Harley Davidson 2009 Dyna Models. Service manual — page 28

4.19

EVAPORATIVE EMISSIONS CONTROL (CA
MODELS)

GENERAL

Motorcycles sold in some markets are equipped with an
evaporative (EVAP) emissions control system. See

The EVAP system functions as follows:

•

The fuel vapor vent tube connected to the vapor valve on
the fuel tank top plate allows fuel vapors in the fuel tank
to be vented to the charcoal canister. If the motorcycle is
tipped, the vapor valve also prevents the loss of gasoline
through the vent tube.

•

Under certain engine conditions, the ECM (working in
conjunction with the EFI system relay) opens the purge
solenoid. Negative pressure (vacuum) draws the fuel
vapors stored in the charcoal canister through the purge

tube to the induction module, where they are burned as
part of the normal combustion process.

Keep evaporative emissions vent lines away from exhaust
and engine. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00266a)

NOTE

The EVAP system has been designed to operate with a min-
imum of maintenance. Check that all tubes are correctly routed
and properly connected. Also, verify that the tubes are not
pinched or kinked, and that there is no contact with the engine
parts.

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Vapor valve

Throttle body

Purge hose

Charcoal canister

Elbow connector

Fuel tank

Vent hose

Figure 4-72. Schematic-CA Evaporative Emissions Control System

CHARCOAL CANISTER

Removal

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

See

Figure 4-73

. The EVAP charcoal canister is mounted

between the forward frame downtubes.

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2009 Dyna Service: Fuel System 4-41

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Figure 4-73. Charcoal Canister Location

Remove maxi-fuse. See

7.7 FUSES AND RELAYS

Pull clean air hose (connection from air cleaner backplate)
off nipple on right side of charcoal canister.

With a screwdriver, lift up the tang on the canister bracket
and slide the canister sideways until it drops free from the
bracket.

See

Figure 4-74

. Note the two hose connections on the

left side of the canister. To verify correct assembly, label
each hose to match the stamps on the canister before
disconnecting.

Remove canister.

Installation

See

Figure 4-73

. Slide canister into mounting bracket until

canister clicks in place.

See

Figure 4-74

. Attach hoses to canister nipples as

marked.

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Purge hose to canister

Vent hose from fuel tank and vapor valve

Figure 4-74. Charcoal Canister Connections

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Figure 4-75. Hose Routing-Clean Air Inlet Hose

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4-42 2009 Dyna Service: Fuel System

TABLE OF CONTENTS

SUBJECT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE NO.

DRIVE

5.1

FASTENER TORQUE VALUES

FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

NOTES

TORQUE VALUE

FASTENER

5.4 DRIVE COMPONENTS, Installation

20.3-25.8 Nm

15-19 ft-lbs

Chain tensioner fasteners

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

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

5.6 CLUTCH, Clutch Pack and Bearing

10.2-12.4 Nm

90-110 in-lbs

Diaphragm spring retainer bolts

5.3 PRIMARY CHAINCASE COVER, Installation

12.2-13.6 Nm

108-120 in-lbs

Primary cover fasteners

5.5 PRIMARY CHAINCASE HOUSING, Installation

33.9-36.6 Nm

25-27 ft-lbs

Sealing fasteners

5.3 PRIMARY CHAINCASE COVER, Installation

20.3-25.6 Nm

15-19 ft-lbs

Sleeve

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

9.5-12.2 Nm

84-108 in-lbs

Transmission lockplate screws

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

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2009 Dyna Service: Drive 5-1

5.2

SPECIFICATIONS: DRIVE

SPECIFICATIONS

Table 5-1. Sprocket Specifications

NO. OF TEETH

SPROCKETS

DOM/HDI

Compensating

Clutch

Transmission

Rear Wheel

Table 5-2. Clutch Specifications

DESCRIPTION

CLUTCH

Wet-multiple disc

Type

1/16-1/8 in.

