Harley Davidson 2009 Dyna Models. Service manual — page 12
2.17
TIRES
GENERAL
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)
Be sure tires are properly inflated, balanced and have
adequate tread. Inspect your tires regularly and see a
Harley-Davidson dealer for replacements. Riding with
excessively worn, unbalanced or under-inflated tires can
adversely affect stability and handling, which could result
in death or serious injury. (00014a)
New tires should be stored on a horizontal tire rack. Avoid
stacking new tires in a vertical stack. The weight of the stack
compresses the tires and closes down the beads.
Tires should be inspected for punctures, cuts, breaks and wear
at least weekly.
. The tread wear indicator bars will appear on
tire tread surfaces when 1/32 in. (0.8 mm) or less of tread
remains. Always remove tires from service before they reach
the tread wear indicator bars.
New tires are needed if any of the following conditions exist.
See
.
1.
Tire wear indicator bars are visible on the tread surfaces.
2.
Tire cords or fabric are visible through cracked sidewalls,
snags or deep cuts.
3.
A bump, bulge or split in the tire.
4.
Puncture, cut or other damage to the tire that cannot be
repaired.
1
2
sm02177
1.
Sidewall
2.
Tread surface
Figure 2-79. Tread Wear Indicators (Typical)
REMOVAL
NOTE
Care must be taken when removing and installing tire to prevent
cosmetic damage to wheel. This is especially true with wheels
that feature painted surfaces.
1.
Remove wheel from motorcycle:
a.
Front wheel: see
.
b.
Rear wheel: see
.
2.
Deflate tire.
NOTE
On tube type wheels, it is not necessary to completely remove
tire from rim. Removing one side allows the tube to be replaced
and allows for inspection of tire.
3.
Loosen both tire beads from rim flange. In most cases, a
bead breaker machine will be required to loosen the beads
from the rim.
4.
Remove tire.
2009 Dyna Service: Chassis 2-55
CLEANING, INSPECTION AND REPAIR
1.
Clean the inside of tire and outer surface of tube.
2.
If rim is dirty or rusty, clean with a stiff wire brush.
3.
Check wheels for lateral and radial runout before installing
a new tire.
a.
Models with laced wheels: see
.
b.
Models with cast wheels: see
4.
Inspect the tire and tube for wear and damage. Inspect
tread depth. Replace worn tires. Replace damaged tubes.
Replace punctured or damaged tires. In some cases, small
punctures in the tread area may be repaired from within
the demounted tire by a Harley-Davidson dealer. Speed
should NOT exceed 50 mph (80 km/h) for the first 24 hours
after repair, and the repaired tire should NEVER be used
over 80 mph (130 km/h). Failure to follow this warning
could result in death or serious injury. (00015a)
5.
Tubeless tires may be repaired in the tread area only if
the puncture is 1/4 in. (6.4 mm) or smaller. All repairs must
be made from inside the tire.
6.
Acceptable repair method involves the use of a patch and
plug combination.
INSTALLATION
Harley-Davidson front and rear tires are not the same.
Interchanging front and rear tires can cause tire failure,
which could result in death or serious injury. (00026a)
Do not exceed manufacturer's recommended pressure to
seat beads. Exceeding recommended bead seat pressure
can cause tire rim assembly to burst, which could result
in death or serious injury. (00282a)
Do not inflate tire beyond maximum pressure as specified
on sidewall. Over inflated tires can blow out, which could
result in death or serious injury. (00027a)
For tire pressures, see
.
Some tires have arrows molded into the tire sidewall. These
tires should be mounted on the rim with the arrow pointing in
the direction of forward rotation. The colored dot on the sidewall
is a balance mark and should be located next to the valve stem
hole.
Tube Type Tires
Match tires, tubes, air valves and caps to the correct wheel
rim. Contact a Harley-Davidson dealer. Mismatching can
result in damage to the tire bead, allow tire slippage on
the rim or cause tire failure, which could result in death
or serious injury. (00023a)
Use inner tubes on laced (wire spoked) wheels. Using
tubeless tires on laced wheels can cause air leaks, which
could result in death or serious injury. (00025a)
NOTES
•
For correct tire and tube types, see
•
Whenever a tube type tire is replaced, the tube should
also be replaced. Inner tubes should be patched only as
an emergency measure. Replace a damaged or patched
tube as soon as possible. Rim bands must be used on all
laced wheels.
1.
