rear fork bearings

Check tightness

Critical fasteners

Inspect

Engine mounts and stabilizer links

Check battery and clean connections

Battery

Inspect for leaks, cracks, and loose
or missing fasteners or heat shields

Exhaust system

Verify component and system func-
tions

Road test

1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are
mechanically qualified.

NOTES:

2. Disassemble, lubricate and inspect every 30,000 miles (48,000 kilometers).
3. Perform annually.
4. Not all vehicles are equipped with spoke wheels. Consult appropriate topic in service manual.
5. Replace D.O.T. 4 HYDRAULIC BRAKE FLUID and flush system every two (2) years.
6. Disassemble, lubricate and inspect every 50,000 miles (80,000 kilometers).

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2009 Dyna Service: Maintenance 1-7

Table 1-2. Quick Reference Maintenance Chart

DATA

SPECIFICATION

ITEM SERVICED

14-21 ft-lbs (19.0-28.5 Nm)

Drain plug torque

Engine oil and filter

3 qt. (2.4 L)

Oil capacity

Hand tighten 1/2-3/4 turn after gasket contact

Filter

63798-99A

Chrome filter part number

63731-99A

Black filter part number

32 oz. (0.95 liters)

Lubricant capacity

Primary chain lubricant

14-21 ft-lbs (19.0-28.5 Nm)

Primary chaincase drain plug torque

1/2-1 turn

Free play at adjuster screw

Clutch adjustment

72-120 in-lbs (8.1-13.6 Nm)

Adjuster screw locknut torque

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

Free play at hand lever

84-108 in-lbs (9.5-12.2 Nm)

Clutch inspection cover torque

Check with motorcycle at normal operating temper-
ature and parked on jiffy stand. Remove and wipe
off dipstick. Place dipstick in filler hole with filler
plug resting on threads and remove. Lubricant level
should be between upper and lower ends of the oil
level indicator marks on the dipstick.

Lubricant level

Transmission lubricant

32 oz (0.95 liters)

Lubricant capacity

14-21 ft-lbs (19.0-28.5 Nm)

Transmission drain plug torque

25-75 in-lbs (2.8-8.5 Nm)

Filler plug/dipstick torque

Front: 30 psi (207 kPa)

Pressure for solo rider

Tire condition and pres-
sure

Rear: 36 psi (248 kPa)

All except FXDF

Front: 30 psi (207 kPa)

Pressure for rider and passenger

Rear: 40 psi (276 kPa)

All except FXDF

Front: 36 psi (248 kPa)

Pressure for solo rider

Rear: 36 psi (248 kPa)

FXDF

Front: 36 psi (248 kPa)

Pressure for rider and passenger

Rear: 40 psi (276 kPa)

FXDF

Replace tire if 1/32 in. (0.8 mm) or less of tread
pattern remains

Wear

55-65 in-lbs (6.5-7.3 Nm)

Spoke nipple torque

Wheel spokes

99953-99A (12 oz.)

D.O.T. 4 hydraulic brake fluid part numbers

Brake fluid reservoir level

1/8-1/4 in. (3.2-6.4 mm) below gasket surface

Proper fluid level

6-8 in-lbs (0.7-0.9 Nm)

Master cylinder reservoir cover torque

0.04 in. (1.02 mm)

Minimum brake pad thickness

Brake pad linings and
discs

See stamp on side of disc

Minimum brake disc thickness

10 lb. (4.5 kg)

Upward measurement force applied at midpoint of
bottom of belt strand

Drive belt

FXD, FXDF-5/16-3/8 in. (7.9-9.5 mm)

With motorcycle On jiffy stand without rider or lug-
gage

FXDB, FXDC, FXDL-1/4-5/16 in. (6.4-7.9 mm)

FXD, FXDF-1/2-9/16 in. (12.7-14.3 mm)

Vehicle upright with rear wheel in air

FXDB, FXDC, FXDL-5/16-3/8 in. (7.9-9.5 mm)

40-60 in-lbs (4.5-6.8 Nm)

Air cleaner cover bracket screw torque

Air cleaner

36-60 in-lbs (4.1-6.8 Nm)

Air cleaner cover screw torque

LOCTITE THREADLOCKER 243

Adhesive for air cleaner cover screw

Part No. 99642-97 (6 ml)

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1-8 2009 Dyna Service: Maintenance

Table 1-2. Quick Reference Maintenance Chart

DATA

SPECIFICATION

ITEM SERVICED

SUPER OIL Part No. 94968-85TV (1/4 fl. oz.)