(1.6-3.2 mm)

Clutch lever freeplay
(after internal adjustment)

Table 5-3. Gear Specifications

OVERALL GEAR RATIO

GEAR

DOM/HDI

9.312

First (low)

6.421

Second

4.774

Third

3.926

Fourth

3.279

Fifth

2.790

Sixth (high)

NOTE

Overall gear ratios indicate number of engine revolutions
required to drive rear wheel one revolution.

HOME

5-2 2009 Dyna Service: Drive

5.3

PRIMARY CHAINCASE COVER

GENERAL

The primary chaincase is a sealed housing containing the
primary chain, chain tensioner, clutch, engine compensating
sprocket and alternator.

For information on primary chain lubrication, see

1.10 PRIMARY CHAIN

REMOVAL

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)

Disconnect negative battery cable.

Drain the primary chaincase lubricant. See

1.10 PRIMARY

CHAIN, Changing Primary Chaincase Lubricant

See

Figure 5-1

. When lubricant has drained, remove short

(1) and long (2) cover fasteners and cover.

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Short cover fasteners

Long cover fasteners

Figure 5-1. Primary Chaincase Cover

INSTALLATION

See

Figure 5-2

. On FXDF models, be sure sleeve (3) is

installed in primary chaincase cover (2). Apply two drops
of LOCTITE THREADLOCKER 262 (red) to sleeve threads
and tighten sleeve to 15-19 ft-lbs (20.3-25.6 Nm).

See

Figure 5-19

. On all but FXDF models, replace tower

gasket (9).

NOTE

The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.

See

Figure 5-2

. Install new cover gasket (1).

See

Figure 5-1

. Install short (1) and long (2) primary cover

fasteners in positions shown. Snug fasteners.

See

Figure 5-3

. Tighten primary cover fasteners (1-13) to

108-120 in-lbs (12.2-13.6 Nm) in the sequence shown.

Do not overfill the primary chaincase with lubricant.
Overfilling can cause rough clutch engagement, incom-
plete disengagement, clutch drag and/or difficulty in
finding neutral at engine idle. (00199b)

Place motorcycle in an upright position and fill primary
chaincase. See

1.10 PRIMARY CHAIN, Changing Primary

Chaincase Lubricant

Connect negative battery cable.

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Cover gasket

Primary chaincase cover

Sleeve (FXDF models)

Figure 5-2. Primary Chaincase Cover Gasket

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Figure 5-3. Primary Chaincase Cover Torque Sequence

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2009 Dyna Service: Drive 5-3

5.4

DRIVE COMPONENTS

REMOVAL

TOOL NAME

PART NUMBER

PRIMARY DRIVE LOCKING TOOL

HD-47977

NOTES

To remove the primary chain, remove compensating sprocket,
clutch assembly and primary chain as an assembly:

Remove primary chaincase cover. See

5.3 PRIMARY

CHAINCASE COVER, Removal

See

Figure 5-4

. Remove chain tensioner fasteners (2)

then remove chain tensioner (1).

Using a colored marker, mark one of the links of the
primary chain. Maintaining the original direction of rotation
during assembly may prolong service life.

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

See

Figure 5-5

. Loosen locknut (3).

Remove retaining ring (1) and release plate (2).

Do not apply heat to remove the clutch hub nut. Fuel vapor
and possible fuel mixture in crankcase oil is extremely
flammable and highly explosive, which could result in
death or serious injury. (00440b)

NOTES

•

See

Figure 5-7

. When removing the clutch hub mainshaft

nut the PRIMARY DRIVE LOCKING TOOL (Part No. HD-
47977) must be placed between the teeth of the engine
and clutch sprockets.

•

The mainshaft nut has left handed threads, so turn clock-
wise to remove.

•

Do not use PRIMARY DRIVE LOCKING TOOL (Part No.
HD-41214) to remove or install components. Damage to
components can occur if this tool is used. Use only
PRIMARY DRIVE LOCKING TOOL (Part No. HD-47977)
to remove and install components.

Using a breaker bar, rotate clutch hub mainshaft nut in
direction shown to remove.

NOTE

See

Figure 5-8

. When removing the compensating sprocket

bolt, the PRIMARY DRIVE LOCKING TOOL (Part No. HD-
47977) must be placed between the teeth of the engine and
clutch sprockets.