See
. On laced wheels, install a rim strip into
the rim well. Make sure no spokes protrude through
nipples, and be sure to align the valve stem hole in rim
strip with valve stem hole in rim.
2.
Install tube and tire.
sm02466
Figure 2-80. Installing Rim Strip
2-56 2009 Dyna Service: Chassis
Tubeless Tires
Only install original equipment tire valves and valve caps.
A valve, or valve and cap combination, that is too long or
too heavy can strike adjacent components and damage
the valve, causing rapid tire deflation. Rapid tire deflation
can cause loss of vehicle control, which could result in
death or serious injury. (00281a)
1.
. On tubeless wheels, damaged or leaking
valve stems must be replaced. Install rubber grommet (3)
on valve stem.
2.
Insert valve stem into rim hole.
3.
Install metal washer (2).
4.
Install nut and tighten to 12-15 in-lbs (1.4-1.7 Nm).
5.
Install tire.
1
3
2
sm02467
1.
Nut
2.
Metal washer
3.
Rubber grommet
Figure 2-81. Tubeless Tire Valve Stem
2009 Dyna Service: Chassis 2-57
2.18
FRONT FORK
REMOVAL
1.
Support motorcycle so front end is off floor and forks are
fully extended. Remove brake caliper and front wheel. See
2.
Remove front fender. See
3.
Loosen screws. Do not remove tube caps. Slide fork sides
downward clear of fork brackets.
4.
Repeat procedure for opposite fork tube and slider
assembly.
DISASSEMBLY
TOOL NAME
PART NUMBER
FORK HOLDING TOOL
HD-41177
1.
See
. Clamp fork tube and slider assembly in
FORK HOLDING TOOL (Part No. HD-41177) and mount
in vise.
NOTE
In next step, use a 12mm allen wrench to loosen seat pipe
screw.
2.
. While internal components are still under
tension and less prone to rotate, break loose but do not
completely unthread seat pipe screw.
NOTE
On right fork tube and slider assembly, remove axle holder to
access seat pipe screw.
Wear safety glasses or goggles when servicing fork
assembly. Do not remove slider tube caps without relieving
spring preload or caps and springs can fly out, which could
result in death or serious injury. (00297a)
3.
See
. Remove fork tube cap (7) and O-ring
(6).
4.
Remove the long spring collar (8).
5.
Remove from fork holding tool and invert fork over a suit-
able container. Allow fork to drain. Extend and retract slider
several times to push oil out of internal components. The
washer (5), and spring (4) will fall out of fork tube.
6.
Clamp fork tube in holder. Mount fork holding tool horizont-
ally in vise.
7.
See
. Remove slider cover from slider by
inserting brass drift into notch in slider and lightly tapping
cover.
8.
. Compress oil seal retaining ring (11) and
remove retaining ring from groove in top of slider bore.
9.
Remove seat pipe screw (20) and washer (19) from bottom
of slider (16, 17). Retain the seat pipe screw and washer.
10. Withdraw slider from fork tube (1) until bushing guide (14)
contacts bushing (24) on fork tube. Bushing guide is a
slight interference fit in slider.
11. Using the slider as a slide hammer, hit the bushing with
the bushing guide with a quick continuous stroke until
slider is pulled free of the fork tube.
12. Drain the slider and allow the stop oil lock piece (15) to
fall free.
NOTE
If replacing the slider only, the components remaining in the
fork tube can be left assembled and the fork re-assembled.
See
13. If still attached to seat pipe, remove stop oil lock piece
from the lower end of seat pipe.
14. Remove seat pipe (3) piston and ring assembly.
15. Remove rebound spring (2).
16. Remove oil seal (12), seal spacer (13), and bushing guide
(14).
17. Repeat procedure for opposite fork tube and slider
assembly.
sm03229
Figure 2-82. Fork Holding Tool (mounted vertically to
slider)
2-58 2009 Dyna Service: Chassis
sm03224
Figure 2-83. Notch in Slider
sm03225
Figure 2-84. Seat Pipe Screw (right fork assembly)
2009 Dyna Service: Chassis 2-59
4
22
20
16
10
23
21
8
9
11
12
13
14
15
5
1
2
3
6
7
24
18
17
19
sm02848
13.
1.
Oil seal spacer
Fork tube
2.
14.
Spring
Bushing guide
15.
3.
Lower stop
Seat pipe
4.
16.
Spring
Slider assembly (left)
17.
5.
