Harley Davidson 2009 Dyna Models. Service manual — page 36

Table D-1. Acronyms and Abbreviations

DESCRIPTION

ACRONYM OR ABBREVIATION

Idle Air Control

IAC

Intake Air Temperature

IAT

Instrument Cluster

IC

Inside Diameter

ID

Ignition Light/Key Switch

IGN

Inch

In.

Injector Pulse Width

INJ PW

Inch-Pounds

in-lbs

Kilogram

Kg

Kilometer

Km

Kilopascal

kPa

Kilometers Per Hour

km/hr

Liter

L

Liquid Crystal Display

LCD

Light Emitting Diode

LED

Milliampere

mA

Manifold Absolute Pressure

MAP

milliliter

ml

millimeter

mm

Miles Per Hour

MPH

millisecond

ms

Newton-Meter

Nm

Not Applicable

N/A

Number

no.

Oxygen

O2

Outside Diameter

OD

Original Equipment Manufacturer

OEM

Ounce

oz

Parts and Accessories

P&A

Part Number

PN

Pounds per Square Inch

PSI

Reserve

RES

Revolutions Per Minute

RPM

Cubic Feet per Hour at Standard Conditions

SCFH

Throttle Control Actuator

TCA

Top Dead Center

TDC

Twist Grip Sensor

TGS

Throttle Position

TP

Intake Air Temperature/Manifold Absolute Pressure

TMAP

Turn Signal Module

TSM

Turn Signal/Security Module

TSSM

Volt

V

Volts of Alternating Current

VAC

HOME

D-2 2009 Dyna Service: Appendix D Glossary

Table D-1. Acronyms and Abbreviations

DESCRIPTION

ACRONYM OR ABBREVIATION

Volts of Direct Current

VDC

Vehicle Identification Number

VIN

Vehicle Speed Sensor

VSS

HOME

2009 Dyna Service: Appendix D Glossary D-3

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

1.27 STORAGE, Placing in Storage

STORAGE COVER

98716-87A

3.19 BOTTOM END OVERHAUL: ASSEMBLY, Crank-
case

HIGH-PERFORMANCE SEALANT, GRAY

99650-02

2.24 REAR FORK, Assembly

WHEEL BEARING GREASE

99855-89

1.18 BATTERY MAINTENANCE, Storage

GLOBAL BATTERY CHARGER

99863-01A

2.18 FRONT FORK, Assembly

FORK SEAL DRIVER

B-45305

3.23 CYLINDER HEAD, Valve Guide Replacement

VALVE GUIDE REAMER

B-45523

3.23 CYLINDER HEAD, Valve Guide Replacement

VALVE GUIDE DRIVER

B-45524-1

3.23 CYLINDER HEAD, Valve Guide Replacement

VALVE GUIDE INSTALLER SLEEVE

B-45524-2A

3.23 CYLINDER HEAD, Inspection

VALVE GUIDE HONE

B-45525

3.23 CYLINDER HEAD, Valve Guide Replacement

VALVE GUIDE HONE

B-45525

3.28 CRANKCASE, Right Crankcase Half

CRANKCASE BEARING
REMOVER/INSTALLER

B-45655

3.28 CRANKCASE, Left Crankcase Half

CRANKCASE BEARING
REMOVER/INSTALLER

B-45655

A.2 AUTOFUSE ELECTRICAL CONNECTORS, Autofuse
Connector Repair

SNAP-ON TERMINAL PICK

GA500A

3.28 CRANKCASE, Sprocket Shaft Bearing Inner Race

ROBINAIR HEAT GUN

HD-25070

7.32 HANDLEBAR SWITCH ASSEMBLIES, Repair Pro-
cedures

ROBINAIR HEAT GUN

HD-25070

A.17 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair

ROBINAIR HEAT GUN

HD-25070

3.8 TROUBLESHOOTING, Compression Test

CYLINDER COMPRESSION GAUGE

HD-33223-1

2.19 STEERING HEAD, Disassembly

UNIVERSAL DRIVER

HD-33416

3.23 CYLINDER HEAD, Disassembly

VALVE SPRING COMPRESSOR

HD-34736-B

3.23 CYLINDER HEAD, Assembly

VALVE SPRING COMPRESSOR

HD-34736-B

3.23 CYLINDER HEAD, Inspection

VALVE GUIDE CLEANING BRUSH

HD-34751

3.23 CYLINDER HEAD, Valve Guide Replacement

VALVE GUIDE CLEANING BRUSH

HD-34751

3.23 CYLINDER HEAD, Valve Guide Replacement

VALVE GUIDE CLEANING BRUSH

HD-34751

3.23 CYLINDER HEAD, Valve and Seat Refacing

VALVE GUIDE CLEANING BRUSH

HD-34751

3.23 CYLINDER HEAD, Assembly

VALVE GUIDE CLEANING BRUSH

HD-34751

3.28 CRANKCASE, Sprocket Shaft Bearing Inner Race

MAINSHAFT BEARING INNER RACE
PULLER/INSTALLER

HD-34902-B

5.5 PRIMARY CHAINCASE HOUSING, Mainshaft Bearing
Inner Race

MAINSHAFT BEARING INNER RACE
REMOVER/INSTALLER

HD-34902-C

6.7 MAIN DRIVE GEAR AND BEARING, Removal

PILOT

HD-35316-10

6.7 MAIN DRIVE GEAR AND BEARING, Removal

RECEIVER CUP

HD-35316-11

6.7 MAIN DRIVE GEAR AND BEARING, Installation

INSTALLER CUP

HD-35316-12

6.7 MAIN DRIVE GEAR AND BEARING, Removal

CROSS PLATE

HD-35316-3A

6.7 MAIN DRIVE GEAR AND BEARING, Installation

CROSS PLATE

HD-35316-3A

6.7 MAIN DRIVE GEAR AND BEARING, Removal

8 IN. BOLT

HD-35316-4A

6.7 MAIN DRIVE GEAR AND BEARING, Installation

8 IN. BOLT

HD-35316-4A

6.7 MAIN DRIVE GEAR AND BEARING, Removal

12 IN. BOLT

HD-35316-5

6.7 MAIN DRIVE GEAR AND BEARING, Installation

12 IN. BOLT

HD-35316-5

6.7 MAIN DRIVE GEAR AND BEARING, Removal

WASHER

HD-35316-7