Using a breaker bar, rotate compensating sprocket bolt in
direction shown to remove.

See

Figure 5-9

. Remove bolt (6) and washer (5).

NOTE

Using a colored marker or paint pen, mark one of the outboard
links of the primary chain. Maintaining the original direction of
rotation during assembly may prolong service life.

See

Figure 5-6

. Remove clutch assembly, primary chain

and compensating sprocket assembly as a single
assembly.

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Chain tensioner

Chain tensioner fasteners

Figure 5-4. Chain Tensioner

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Retaining ring

Release plate

Locknut

Figure 5-5. Clutch

HOME

5-4 2009 Dyna Service: Drive

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Figure 5-6. Remove Drive Components

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Engine sprocket

Primary drive locking tool

Clutch sprocket

Mainshaft nut

Figure 5-7. Removing Clutch Hub Mainshaft Nut

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Bolt

Primary drive locking tool

Figure 5-8. Removing Compensating Sprocket Bolt

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Rotor

Sliding cam

Compensating sprocket

Shaft extension

Washer

Bolt

Figure 5-9. Compensating Sprocket

INSTALLATION

TOOL NAME

PART NUMBER

PRIMARY DRIVE LOCKING TOOL

HD-47977

NOTE

The primary chain, compensating sprocket and clutch assembly
must be installed as an assembly.

HOME

2009 Dyna Service: Drive 5-5

See

Figure 5-10

. Apply a thin layer of primary chaincase

oil to the inner diameter of the compensating sprocket (3)
and the splines of shaft extension (4). Assemble shaft
extension, compensating sprocket and sliding cam (2).
Place primary chain over compensating sprocket
assembly.

Place drive components (primary chain, compensating
sprocket assembly, and clutch assembly) into position.
The clutch hub and shaft extension are splined, so a slight
rotation of the chain drive will aid installation.

Install new bolt (6) and washer (5) hand tight.

NOTE

Clutch hub mainshaft nut has left handed threads, so turn
counterclockwise to install.

Clean and prime threads of nut. Apply two drops of LOC-
TITE THREADLOCKER 262 (red) to the threads of the
clutch hub mainshaft nut. Start nut onto mainshaft and
tighten hand tight.

NOTE

See

Figure 5-11

. When tightening the compensating sprocket

bolt, the PRIMARY DRIVE LOCKING TOOL (Part No. HD-
47977) must be placed between the teeth of the engine and
clutch sprockets.

Tighten compensating sprocket to 100 ft-lbs (135.7 Nm).

Loosen compensating sprocket back 1 full turn (360
degrees).

Tighten compensating sprocket to 140 ft-lbs (190 Nm).

NOTE

See

Figure 5-12

. When tightening the clutch hub mainshaft

nut the PRIMARY DRIVE LOCKING TOOL must be placed
between the teeth of the engine and clutch sprockets.

Tighten clutch hub mainshaft nut to 70-80 ft-lbs (94.9-108.5
Nm). Remove primary drive locking tool.

See

Figure 5-13

. Install release plate (5) with locknut (2)

and adjuster screw (3) into clutch hub bore. The word
"OUT" stamped on the release plate should face outward.

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

10. Inspect retaining ring (4) and replace if necessary. Install

retaining ring in clutch hub bore to lock release plate in
position. Verify that the retaining ring is completely seated
in the groove.

11. Adjust clutch. See

1.12 CLUTCH, Adjustment

NOTE

Primary chain tensioner is non-repairable. If tensioner is worn
or damaged, assembly must be replaced.

12. See

Figure 5-14

. Although primary chain tensioner is sold

as an assembly, tensioner parts can be disassembled. If
primary chain tensioner becomes disassembled, assemble
in order shown.

13. See

Figure 5-15

. Locate end of spring rod (2) on roll pin

(3).

14. See

Figure 5-16

. Slide wedge (2) of primary chain ten-

sioner in direction of arrow until all travel is removed.

15. Push shoe (1) down until it contacts wedge. Keep tension

on shoe so wedge stays in place.