Slider assembly (right)
Washer
6.
18.
O-ring
Reflector
19.
7.
Washer
Fork tube cap
8.
20.
Spring collar
Seat pipe screw
21.
9.
Axle cap fastener
Slider cover
10.
22.
Dust seal
Lockwasher
23.
11.
Axle cap
Oil seal retaining ring
12.
24.
Oil seal
Bushing
Figure 2-85. Front Fork
2-60 2009 Dyna Service: Chassis
CLEANING AND INSPECTION
1.
Thoroughly clean and inspect each part. If inspection
shows that any parts are bent, broken or damaged, those
parts should be repaired or replaced.
2.
See
. Inspect fork tube bushing (24) and
bushing guide (14) and replace as required.
3.
Always replace oil seals (12) and o-rings (6).
4.
Check dust cover (9) where it rubs on fork tube. The dust
cover should present a good continuous seal and not show
excessive wear.
5.
Check the slider tube (1) where it rubs on dust cover. The
tube should show a bright, shining surface, free of scoring
or abrasions.
6.
If springs (4) are broken, replace springs.
7.
If a fork tube or slider (16, 17) is bent or damaged, replace
it.
8.
Replace all other worn or damaged components as
necessary.
ASSEMBLY
TOOL NAME
PART NUMBER
FORK SEAL DRIVER
B-45305
FORK HOLDING TOOL
HD-41177
PRO-LEVEL OIL GAUGE
HD-59000A
TYPE E FORK OIL
HD-99884-80
1.
. Insert seat pipe assembly (3) with the
spring (2) into slider tube (1).
2.
Slide bushing guide (14) down to bushing (24) on fork tube
(1). Follow with spacer (13), oil seal (12), retaining ring
(11), dust shield (10) and slider cover (9).
3.
Install fork tube into FORK HOLDING TOOL (Part No. HD-
41177) mounted horizontally in a vise.
4.
Fit lower stop (15) onto seat pipe.
5.
See
. Side seat pipe back into fork tube until
seat pipe is centered in tube.
6.
See
. Gently install slider assembly (16, 17)
onto slider tube and bushing (24).
7.
Thread seat pipe screw (20) and washer (19) into seat
pipe through bottom of slider assembly. Draw fastener
into seat pipe but do not tighten.
8.
Verify action of fork by sliding slider up and down fork tube.
9.
Assemble the FORK SEAL DRIVER (Part No. B-45305)
over fork tube in front of oil seal.
NOTE
Chamfered lips on oil seal MUST face towards oil in fork.
10. See
. Holding fork seal driver (4) together, tap
oil seal (3), spacer (2) and bushing guide (1) into slider
bore.
11. See
. Install oil seal retaining ring (11) into
groove in top of oil seal.
12. Push dust seal (10) against oil seal and stopper ring.
13. Rotate slider cover (9) to match any removal burrs to notch
in slider and snap slider cover into place.
14. Move slider through its full range of travel several times
to verify alignment. Then, pulling down on slide to apply
downward force on rebound spring, tighten seat pipe screw
to 106-159 in-lbs (12-18 Nm).
15. Re-position fork tube vertically in fork holding tool. With
slider tube compressed, fill the fork with Harley-Davidson
TYPE E FORK OIL (Part No. HD-99884-80) until it is 4.3
in. (110 mm), approximately 26.6 oz (787 cc) from top of
fork tube:
16. Slowly pump slider 8 to 10 times to exhaust air from
assembly. Fully compress slider to determine oil level.
NOTE
Fork oil level is measured from top of fork tube, with spacer
and spring removed and fork fully compressed.
17. Using the PRO-LEVEL OIL GAUGE (Part No. HD-
59000A), adjust the oil level to specification.
18. Pull out the slider and install the spring (4) in the fork tube
with the tightly wound end at the bottom.
19. Install the washer (5) and spring collar (8).
Wear safety glasses or goggles when servicing fork
assembly. Do not remove slider tube caps without relieving
spring preload or caps and springs can fly out, which could
result in death or serious injury. (00297a)
20. With a new O-ring, install and tighten fork tube caps to
16-43 ft-lbs (22-58 Nm).
NOTE
To prevent cross threading fork tube caps, use caution when
threading in the caps with the spring compressed.
21. Repeat for opposite fork tube and slider assembly.
sm03226
Figure 2-86. Seat Pipe Centered in Fork Tube
2009 Dyna Service: Chassis 2-61
1
2
3
4
sm03227
1.