6.7 MAIN DRIVE GEAR AND BEARING, Installation

WASHER

HD-35316-7

6.7 MAIN DRIVE GEAR AND BEARING, Installation

BEARING DRIVER

HD-35316-8

6.7 MAIN DRIVE GEAR AND BEARING, Removal

BEARING DRIVER

HD-35316-9

I

T

OOLS

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

6.7 MAIN DRIVE GEAR AND BEARING, Removal

MAIN DRIVE GEAR/BEARING REMOVER
AND INSTALLER

HD-35316-C

1.14 REAR BELT DEFLECTION, Inspection

H-D BELT TENSION GAUGE

HD-35381-B

3.8 TROUBLESHOOTING, Cylinder Leakdown Test

CYLINDER LEAKDOWN TESTER

HD-35667-A

3.23 CYLINDER HEAD, Valve and Seat Refacing

NEWAY VALVE SEAT CUTTER SET

HD-35758-C

A.14 PACKARD METRI-PACK TERMINALS, Metri-Pack
Terminal Crimps

PACKARD TERMINAL CRIMP TOOL

HD-38125-6

A.8 DEUTSCH MINI TERMINAL REPAIR, Deutsch Mini
Terminal Crimps

PACKARD TERMINAL CRIMPER

HD-38125-7

A.14 PACKARD METRI-PACK TERMINALS, Metri-Pack
Terminal Crimps

PACKARD TERMINAL CRIMPER

HD-38125-7

A.14 PACKARD METRI-PACK TERMINALS, Metri-Pack
Terminal Crimps

PACKARD CRIMPING TOOL

HD-38125-8

A.17 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair

PACKARD CRIMPING TOOL

HD-38125-8

2.19 STEERING HEAD, Disassembly

STEERING HEAD BEARING RACE
REMOVER

HD-39301-A

2.19 STEERING HEAD, Assembly

STEERING HEAD BEARING RACE
INSTALLER

HD-39302

3.19 BOTTOM END OVERHAUL: ASSEMBLY, Crank-
case

SPROCKET SHAFT OIL SEAL INSTALLER

HD-39361-B

3.23 CYLINDER HEAD, Valve Guide Replacement

CYLINDER HEAD SUPPORT STAND

HD-39782-1

3.23 CYLINDER HEAD, Valve Guide Replacement

INTAKE SEAT ADAPTER

HD-39782-3

3.23 CYLINDER HEAD, Valve Guide Replacement

EXHAUST SEAT ADAPTER

HD-39782-4

3.23 CYLINDER HEAD, Valve Guide Replacement

CYLINDER HEAD SUPPORT STAND KIT

HD-39782-B

3.23 CYLINDER HEAD, Disassembly

CYLINDER HEAD HOLDING FIXTURE

HD-39786

3.23 CYLINDER HEAD, Valve Guide Replacement

CYLINDER HEAD HOLDING FIXTURE

HD-39786

3.23 CYLINDER HEAD, Valve and Seat Refacing

CYLINDER HEAD HOLDING FIXTURE

HD-39786

3.23 CYLINDER HEAD, Assembly

CYLINDER HEAD HOLDING FIXTURE

HD-39786

3.23 CYLINDER HEAD, Valve Guide Replacement

REAMER T-HANDLE

HD-39847

3.23 CYLINDER HEAD, Valve Guide Replacement

REAMER LUBRICANT

HD-39964

A.6 DEUTSCH STANDARD TERMINAL REPAIR, Deutsch
Standard Terminal Crimps

DEUTSCH TERMINAL CRIMP TOOL

HD-39965-A

7.32 HANDLEBAR SWITCH ASSEMBLIES, Repair Pro-
cedures

ULTRA TORCH UT-100

HD-39969

A.17 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair

ULTRA TORCH UT-100

HD-39969

2.18 FRONT FORK, Disassembly

FORK HOLDING TOOL

HD-41177

4.16 FUEL PRESSURE TEST, Testing

FUEL PRESSURE GAUGE

HD-41182

7.32 HANDLEBAR SWITCH ASSEMBLIES, Repair Pro-
cedures

HEAT SHIELD ATTACHMENT

HD-41183

A.17 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair

HEAT SHIELD ATTACHMENT

HD-41183

4.18 INTAKE LEAK TEST, Leak Tester

PROPANE ENRICHMENT KIT

HD-41417

A.5 DEUTSCH ELECTRICAL CONNECTORS, Deutsch
Connector Repair

DEUTSCH CONNECTOR SERVICE KIT

HD-41475

II TOOLS

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

A.5 DEUTSCH ELECTRICAL CONNECTORS, Deutsch
Connector Repair

FLAT BLADE L-HOOK

HD-41475-100

1.21 STEERING HEAD BEARINGS, Adjustment

HUBCAP REMOVER AND INSTALLER

HD-41494

A.1 AMP MULTILOCK CONNECTORS, AMP Multilock
Connector Repair

AMP MULTILOCK CRIMPER

HD-41609

1.5 ENGINE OIL AND FILTER, Changing Oil and Filter

OIL FILTER WRENCH

HD-42311

3.16 TOP END OVERHAUL: DISASSEMBLY, Piston

PISTON PIN CIRCLIP
REMOVER/INSTALLER

HD-42317-A

3.17 TOP END OVERHAUL: ASSEMBLY, Piston

PISTON PIN CIRCLIP
REMOVER/INSTALLER

HD-42317-A

3.16 TOP END OVERHAUL: DISASSEMBLY, Piston

PISTON PIN REMOVER

HD-42320-B

3.17 TOP END OVERHAUL: ASSEMBLY, Cylinder

PISTON SUPPORT PLATE

HD-42322

3.16 TOP END OVERHAUL: DISASSEMBLY, Cylinder
Head

CYLINDER TORQUE PLATES

HD-42324-A

3.24 CYLINDER, Cleaning

CYLINDER TORQUE PLATES

HD-42324-A

3.26 CAM SUPPORT PLATE AND COVER, Cam Needle
Bearings

CAMSHAFT NEEDLE BEARING
REMOVER/INSTALLER

HD-42325-A

3.19 BOTTOM END OVERHAUL: ASSEMBLY, Crank-
case

CRANKSHAFT GUIDE

HD-42326-B

3.28 CRANKCASE, Right Crankcase Half

CRANKCASE BEARING
REMOVER/INSTALLER BASE

HD-42720-5

3.28 CRANKCASE, Left Crankcase Half

CRANKCASE BEARING
REMOVER/INSTALLER BASE

HD-42720-5

A.7 DEUTSCH SOLID BARREL MINI TERMINAL
REPAIR, Deutsch Solid Barrel Terminal Crimps