Lubricant

Clutch and throttle
cables

35-45 in-lbs (4.0-5.1 Nm)

Handlebar switch housing screw torque

HD-6R12

Type

Spark plugs

0.038-0.043 in. (0.97-1.09 mm)

Gap

12-18 ft-lbs (16.3-24.4 Nm)

Torque

950-1050 RPM

Idle speed

Engine idle speed

See

2.18 FRONT FORK

Amount

Front fork oil

HYDRAULIC FORK OIL (TYPE E)

Type

Part No. 99884-80 (16 oz.)

60-70 in-lbs (6.8-7.9 Nm)

Battery terminal torque

Battery

Table 1-3. Lubricants, Greases, Sealants

PACKAGE

PART NUMBER

ITEM

1 oz squeeze tube

98960-97

Anti-Seize Lubricant

squeeze packet

42830-05 (included in master cylinder
rebuild kit)

CCI #20 Brake Grease

12 oz. bottle

99953-99A

D.O.T. 4 Brake Fluid

1 oz squeeze tube

99861-02

Electrical Contact Lubricant

1 qt bottle

99851-05

Genuine Harley-Davidson Formula+
Transmission and Primary Chaincase
Lubricant

squeeze packet

42820-04

G40M Brake Grease

1.9 oz squeeze tube

99650-02

Gray High Performance Sealant

3.5 oz tube

99653-85

HYLOMAR Gasket and Thread Sealant

6 ml squeeze tube

99818-97

Loctite Pipe Sealant With Teflon 565

Loctite Prism Primer (770)

Loctite Prism Superbonder (411)

Loctite Superbonder 420 Adhesive

6 ml squeeze tube

99642-97

Loctite Threadlocker 243 (blue)

6 ml squeeze tube

94759-99

Loctite Threadlocker 262 (red)

10 ml bottle

98618-03

Loctite Threadlocker 272

14 oz. cartridge

99857-97

Special Purpose Grease

1/4 fl. oz

94968-85TV

Super Oil

16 oz bottle

99884-80

Type "E" Hydraulic Fork Oil

HOME

2009 Dyna Service: Maintenance 1-9

1.4

FUEL AND OIL

FUEL

Refer to

Table 1-4

. Always use a good quality unleaded gas-

oline. Octane ratings are usually found on the pump.

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)

Modern service station pumps dispense a high flow of gasoline
into a motorcycle fuel tank making air entrapment and pressur-
ization a possibility.

Table 1-4. Octane Ratings

RATING

SPECIFICATION

91 (95 RON)

Pump Octane (R+M)/2

GASOLINE BLENDS

Your motorcycle was designed to get the best performance
and efficiency using unleaded gasoline. Most gasoline is
blended with alcohol and/or ether to create oxygenated blends.
The type and amount of alcohol or ether added to the fuel is
important.

Do not use gasoline that contains methanol. Doing so can
result in fuel system component failure, engine damage
and/or equipment malfunction. (00148a)

•

Gasoline containing METHYL TERTIARY BUTYL ETHER
(MTBE): Gasoline/MTBE blends are a mixture of gasoline

and as much as 15% MTBE. Gasoline/MTBE blends can
be used in your motorcycle.

•

ETHANOL is a mixture of 10% ethanol (Grain alcohol) and
90% unleaded gasoline. Gasoline/ethanol blends can be
used in your motorcycle if the ethanol content does not
exceed 10%.

•

REFORMULATED OR OXYGENATED GASOLINES
(RFG): Reformulated gasoline is a term used to describe
gasoline blends that are specifically designed to burn
cleaner than other types of gasoline, leaving fewer tailpipe
emissions. They are also formulated to evaporate less
when you are filling your tank. Reformulated gasolines
use additives to oxygenate the gas. Your motorcycle will
run normally using this type of gas and Harley-Davidson
recommends you use it when possible, as an aid to cleaner
air in our environment.

•

Do not use race gas or octane boosters. Use of these fuels
will damage the fuel system.

Some gasoline blends might adversely affect the starting,
driveability or fuel efficiency of the motorcycle. If any of these
problems are experienced, try a different brand of gasoline or
gasoline with a higher octane blend.

ENGINE LUBRICATION

Do not switch lubricant brands indiscriminately because
some lubricants interact chemically when mixed. Use of
inferior lubricants can damage the engine. (00184a)

Engine oil is a major factor in the performance and service life
of the engine. Always use the proper grade of oil for the lowest
temperature expected before the next scheduled oil change.
Refer to

Table 1-5

. Your authorized dealer has the proper oil

to suit your requirements.

If it is necessary to add oil and Harley-Davidson oil is not
available, use an oil certified for diesel engines. Acceptable
diesel engine oil designations include: CF-4, CG-4, CH-4 and
CI-4.

The preferred viscosities for the diesel engine oils in des-
cending order are: 20W50, 15W40 and 10W40.

At the first opportunity, see an authorized dealer to change
back to 100 percent Harley-Davidson oil.