Bushing guide
2.
Spacer
3.
Oil seal (chamfered lips must face oil)
4.
Fork seal driver
Figure 2-87. Assembled Fork Seal Driver
INSTALLATION
1.
See
. Insert fork tube and slider assemblies
through lower triple clamp and upper triple clamp. Fork
tubes should protrude above upper triple clamp 0.450-
0.500 in. (11.4-12.7 mm). Measurement must be taken at
midpoint of fork tube between top surface of triple clamp
to top of fork cap. Tighten pinch bolts to 30-35 ft-lbs (41-
48 Nm).
2.
Install front fender and bracket. See
.
3.
Install front brake caliper hydraulic lines and install front
brake calipers. See
. Install front wheel
and align the wheel to the forks.
sm03228
Figure 2-88. Fork Tube Protrusion: Typical
2-62 2009 Dyna Service: Chassis
2.19
STEERING HEAD
REMOVAL
1.
Remove fork sides. See
.
2.
Remove the headlamp from lower fork bracket. See
3.
. Remove the fork stem cap (1). Remove
the fork stem nut and the handlebar with upper bracket
(4). Be careful not to pinch or kink control cables.
4.
Remove the adjusting nut (5) and pull the fork stem and
bracket (12) out of the steering head. Remove the upper
dust shield (6) and bearing cone (7). Slide fork stem (12)
and bracket (13) from frame.
3
1
7
4
2
6
8
9
10
13
11
5
14
12
sm02274
1.
Fork stem cap
2.
Hardened flat washer
3.
Fork stem nut
4.
Upper fork bracket
5.
Adjusting nut
6.
Upper dust shield
7.
Bearing cone
8.
Bearing cup
9.
Bearing cup
10. Bearing cone
11. Lower dust shield
12. Fork stem
13. Lower fork bracket
14. Retaining ring
Figure 2-89. Steering Head
2009 Dyna Service: Chassis 2-63
INSPECTION
1.
Check upper and lower bearing races in steering head. If
they are pitted or grooved, replace the bearings and races
in sets.
Replace both bearing assemblies even if one assembly
appeares to be good. Mismatched bearings can lead to
excessive wear and premature replacement. (00532b)
2.
Check the roughness of the bearings by turning them in
the race. Replace bearings if they do not turn freely and
smoothly.
DISASSEMBLY
TOOL NAME
PART NUMBER
UNIVERSAL DRIVER
HD-33416
STEERING HEAD BEARING RACE
REMOVER
HD-39301-A
1
2
3
sm02275
1.
Remover (2 pieces)
2.
Collet
3.
Driver
Figure 2-90. Race Remover Tools
Steering Head Bearing Race Removal
1.
. With the tapered side down, seat the
two-piece STEERING HEAD BEARING RACE
REMOVER (Part No. HD-39301-A) (1) on the upper
bearing race leaving a gap in the middle.
2.
Install the collet (2) on the UNIVERSAL DRIVER (Part
No. HD-33416).
3.
Insert the driver at the bottom of the steering head tube
(3), and while holding the remover tool on the race, center
the collet in the gap. Tap the driver to remove the upper
race.
4.
Reverse the tool and repeat the procedure (4) to remove
the lower bearing race.
NOTE
If bearing cups are removed, the bearings cannot be reused.
They must be replaced. The lower bearing cone is not pressed
on fork stem and may be slipped off fork stem along with lower
dust shield.
1
2
3
4
sm02489
1.
Install remover on upper race
2.
Install collet on driver
3.
Install driver in remover and remove upper race
4.
Remove lower race
Figure 2-91. Remove Races
2-64 2009 Dyna Service: Chassis
ASSEMBLY
TOOL NAME
PART NUMBER
STEERING HEAD BEARING RACE
INSTALLER
HD-39302
SPECIAL PURPOSE GREASE
HD-99857-97
1.
Pack the new bearings with SPECIAL PURPOSE
GREASE (Part No. HD-99857-97).
NOTE
Press only on inner bearing race or damage to bearing will
occur.
2.
. Install the lower dust shield (11) and new
bearing (10) on the fork stem (12).
Properly seat bearing cups in steering head bore. Improper
seating can loosen fork stem bearings adversely affecting
stability and handling, which could result in death or ser-
ious injury. (00302a)
3.
Lubricate the races with engine oil. Install the new races
using STEERING HEAD BEARING RACE
INSTALLER (Part No. HD-39302).