ELECTRICAL CRIMPER TOOL

HD-42879

2.6 SEALED WHEEL BEARINGS, Removal

25 MM COLLET

HD-44060-10

2.6 SEALED WHEEL BEARINGS, Removal

WHEEL BEARING INSTALLER/REMOVER

HD-44060A

2.6 SEALED WHEEL BEARINGS, Installation

WHEEL BEARING INSTALLER/REMOVER

HD-44060A

4.16 FUEL PRESSURE TEST, Testing

FUEL PRESSURE GAUGE ADAPTER

HD-44061

1.5 ENGINE OIL AND FILTER, Changing Oil and Filter

OIL FILTER WRENCH

HD-44067

3.28 CRANKCASE, Sprocket Shaft Bearing Inner Race

FLYWHEEL SUPPORT FIXTURE

HD-44358

4.4 IDLE SPEED, General

DIGITAL TECHNICIAN

HD-44750

A.16 PACKARD MICRO-64 CONNECTORS, Packard
Micro-64 Connector Repair

PACKARD MICRO-64 TERMINAL
REMOVER

HD-45928

A.16 PACKARD MICRO-64 CONNECTORS, Packard
Micro-64 Connector Repair

PACKARD MICRO-64 TERMINAL
CRIMPER

HD-45929

5.7 TRANSMISSION SPROCKET, Removal

FINAL DRIVE SPROCKET LOCKING TOOL

HD-46282-A

5.7 TRANSMISSION SPROCKET, Installation

FINAL DRIVE SPROCKET LOCKING TOOL

HD-46282-A

3.16 TOP END OVERHAUL: DISASSEMBLY, Rocker
Covers

LOWER ROCKER BOX WRENCH

HD-47248

3.16 TOP END OVERHAUL: DISASSEMBLY, Rocker
Covers

UPPER ROCKER BOX WRENCH

HD-47258

7.8 IGNITION SWITCH/FORK LOCK, FXD, FXDL, FXDB
Models

IGNITION SWITCH/FORK LOCK WRENCH

HD-47853

6.7 MAIN DRIVE GEAR AND BEARING, Installation

INSTALLER

HD-47856-1

6.7 MAIN DRIVE GEAR AND BEARING, Installation

PILOT

HD-47856-2

TOOLS III

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

6.7 MAIN DRIVE GEAR AND BEARING, Installation

ADAPTER

HD-47856-3

6.7 MAIN DRIVE GEAR AND BEARING, Installation

NUT

HD-47856-6

6.7 MAIN DRIVE GEAR AND BEARING, Installation

CROW'S FOOT WRENCH

HD-47856-7

5.7 TRANSMISSION SPROCKET, Removal

MAINSHAFT LOCKNUT WRENCH

HD-47910

5.7 TRANSMISSION SPROCKET, Installation

MAINSHAFT LOCKNUT WRENCH

HD-47910

6.7 MAIN DRIVE GEAR AND BEARING, Cleaning and
Inspection

MAIN DRIVE GEAR BEARING AND SEAL
INSTALLATION TOOL

HD-47932

3.18 BOTTOM END OVERHAUL: DISASSEMBLY, Cam
Support Plate and Cover

CRANKSHAFT/CAMSHAFT SPROCKET
LOCKING TOOL

HD-47941

3.19 BOTTOM END OVERHAUL: ASSEMBLY, Cam
Support Plate and Cover

CRANKSHAFT/CAMSHAFT SPROCKET
LOCKING TOOL

HD-47941

3.26 CAM SUPPORT PLATE AND COVER, Camshafts

CAMSHAFT ASSEMBLY TOOL

HD-47956

5.4 DRIVE COMPONENTS, Removal

PRIMARY DRIVE LOCKING TOOL

HD-47977

A.9 MOLEX CONNECTORS, Molex Connector Repair

MOLEX ELECTRICAL CONNECTOR TER-
MINAL REMOVER

HD-48114

A.9 MOLEX CONNECTORS, Crimp Terminal to Lead

ELECTRICAL CRIMP TOOL

HD-48119

3.16 TOP END OVERHAUL: DISASSEMBLY, Rocker
Arm Support Plate

CRANKSHAFT ROTATING WRENCH

HD-48283

2.16 REAR BRAKE CALIPER, Disassembly

BRAKE CALIPER PISTON REMOVER

HD-48648

2.14 FRONT BRAKE CALIPER, Disassembly

FRONT BRAKE CALIPER PISTON
REMOVER

HD-48649

2.12 VEHICLE ALIGNMENT, Inspection

AXLE ALIGNMENT PLUG SET

HD-48856

2.18 FRONT FORK, Assembly

PRO-LEVEL OIL GAUGE

HD-59000A

5.7 TRANSMISSION SPROCKET, Removal

PILOT

HD-94660-2

5.7 TRANSMISSION SPROCKET, Installation

PILOT

HD-94660-2

2.10 TRUING LACED WHEELS, Lateral Truing

SPOKE WRENCH

HD-94681-80

1.19 SUSPENSION ADJUSTMENTS, Rear Shock Preload
Adjustment

SPANNER WRENCH

HD-94700-52C

3.21 ROCKER ARM SUPPORT PLATE, Cleaning and
Inspection

ROCKER ARM BUSHING REAMER

HD-94804-57

6.7 MAIN DRIVE GEAR AND BEARING, Removal

LONG BOLTS

HD-95637-10

3.28 CRANKCASE, Sprocket Shaft Bearing Inner Race

WEDGE ATTACHMENT

HD-95637-46B

6.7 MAIN DRIVE GEAR AND BEARING, Removal

WEDGE ATTACHMENT

HD-95637-46B

3.17 TOP END OVERHAUL: ASSEMBLY, Cylinder

THREADED CYLINDERS

HD-95952-1

3.17 TOP END OVERHAUL: ASSEMBLY, Cylinder

CONNECTING ROD CLAMPING TOOL

HD-95952-33C

3.17 TOP END OVERHAUL: ASSEMBLY, Cylinder

PISTON RING COMPRESSOR

HD-96333-51F