Table 1-5. Recommended Engine Oils

COLD WEATHER

STARTS BELOW 50° F

(10° C)

LOWEST AMBIENT

TEMPERATURE

H-D RATING

VISCOSITY

H-D TYPE

Excellent

Below 40° F (4° C)

HD 360

SAE 10W40

H-D Multi-grade

Good

Above 40° F (4° C)

HD 360

SAE 20W50

H-D Multi-grade

Poor

Above 60° F (16° C)

HD 360

SAE 50

H-D Regular Heavy

Poor

Above 80° F (27° C)

HD 360

SAE 60

H-D Extra Heavy

HOME

1-10 2009 Dyna Service: Maintenance

WINTER LUBRICATION

In colder climates, the engine oil should be changed often. If
motorcycle is used frequently for short trips, less than 15 miles
(24 kilometers), in ambient temperatures below 60° F (16° C),
oil change intervals should be reduced to 1500 miles (2400
kilometers). Motorcycles used only for short runs must have a
thorough tank flush-out before new oil is put in. The tank flush-
out should be performed by an authorized dealer or qualified
technician.

NOTE

The further below freezing the temperature drops, the shorter
the oil change interval should be.

Water vapor is a normal by-product of combustion in any
engine. During cold weather operation, some of the water vapor
condenses to liquid form on the cool metal surfaces inside the
engine. In freezing weather this water will become slush or ice
and, if allowed to accumulate too long, may block the oil lines
and cause damage to the engine.

If the engine is run frequently and allowed to thoroughly warm
up, most of this water will become vapor again and will be
blown out through the crankcase breather.

If the engine is not run frequently and allowed to thoroughly
warm up, this water will accumulate, mix with the engine oil
and form a sludge that is harmful to the engine.

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2009 Dyna Service: Maintenance 1-11

1.5

ENGINE OIL AND FILTER

CHECKING AND ADDING OIL

Oil level cannot be accurately measured on a cold engine.
For pre-ride inspection, with motorcycle leaning on jiffy
stand on level ground, oil should register on dipstick
between arrows when engine is cold. Do not add oil to
bring the level to the FULL mark on a COLD engine.
(00185a)

Check engine oil level:

•

As part of the pre-ride inspection.

•

At each fuel fill.

•

At every scheduled service interval.

Type of Oil

Refer to

Table 1-5

. Use the proper grade of oil for the lowest

temperature expected before the next oil change. For informa-
tion regarding winter needs, see

1.4 FUEL AND OIL

If it is necessary to add oil and Harley-Davidson oil is not
available, use an oil certified for diesel engines. Acceptable
diesel engine oil designations include CF-4, CG-4, CH-4 and
CI-4. The preferred viscosities for the diesel engine oils, in
descending order, are 20W50, 15W40 and 10W40. At the first
opportunity, see a Harley-Davidson dealer to change back to
100 percent Harley-Davidson oil.

Checking with Cold Engine

See

Figure 1-1

. Unscrew and remove engine oil filler cap

with attached dipstick. Wipe dipstick clean.

Reinstall filler cap. Turn filler cap clockwise until it stops.

See

Figure 1-2

. Again, unscrew and remove filler cap and

check oil level on dipstick. If oil level in pan is below lower
mark on dipstick, add enough Harley-Davidson oil to bring
level up between lower mark (1) and cold check level (2)
on dipstick.

NOTE

Be sure to clean oil from dipstick threads. If oil is present on
dipstick threads, it can weep past dipstick o-ring. This condition
may be incorrectly diagnosed as an oil leak.

Replace filler cap and screw in securely.

sm02443

Figure 1-1. Checking Engine Oil Level

om01006

ADD QT (lower) mark

Cold check level

FULL (hot check) mark

Figure 1-2. Engine Oil Dipstick

Checking with Warm Engine

Ride motorcycle until engine is warmed up to operating temper-
ature, then do the following.

Idle motorcycle on jiffy stand for 1-2 minutes.

Shut motorcycle off and with motorcycle leaning on jiffy
stand on level ground, unscrew and remove engine oil
filler cap with attached dipstick. Wipe dipstick clean.

Reinstall filler cap. Turn filler cap clockwise until it stops.

See

Figure 1-2

. Again, unscrew and remove filler cap and

check oil level on dipstick. If oil level in pan is below lower
mark on dipstick, add enough Harley-Davidson oil to bring
level up between lower mark (1) and cold check level (2)
on dipstick.

NOTE

Be sure to clean oil from dipstick threads. If oil is present on
dipstick threads, it can weep past dipstick o-ring. This condition
may be incorrectly diagnosed as an oil leak.

HOME

1-12 2009 Dyna Service: Maintenance

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Harley Davidson 2009 Dyna Models. Service manual — page 3

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