INSTALLATION
Properly adjust fork stem bearings. Improper adjustments
affect stability and handling, which could result in death
or serious injury. (00301a)
1.
See
. Insert the stem and bracket assembly
into the frame steering head and install the upper bearing
(7) and dust shield (6). Secure with the adjusting nut (5).
Tighten the adjusting nut until there is no noticeable shake
or freeplay between bearings and races. Fork stem must
turn freely from side to side.
NOTE
The washer under the fork stem nut is a special hardened
material. Never replace this washer with a common flat washer.
Doing so may allow the fork stem nut torque to loosen resulting
in loss of steering control.
2.
Install upper bracket (4), hardened flat washer (2).
NOTE
•
Original equipment fork stem nut has a blue coating. If a
new nut is being installed, the replacement nut will not
have a coating.
•
Whenever the stem nut is loosened or removed, the
threads must be lubricated with anti-seize lubricant prior
to assembly and tightening.
3.
Lubricate threads of fork stem nut (3) with a light coating
of anti-seize lubricant. Install stem nut and tighten securely.
4.
Install the headlamp assembly. See
.
5.
Install fork sides. See
.
6.
Adjust steering head bearings. See
7.
Tighten fork stem nut to 70-80 ft-lbs (94.9-108.4 Nm).
8.
Install the fork stem cap.
9.
Align headlamp. See
2009 Dyna Service: Chassis 2-65
2.20
BELT GUARD
REMOVAL
1.
. Remove front fastener (1) and washer
(2).
2.
Remove rear fastener (3) and washer (2) from nut (7).
3.
Lift belt guard (8) away from rear fork.
4.
Disassemble belt guard by removing grommets (6) and
spacers (5).
INSTALLATION
1.
See
. If removed, install grommets (6) and
spacers (5) on belt guard.
2.
Place assembled belt guard over front and rear tabs on
rear fork.
3.
Loosely install front fastener (1) and washer (2).
4.
Loosely install rear fastener (3) and washer (2) with nut
(7).
5.
Tighten front fastener (1) to 10-15 ft-lbs (13.6-20.3 Nm).
6.
Tighten rear fastener (3) and nut (7) to 10-15 ft-lbs (13.6-
20.3 Nm).
7.
Verify that belt guard does not contact belt during rear fork
travel.
1
6
8
3
6
7
2
5
5
4
2
sm02278
1.
Front fastener
2.
Washer (2)
3.
Rear fastener
4.
Screw, belt guard bracket (2)
5.
Spacer (2)
6.
Grommet (2)
7.
Nut
8.
Belt guard
Figure 2-92. Belt Guard
2-66 2009 Dyna Service: Chassis
2.21
DEBRIS DEFLECTOR
REMOVAL
. Remove three screws to detach debris
deflector from rear fork.
INSTALLATION
. Attach debris deflector to rear fork using three
screws. Tighten to 40-60 in-lbs (4.5-6.8 Nm).
sm02279
Figure 2-93. Debris Deflector Screws
2009 Dyna Service: Chassis 2-67
2.22
THROTTLE CONTROL
REMOVAL/DISASSEMBLY
1.
See
. Loosen cable adjuster jam nuts. Screw
throttle cable adjuster until it is a short as possible.
Remove the two screws that hold the handlebar housing
together to separate the upper and lower housings.
2.
Unhook the ferrules and cables from the throttle grip and
lower housing.
3.
Remove air cleaner assembly and disconnect throttle
cables from induction module. See
4.
. Pull the cables from the housing by pla-
cing a drop of oil on the retaining ring that holds the cable
in the housing, then firmly pull the bent tubing portion of
the cable out of the housing using a rocking motion.
1
sm02479
1.
Adjuster jam nut (2)
Figure 2-94. Handlebar Throttle Control
5
4
3
2
1
sm01084
1.
Throttle cable (silver insert, front hole)
2.
Groove in throttle grip
3.
Notch
4.
Brass ferrule
5.
Idle cable (gold insert, rear hole)
Figure 2-95. Throttle Cable Attachment
CLEANING AND INSPECTION
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
1.
Wash all components in non-flammable cleaning solvent.
Blow parts dry with low pressure compressed air.
2.
Replace the control cables if frayed, kinked or bent.
3.
Put one or two drops of oil into the housing of each control
cable.
ASSEMBLY/INSTALLATION
1.