3.23 CYLINDER HEAD, Inspection

VALVE SPRING TESTER

HD-96796-47

3.7 OIL PRESSURE, Checking Oil Pressure

OIL PRESSURE GAUGE SET

HD-96921-52D

4.6 FUEL TANK, Installation

HOSE CLAMP PLIERS

HD-97087-65B

3.19 BOTTOM END OVERHAUL: ASSEMBLY, Crank-
case

SPROCKET SHAFT BEARING INSTALLER

HD-97225-55C

3.28 CRANKCASE, Sprocket Shaft Bearing Inner Race

SPROCKET SHAFT BEARING INSTALLER

HD-97225-55C

2.10 TRUING LACED WHEELS, Lateral Truing

WHEEL TRUING STAND

HD-99500-80

2.11 CHECKING CAST WHEEL RUNOUT, Radial
Runout

WHEEL TRUING AND BALANCING STAND

HD-99500-80

IV TOOLS

Tools Used in This Manual

NOTES

TOOL NAME

PART NUMBER

2.19 STEERING HEAD, Assembly

SPECIAL PURPOSE GREASE

HD-99857-97

2.18 FRONT FORK, Assembly

TYPE E FORK OIL

HD-99884-80

6.6 TRANSMISSION ASSEMBLY, Disassembly

TRANSMISSION SHAFT RETAINING RING
PLIERS

J-5586A

6.7 MAIN DRIVE GEAR AND BEARING, Removal

NICE BEARING

RS-25100-200

6.7 MAIN DRIVE GEAR AND BEARING, Removal

NICE BEARING

RS-25100-200

A.13 PACKARD 630 METRI-PACK CONNECTORS, 630
Metri-Pack Connector Repair

SNAP-ON PICK

SNAP-ON TT600-3

TOOLS V

2009 Dyna Models Service Manual

NOTES

TORQUE VALUE

FASTENER

7.30 ACTIVE EXHAUST, Installation

4.1-6.8 Nm

36-60 in-lbs

Active exhaust module fasteners

1.3 MAINTENANCE SCHEDULE, General

4.5-6.8 Nm

40-60 in-lbs

Air cleaner cover bracket screw

1.8 AIR CLEANER AND EXHAUST
SYSTEM, Installation

4.5-6.8 Nm

40-60 in-lbs

Air cleaner cover bracket screw

4.5 AIR CLEANER ASSEMBLY, Installation

4.5-6.8 Nm

40-60 in-lbs

Air cleaner cover bracket screw

1.3 MAINTENANCE SCHEDULE, General

4.1-6.8 Nm

36-60 in-lbs

Air cleaner cover screw

1.8 AIR CLEANER AND EXHAUST
SYSTEM, Installation

4.1-6.8 Nm

36-60 in-lbs

Air cleaner cover screw

4.5 AIR CLEANER ASSEMBLY, Installation

4.1-6.8 Nm

36-60 in-lbs

Air cleaner cover screw

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

1.3 MAINTENANCE SCHEDULE, General

6.8-7.9 Nm

60-70 in-lbs

Battery terminal screw

1.18 BATTERY MAINTENANCE, Installation and
Connection

6.8-7.9 Nm

60-70 in-lbs

Battery terminal screw

1.18 BATTERY MAINTENANCE, Installation and
Connection

6.8-7.9 Nm

60-70 in-lbs

Battery terminal screw

7.9 BATTERY TRAY AND BATTERY
CABLES, Battery Tray

10.8-13.6 Nm

96-120 in-lbs

Battery tray screws

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

1.16 BLEEDING BRAKES, Procedure

9.0-11.3 Nm

80-100 in-lbs

Bleeder valve

1.17 BRAKE PADS AND DISCS, Brake Pad
Replacement

20.3-22.6 Nm

15-16 ft-lbs

Brake bridge bolt/pad pin, front caliper

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

1.17 BRAKE PADS AND DISCS, Brake Pad
Replacement

9.0-13.6 Nm

80-120 in-lbs

Brake pad pin, rear caliper

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

3.17 TOP END OVERHAUL: ASSEMBLY, Breather
Assembly

10.2-13.6 Nm

90-120 in-lbs

Breather assembly bolts

4.5 AIR CLEANER ASSEMBLY, Installation/metric

29.8-32.5 Nm

22-24 ft-lbs

Breather bolts

VII

T

ORQ

UE

V

ALUES

2009 Dyna Models Service Manual

NOTES

TORQUE VALUE

FASTENER

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

11.3-13.6 Nm

100-120 in-lbs

Cam chain tensioner fasteners

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

14.1-17.5 Nm

125-155 in-lbs

Cam cover screws

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

10.2-13.6 Nm

90-120 in-lbs

Cam support plate screws

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

10.2-13.6 Nm

90-120 in-lbs

Cam support plate screws

5.4 DRIVE COMPONENTS, Installation

20.3-25.8 Nm

15-19 ft-lbs

Chain tensioner fasteners

7.17 CRANK POSITION SENSOR (CKP), Installa-
tion

10.2-13.6 Nm

90-120 in-lbs

CKP sensor screw

1.3 MAINTENANCE SCHEDULE, General

8.1-13.6 Nm

72-120 in-lbs

Clutch adjuster screw locknut

6.5 CLUTCH RELEASE COVER, Assembly and
Installation

10.2-13.6 Nm

90-120 in-lbs

Clutch cable fitting

5.6 CLUTCH, Clutch Pack Only

10.2-12.4 Nm

90-110 in-lbs

Clutch diaphragm spring retainer bolts

5.4 DRIVE COMPONENTS, Installation

94.9-108.5 Nm

70-80 ft-lbs

Clutch hub mainshaft nut

1.3 MAINTENANCE SCHEDULE, General

9.5-12.2 Nm

84-108 in-lbs

Clutch inspection cover screw

1.10 PRIMARY CHAIN, Changing Primary Chain-
case Lubricant

9.5-12.2 Nm

84-108 in-lbs

Clutch inspection cover screw

1.12 CLUTCH, Adjustment

9.5-12.2 Nm

84-108 in-lbs

Clutch inspection cover screw

1.12 CLUTCH, Adjustment

8.1-13.6 Nm

72-120 in-lbs

Clutch jam nut

6.5 CLUTCH RELEASE COVER, Assembly and
Installation

9.5-12.2 Nm

84-108 in-lbs

Clutch release cover screws

5.4 DRIVE COMPONENTS, Installation

190 Nm

140 ft-lbs

Compensating sprocket bolt-final torque

5.4 DRIVE COMPONENTS, Installation

135.7 Nm

100 ft-lbs

Compensating sprocket bolt-initial torque

7.19 FUEL GAUGE, FXD Models

2.0-2.7 Nm

18-24 in-lbs

Console mounting screws

7.25 INDICATOR LAMPS, Installation

2.0-2.7 Nm

18-24 in-lbs

Console mounting screws (FXDB)

7.8 IGNITION SWITCH/FORK LOCK, FXDC, FXDF
Models (Ignition Switch Only)

2.0-2.7 Nm

18-24 in-lbs

Console mounting screws (FXDC, FXDF)

7.21 INSTRUMENTS: FXDC/FXDF, Installation

2.0-2.7 Nm

18-24 in-lbs

Console mounting screws (FXDC/FXDF)

7.25 INDICATOR LAMPS, Installation

2.0-2.7 Nm

18-24 in-lbs

Console mounting screws (FXDC/FXDF)

7.22 INSTRUMENTS: FXDB/FXDL, Installation

2.0-2.7 Nm

18-24 in-lbs

Console to fuel tank fasteners

7.22 INSTRUMENTS: FXDB/FXDL, Installation

2.0-2.7 Nm

18-24 in-lbs

Console to fuel tank fasteners

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Crankcase

20.3-25.8 Nm

15-19 ft-lbs

Crankcase bolts, final

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Crankcase

13.6 Nm

10 ft-lbs

Crankcase bolts, initial

3.28 CRANKCASE, Pipe Plug and Oil Fittings

13.6-16.3 Nm

120-144 in-lbs

Crankcase pipe plugs

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

32.5 Nm

24 ft-lbs

Crank sprocket bolt, final torque

3.17 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/See special method to tighten

20.3-23.0 Nm

15-17 ft-lbs

Cylinder head bolts, final

3.24 CYLINDER, Inspection

20.3-23.1 Nm

15-17 ft-lbs

Cylinder head bolts, final

3.17 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/See special method to tighten

13.5-16.2 Nm

120-144 in-lbs

Cylinder head bolts, initial

3.24 CYLINDER, Inspection

13.6-16.3 Nm

120-144 in-lbs

Cylinder head bolts, initial

VIII TORQUE VALUES

2009 Dyna Models Service Manual

NOTES

TORQUE VALUE

FASTENER

3.13 ASSEMBLING MOTORCYCLE AFTER
SERVICE, Procedure

47.5-54.2 Nm

35-40 ft-lbs

Cylinder head bracket bolts

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

47.5-54.2 Nm

35-40 ft-lbs

Cylinder head bracket bolts

3.28 CRANKCASE, Cylinder Studs

3.6-27.1 Nm

10-20 ft-lbs

Cylinder stud

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

5.6 CLUTCH, Clutch Pack and Bearing

10.2-12.4 Nm

90-110 in-lbs

Diaphragm spring retainer bolts

1.5 ENGINE OIL AND FILTER, Changing Oil and
Filter

19.0-28.5 Nm

14-21 ft-lbs

Drain plug, engine

3.30 OIL PAN, Installation/Clean plug before
installation

19.0-28.5 Nm

14-21 ft-lbs

Drain plug, engine

7.3 ELECTRICAL CADDY, Installation

4.5-6.8 Nm

40-60 in-lbs

Electrical caddy fasteners, front

7.3 ELECTRICAL CADDY, Installation

10.2-12.4 Nm

90-110 in-lbs

Electrical caddy fasteners, top

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

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)