Apply a light coating of graphite to the handlebar and
inside surface of the housings.
2.
See
. Attach the control cable assemblies to
the lower housing.
a.
Push the silver insert of the throttle cable housing into
the hole in front of the tension adjuster screw.
b.
Push the gold insert of the idle cable housing into the
hole at the rear of the tension adjuster screw.
c.
Install adjusting screw, spring and friction pad in the
lower housing if they were removed.
3.
Position the throttle grip on the handlebar. Place the lower
housing on the throttle. Position the ferrules and retaining
rings over the cable balls and seat them in the throttle
notches.
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)
4.
Fasten upper housing to lower housing using two screws.
Tighten to 35-45 in-lbs (4.0-5.1 Nm).
5.
Check throttle cable routing.
6.
Install throttle cables and adjust.
7.
Install air cleaner.
THROTTLE CABLE ROUTING
Pinched throttle cables can restrict throttle response,
which could result in loss of control and death or serious
injury. (00423b)
NOTE
•
Control cables must not pull tight when handlebars are
turned to left and right fork stops. Also, be sure control
2-68 2009 Dyna Service: Chassis
cables and wires are clear of fork stops at steering head
so they will not be pinched when fork is turned against
stop.
•
Install cable ties securing throttle cables to frame so that
tail of cable faces top of vehicle. Using this method will
ensure proper placement of cables.
. Throttle cables are routed behind front fork
upper bracket, then under right side of tank to induction module.
sm02480
Figure 2-96. Throttle Cable Routing: FXDF (Typical)
2009 Dyna Service: Chassis 2-69
2.23
REAR SHOCK ABSORBERS
GENERAL
When removing the shocks for repair or replacement, remove
and install one shock first, then the other. This will eliminate
the need for raising the rear end of the motorcycle. If it is
necessary to remove both shocks at once, place the motorcycle
on a center stand with the rear wheel raised off the ground.
For information on preload adjustment and suspension settings,
see
.
REMOVAL
1.
Block motorcycle underneath frame so rear wheel is raised
off the ground.
2.
. Remove lower shock mount screw (1).
Nut (9) is only used on left side.
3.
Remove upper shock mount nut (2), outer washer (4),
chrome cover (3), inner washer (4), and shock absorber
(5).
4.
Repeat for other shock absorber.
5.
If stud (6) is to be removed, remove nut (8) and washer
(7).
2
4
3
5
6
7
8
9
1
sm03773
1.
Lower mounting screw (2)
2.
Upper mounting nut (2)
3.
Cover, chrome (FXDB, FXDC only) (2)
4.
Washer (4)
5.
Shock absorber (2)
6.
Stud (2)
7.
Hardened washer (2)
8.
Nut (2)
9.
Jam nut (lower-left side only)
Figure 2-97. Rear Shock Absorber Mounting (Typical)
INSPECTION
NOTE
Shocks are non-repairable items, except for the rubber
mounting bushings. If the shock is leaking or damaged, it must
be replaced as an assembly.
1.
Examine the rubber mounting bushings for cracks or wear.
Examine the shock for leaks. The unit should not leak and
should compress slightly easier than it extends. Compare
the action of the shock with a new one to judge if it is worn.
Replace the shock if necessary.
2.
Clean and examine the shock mounting hardware. Replace
parts that are worn or damaged.
INSTALLATION
1.
. If removed, install stud (6), hardened
washer (7) and nut (8). Tighten to 70-85 ft-lbs (101.7-115.2
Nm).
2.
Fasten each shock to the frame and rear fork using the
original hardware.
3.
Attach lower shock mount to rear fork.
a.
Apply two to three drops of LOCTITE THREAD-
LOCKER 243 (blue) to threads of bottom bolt (1).
b.
Install bolt and hand tighten.
4.
Apply two to three drops of LOCTITE THREADLOCKER
243 (blue) to threads of shock mount nut (2).
a.
Install inside washer (4), shock (5), cover (3), (if
applicable,) outside washer (4) and upper shock
mount nut (2).
b.
Hand tighten nut (2).
NOTE
Before tightening, rotate shock cover (3) counterclockwise to
provide for proper alignment when tightened.
5.
Tighten upper and lower shock mount screws as follows:
a.
Lower mount: 30-40 ft-lbs (40.7-54.2 Nm)
b.
Upper mount: 30-40 ft-lbs (40.7-54.2 Nm)
2-70 2009 Dyna Service: Chassis
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