3.13 ASSEMBLING MOTORCYCLE AFTER
SERVICE, Procedure

33.9-47.5 Nm

25-35 ft-lbs

Footpeg bracket screws

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

33.9-47.5 Nm

25-35 ft-lbs

Footpeg bracket screws

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

33.9-47.5 Nm

25-35 ft-lbs

Footpeg bracket screws

1.21 STEERING HEAD BEARINGS, Adjustment

95-108.5 Nm

70-80 ft-lbs

Fork stem nut

TORQUE VALUES IX

2009 Dyna Models Service Manual

NOTES

TORQUE VALUE

FASTENER

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

1.17 BRAKE PADS AND DISCS, Brake Pad
Replacement

38.0-51.5 Nm

28-38 ft-lbs

Front caliper mounting bolt

1.17 BRAKE PADS AND DISCS, Brake Pad
Replacement

38.0-51.5 Nm

28-38 ft-lbs

Front caliper mounting bolt

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

33.9-40.7 Nm

25-30 ft-lbs

Front engine mounting bracket bolts

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

7.19 FUEL GAUGE, FXD Models

2.03-2.49 Nm

18-22 in-lbs

Fuel gauge trim ring screws

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

7.21 INSTRUMENTS: FXDC/FXDF, Installation

2.03-2.71 Nm

18-24 in-lbs

Fuel tank trim screws

2.13 FRONT BRAKE MASTER CYL-
INDER, Assembly and Installation

6.8-9.0 Nm

60-80 in-lbs

Handlebar switch clamp screw

7.33 RIGHT HANDLEBAR SWITCH, Installation

6.8-9.0 Nm

60-80 in-lbs

Handlebar switch clamp screws

7.34 LEFT HANDLEBAR SWITCH, Installation

6.8-9.0 Nm

60-80 in-lbs

Handlebar switch clamp screws

1.3 MAINTENANCE SCHEDULE, General

4.0-5.1 Nm

35-45 in-lbs

Handlebar switch housing screw

1.15 THROTTLE CABLES, Cable Inspection,
Lubrication and Adjustment

4.0-5.1 Nm

35-45 in-lbs

Handlebar switch housing screw

2.13 FRONT BRAKE MASTER CYL-
INDER, Assembly and Installation

4.0-5.1 Nm

35-45 in-lbs

Handlebar switch housing screw

7.33 RIGHT HANDLEBAR SWITCH, Installation

4.0-5.1 Nm

35-45 in-lbs

Handlebar switch housing screws

7.34 LEFT HANDLEBAR SWITCH, Installation

4.0-5.1 Nm

35-45 in-lbs

Handlebar switch housing screws

7.12 HEADLAMP, Headlamp Assembly Installation

33.9-40.7 Nm

25-30 ft-lbs

Headlight horizontal adjusting bolt

1.24 HEADLAMP ALIGNMENT, Adjustment

33.9-40.7 Nm

25-30 ft-lbs

Horizontal adjusting bolt

7.29 HORN, Replacement

13.6-20.3 Nm

10-15 ft-lbs

Horn mounting nut

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

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

7.25 INDICATOR LAMPS, Installation

2.0-2.7 Nm

18-24 in-lbs

LED assembly fasteners

3.17 TOP END OVERHAUL: ASSEMBLY, Push
Rods, Lifters and Covers

10.2-13.6 Nm

90-120 in-lbs

Lifter cover screws

7.11 STARTER SOLENOID, Solenoid Contacts

7.3-9.0 Nm

65-80 in-lbs

Long post jam nut

2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation

40.7-54.2 Nm

30-40 ft-lbs

Lower handlebar clamp fastener

X TORQUE VALUES

2009 Dyna Models Service Manual

NOTES

TORQUE VALUE

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

1.21 STEERING HEAD BEARINGS, Adjustment

40.7-47.5 Nm

30-35 ft-lbs

Lower triple clamp pinch bolts

6.6 TRANSMISSION ASSEMBLY, Assembly

74.6-88.2 Nm

55-65 ft-lbs

Mainshaft/countershaft nuts

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

1.3 MAINTENANCE SCHEDULE, General

0.7-0.9 Nm

6-8 in-lbs

Master cylinder reservoir cover

1.7 BRAKES, Fluid Inspection

0.7-0.9 Nm

6-8 in-lbs

Master cylinder reservoir cover screw

1.16 BLEEDING BRAKES, Procedure

0.7-0.9 Nm

6-8 in-lbs

Master cylinder reservoir cover screw

1.17 BRAKE PADS AND DISCS, Brake Pad
Replacement

0.7-0.9 Nm

6-8 in-lbs

Master cylinder reservoir cover screw

1.17 BRAKE PADS AND DISCS, Brake Pad
Replacement

0.7-0.9 Nm

6-8 in-lbs

Master cylinder reservoir cover screw

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

6.8 TRANSMISSION CASE, Installation

13.6-20.3 Nm

120-180 in-lbs

Neutral switch

7.26 NEUTRAL SWITCH, Installation

13.6-20.3 Nm

120-180 in-lbs

Neutral switch

3.30 OIL PAN, Installation

9.5-12.2 Nm

84-108 in-lbs

Oil pan screws

7.27 OIL PRESSURE SWITCH, Installation

10.8-16.3 Nm

96-144 in-lbs

Oil pressure switch

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

4.5-5.1 Nm

40-45 in-lbs

Oil pump screws, initial torque

6.6 TRANSMISSION ASSEMBLY, Installation

9.5-14.9 Nm

84-132 in-lbs

Oil spout fastener

4.13 OXYGEN SENSOR, Installation

39.3-59.7 Nm

29-44 ft-lbs

Oxygen sensor

2.18 FRONT FORK, Installation

41-48 Nm

30-35 ft-lbs

Pinch bolts

3.28 CRANKCASE, Right Crankcase Half

2.8-3.9 Nm

25-35 in-lbs

Piston jet screws

2.24 REAR FORK, Installation

96.3-101.7 Nm

71-75 ft-lbs

Pivot shaft nut

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

46.1 Nm

34 ft-lbs

Primary cam sprocket flange bolts, final
torque

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

20.3 Nm

15 ft-lbs

Primary cam sprocket flange bolts, initial
torque

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

20.3 Nm

15 ft-lbs

Primary cam sprocket flange bolts, initial
torque

1.3 MAINTENANCE SCHEDULE, General

19.0-28.5 Nm

14-21 ft-lbs

Primary chaincase drain plug

1.10 PRIMARY CHAIN, Changing Primary Chain-
case Lubricant

19.0-28.5 Nm

14-21 ft-lbs

Primary chaincase drain plug

5.3 PRIMARY CHAINCASE COVER, Installation

12.2-13.6 Nm

108-120 in-lbs

Primary cover fasteners

1.14 REAR BELT DEFLECTION, Adjust-
ment/Tighten after axle is tightened.

10.8-13.6 Nm

96-120 in-lbs

Rear axle adjuster screw

TORQUE VALUES XI

2009 Dyna Models Service Manual

NOTES

TORQUE VALUE

FASTENER

1.14 REAR BELT DEFLECTION, Adjustment

128.8-142.4 Nm

95-105 ft-lbs

Rear axle 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

7.28 REAR STOPLIGHT SWITCH, Installation

16.3-20.3 Nm

12-15 ft-lbs

Rear stoplight switch

7.14 TURN SIGNALS AND RUNNING
LIGHTS, Rear Lamp Housing Replacement

16.3-21.7 Nm

12-16 ft-lbs

Rear turn signal lamp fastener

2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation

5.6-6.8 Nm

50-60 in-lbs

Riser cover fastener

3.17 TOP END OVERHAUL: ASSEMBLY, Rocker
Arm Support Plate

24.4-29.8 Nm

18-22 ft-lbs

Rocker arm support plate bolts

3.17 TOP END OVERHAUL: ASSEMBLY, Breather
Assembly

20.3-24.4 Nm

15-18 ft-lbs

Rocker cover bolts

3.17 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head

13.6-19.0 Nm

120-168 in-lbs

Rocker housing bolts

5.5 PRIMARY CHAINCASE HOUSING, Installation

33.9-36.6 Nm

25-27 ft-lbs

Sealing fasteners

2.30 SEAT, Installation

6.78-10.17 Nm

60-90 in-lbs

Seat strap nut

3.26 CAM SUPPORT PLATE AND COVER, Cam-
shafts

11.3-13.6 Nm

100-120 in-lbs

Secondary cam chain tensioner fastener

6.6 TRANSMISSION ASSEMBLY, Assembly

13.6-17.0 Nm

120-150 in-lbs

Shift drum detent arm fastener

6.6 TRANSMISSION ASSEMBLY, Assembly

6.4-7.1 Nm

57-63 in-lbs

Shift drum lock plate fasteners

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

24.4-29.8 Nm

18-22 ft-lbs

Shifter foot lever pinch bolt

6.4 SHIFTER LINKAGE, Adjustment

10.8-16.3 Nm

96-144 in-lbs

Shifter linkage locknut

6.8 TRANSMISSION CASE, Assembly

24.4-29.8 Nm

18-22 ft-lbs

Shifter rod lever screw

6.4 SHIFTER LINKAGE, Adjustment

9.0-13.6 Nm

80-120 in-lbs

Shift rod jam 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

5.3 PRIMARY CHAINCASE COVER, Installation

20.3-25.6 Nm

15-19 ft-lbs

Sleeve

7.10 STARTER, Field Coil Assembly

7.9-10.2 Nm

70-90 in-lbs

Solenoid ring terminal nut

1.3 MAINTENANCE SCHEDULE, General

16.3-24.4 Nm

12-18 ft-lbs

Spark plug

1.20 SPARK PLUGS, Inspection

16.3-24.4 Nm

12-18 ft-lbs

Spark plug

2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation

5.6-6.8 Nm

50-60 in-lbs

Speedometer cover fastener

7.24 VEHICLE SPEED SENSOR (VSS), Installation

9.5-12.2 Nm

84-108 in-lbs

Speedometer sensor mounting bolt

1.3 MAINTENANCE SCHEDULE, General

6.5-7.3 Nm

55-65 in-lbs

Spoke nipple

1.9 TIRES AND WHEELS, Wheel Spokes

6.2 Nm

55 in-lbs

Spoke nipple

XII TORQUE VALUES

2009 Dyna Models Service Manual

NOTES

TORQUE VALUE

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

3.13 ASSEMBLING MOTORCYCLE AFTER
SERVICE, Procedure

24.4-29.8 Nm

18-22 ft-lbs

Stabilizer link bolt

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

24.4-29.8 Nm

18-22 ft-lbs

Stabilizer link bolt

7.10 STARTER, Field Coil Assembly

10.2-12.4 Nm

90-110 in-lbs

Starter end cover screw

7.10 STARTER, Installation

33.9-36.6 Nm

25-27 ft-lbs

Starter mounting bolts

7.9 BATTERY TRAY AND BATTERY
CABLES, Battery Cables/metric

7.3-9.6 Nm

65-85 in-lbs

Starter positive terminal nut

7.10 STARTER, Installation

7.3-9.6 Nm

65-85 in-lbs

Starter positive terminal nut

7.10 STARTER, Field Coil Assembly

4.4-7.3 Nm

39-65 in-lbs

Starter thru bolts

7.18 ALTERNATOR AND STATOR, Installation/T27
TORX, use only once

6.2-8.4 Nm

55-75 in-lbs

Stator screws

7.13 TAIL LAMP, Base Replacement: All But FXDB

4.5-5.4 Nm

40-48 in-lbs

Tail lamp base screws: all but FXDB

7.13 TAIL LAMP, Base Replacement: FXDB

9.5-12.2 Nm

84-108 in-lbs

Tail lamp base screws: FXDB

7.13 TAIL LAMP, Tail Lamp Bulb Replacement:
Standard Style

2.3-2.7 Nm

20-24 in-lbs

Tail lamp lens screws

7.13 TAIL LAMP, Base Replacement: All But FXDB

2.3-2.7 Nm

20-24 in-lbs

Tail lamp lens screws: all but FXDB

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

2.22 THROTTLE CONTROL, Assembly/Installation

4.0-5.1 Nm

35-45 in-lbs

Throttle housing screws

4.7 THROTTLE POSITION SENSOR
(TPS), Installation

2.0 Nm

18 in-lbs

Throttle position sensor fasteners

4.15 FUEL PUMP, Installation

2.3 Nm

20 in-lbs

Top plate fasteners

4.15 FUEL PUMP, Installation

2.3 Nm

20 in-lbs

Top plate fasteners

7.20 FUEL GAUGE SENDER, Installation

3.1-3.7 Nm

27-33 in-lbs

Top plate fasteners (all but FXD)

7.20 FUEL GAUGE SENDER, Installation

1.7-2.4 Nm

15-21 in-lbs

Top plate fasteners (FXD)

6.6 TRANSMISSION ASSEMBLY, Installation

17.6-24.4 Nm

13-18 ft-lbs

Transmission case, 5/16 in. hardware

1.3 MAINTENANCE SCHEDULE, General

19.0-28.5 Nm

14-21 ft-lbs

Transmission drain plug

1.11 TRANSMISSION LUBRICANT, Changing
Transmission Lubricant

19.0-28.5 Nm

14-21 ft-lbs

Transmission drain plug

6.6 TRANSMISSION ASSEMBLY, Installation

19.0-28.5 Nm

14-21 ft-lbs

Transmission drain plug

6.8 TRANSMISSION CASE, Installation

19.0-28.5 Nm

14-21 ft-lbs

Transmission drain plug

1.11 TRANSMISSION LUBRICANT, Changing
Transmission Lubricant

2.8-8.5 Nm

25-75 in-lbs

Transmission filler plug/dipstick

1.3 MAINTENANCE SCHEDULE, General

2.8-8.5 Nm

25-75 in-lbs

Transmission filler plug/dipstick torque

7.9 BATTERY TRAY AND BATTERY
CABLES, Battery Cables

17.6-27.1 Nm

13-20 ft-lbs

Transmission ground stud nut

5.7 TRANSMISSION SPROCKET, Installation/LOC-
TITE patch, use 3-5 times

9.5-12.2 Nm

84-108 in-lbs

Transmission lockplate screws

TORQUE VALUES XIII

2009 Dyna Models Service Manual

NOTES

TORQUE VALUE

FASTENER

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

46.1-52.9 Nm

34-39 ft-lbs

Transmission mounting bolts, final torque

6.8 TRANSMISSION CASE, Installation

46.1-52.9 Nm

34-39 ft-lbs

Transmission mounting bolts, final torque

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

20.3 Nm

15 ft-lbs

Transmission mounting bolts, initial
torque

6.8 TRANSMISSION CASE, Installation

20.3 Nm

15 ft-lbs

Transmission mounting bolts, initial
torque

5.7 TRANSMISSION SPROCKET, Installation/Right
hand threads, initial torque only, apply several
drops of LOCTITE THREADLOCKER 271 (red) to
last few threads.

47.5 Nm

35 ft-lbs

Transmission sprocket nut

5.7 TRANSMISSION SPROCKET, Installation

47.5 Nm

35 ft-lbs

Transmission sprocket nut

6.6 TRANSMISSION ASSEMBLY, Installation

9.5-14.9 Nm

84-132 in-lbs

Transmission top cover

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

2.27 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

1.24 HEADLAMP ALIGNMENT, Adjustment

33.9-40.7 Nm

25-30 ft-lbs

Vertical adjusting nut

7.6 VOLTAGE REGULATOR, Installation

6.8-9.0 Nm

60-80 in-lbs

Voltage regulator fasteners

6.8 TRANSMISSION CASE, Installation

9.5-14.9 Nm

84-132 in-lbs

VSS fastener

XIV TORQUE VALUES

1

150 Metri-Pack Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-22

4

480 Metri-Pack Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-25

6

630 Metri-Pack Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-26

A

Active Exhaust Module. . . . . . . . . . . . . . . . . . . . . . . . . . 7-58

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58

Air Cleaner

Backplate Assembly: HDI Models. . . . . . . . . . . . . . . 4-7
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Air Cleaner and Exhaust System

Exhaust System Leak Check. . . . . . . . . . . . . . . . . . 1-19

Air Cleaner Filter

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Alternator

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

AMP Multilock Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Assembling Motorcycle after Service. . . . . . . . . . . . . . . 3-25
Autofuse Electrical Connector. . . . . . . . . . . . . . . . . . . . . . A-5

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

B

Battery

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

Battery Cables

Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Battery Maintenance

Charging Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 1-37
Disconnection and Removal. . . . . . . . . . . . . . . . . . . 1-38
Installation and Connection. . . . . . . . . . . . . . . . . . . 1-39
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
Voltmeter Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

Battery Tray and Battery Cables

Battery Tray Installation. . . . . . . . . . . . . . . . . . . . . . 7-14
Battery Tray Removal. . . . . . . . . . . . . . . . . . . . . . . . 7-14

Belt Guard

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

Bleeding Brakes

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

Bottom End Overhaul: Assembly

Cam Support Plate and Cover. . . . . . . . . . . . . . . . . 3-52
Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Bottom End Overhaul: Disassembly. . . . . . . . . . . . . . . . 3-46

Cam Support Plate and Cover. . . . . . . . . . . . . . . . . 3-46
Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

Bottom End Service

Engine in Chassis (Cam Compartment Service). . . 3-22

Engine Removed (Flywheel Compartment Service or
Complete Engine Overhaul). . . . . . . . . . . . . . . . . . . 3-23

Brake Pads and Discs

Brake Pad Replacement. . . . . . . . . . . . . . . . . . . . . . 1-33
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

Brakes

Fluid Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Rear Pedal Height. . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Breather Assembly

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 3-57
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Installation Overview. . . . . . . . . . . . . . . . . . . . . . . . 3-57
Removal Overview. . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Breather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Bulb Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

C

Cable and Chassis Lubrication. . . . . . . . . . . . . . . . . . . . 1-46

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46
Jiffy Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

Cam Support Plate and Cover

Bottom End Overhaul: Assembly. . . . . . . . . . . . . . . 3-52
Bottom End Overhaul: Disassembly. . . . . . . . . . . . . 3-46
Cam Needle Bearings. . . . . . . . . . . . . . . . . . . . . . . 3-87
Camshafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 3-90
Installation Overview. . . . . . . . . . . . . . . . . . . . . . . . 3-90
Oil Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . 3-87
Removal Overview. . . . . . . . . . . . . . . . . . . . . . . . . . 3-85

Cast Wheel Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Lateral Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Checking and Adding Oil

Cold Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Type of Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Warm Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Checking Cast Wheel Runout

Radial Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Cleaning

Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Cleaning Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Part Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Rust or Corrosion Removal. . . . . . . . . . . . . . . . . . . . 1-5

Clutch

Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Clutch Pack and Bearing. . . . . . . . . . . . . . . . . . . . . 5-16
Clutch Pack Only. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Removal and Installation. . . . . . . . . . . . . . . . . . . . . 5-14

Clutch Control

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73

Clutch Interlock Switch

Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74

Clutch Release Cover

Assembly and Installation. . . . . . . . . . . . . . . . . . . . . . 6-7
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . 6-7

Connectors

Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Console

FXD Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39

Conversions

Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Crankcase

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 3-99
Cylinder Studs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
Left Crankcase Half. . . . . . . . . . . . . . . . . . . . . . . . . 3-93

XV

INDEX