16. See

Figure 5-17

. Insert cable tie (2) as shown to hold

wedge in place. Make sure end of cable tie is located
below primary chain tensioner. If cable tie is installed this
way, it will hang below primary cover gasket surface and
serve as a reminder to remove cable tie before installing
primary cover.

NOTE

Primary chain tensioner will not complete chain adjustment
until vehicle is ridden. Vehicle must be test ridden after ten-
sioner removal/installation to verify proper adjustment.

17. See

Figure 5-18

. Install primary chain tensioner (1) into

place. Install chain tensioner fasteners (2) and tighten to
15-19 ft-lbs (20.3-25.8 Nm). Remove cable tie.

NOTE

The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.

18. Install primary chaincase cover and fill with lubricant. See

5.3 PRIMARY CHAINCASE COVER, Installation

sm02402

Rotor

Sliding cam

Compensating sprocket

Shaft extension

Washer

Bolt

Figure 5-10. Compensating Sprocket

HOME

5-6 2009 Dyna Service: Drive

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Bolt

Primary drive locking tool

Figure 5-11. Installing Compensating Sprocket Bolt

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Primary drive locking tool

Mainshaft nut

Figure 5-12. Installing Clutch Hub Mainshaft Nut

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Diaphragm spring

Locknut

Adjuster screw

Retaining ring

Release plate

Figure 5-13. Clutch

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2009 Dyna Service: Drive 5-7

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Shoe assembly

Wedge

Washer

Spring

Spring rod

Figure 5-14. Primary Chain Tensioner Assembly

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Shoe

Spring rod

Roll pin

Figure 5-15. Spring Rod Location

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Shoe

Wedge

Figure 5-16. Primary Chain Tensioner

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Primary chain tensioner

Cable tie

Figure 5-17. Securing Primary Chain Tensioner

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Chain tensioner

Chain tensioner fasteners

Figure 5-18. Chain Tensioner

HOME

5-8 2009 Dyna Service: Drive

5.5

PRIMARY CHAINCASE HOUSING

REMOVAL

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)

Disconnect negative battery cable.

Remove primary chaincase cover. See

5.3 PRIMARY

CHAINCASE COVER, Removal

Remove starter. See

7.10 STARTER, Removal

Remove primary chain, clutch, and compensating sprocket.
See

5.4 DRIVE COMPONENTS, Removal

See

Figure 5-19

. Remove five sealing fasteners (5) and

remove primary chaincase housing (11). Discard the
crankcase gasket (10) and sealing fasteners.

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Seal

Lock ring

Bearing

Dowel pin

Sealing fastener

Chain tensioner fasteners

Drain plug and o-ring

Chain tensioner

Tower gasket

10. Primary chaincase housing
11. Shifter shaft bushing
12. Crankcase gasket

Figure 5-19. Primary Chaincase Housing

INSPECTION

Inspect primary chaincase for cracks or damaged gasket
surface.

Check the mainshaft bearing. Replace if bearing does not
rotate freely. Replace the lip seal. See

5.5 PRIMARY

CHAINCASE HOUSING, Mainshaft Bearing and Lip Seal

On all but FXDF models, inspect shifter shaft bushing.
Replace if worn or damaged. See

5.5 PRIMARY CHAIN-

CASE HOUSING, Shifter Shaft Bushing

MAINSHAFT BEARING AND LIP SEAL

Removal

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

Remove lip seal from bearing bore on transmission side
of primary chaincase. Use a seal remover or rolling head
pry bar for best results.

Remove retaining ring from groove on transmission side
of bearing.

Support inner primary chaincase on transmission side of
bearing.

NOTE

Support inner primary chain case area on transmission side
while pressing bearing out of primary chaincase. The force
needed to remove bearing may cause damage to primary chain
case.

Place primary chaincase in arbor press. Press out bearing
from clutch side applying pressure to the outer race.

Installation

Inspect the bearing bore to verify that it is clean and
smooth. Install retaining ring in groove on pulley side of
primary chaincase.

Place primary chaincase in arbor press with the transmis-
sion side up.

Support the bearing support area on the clutch side of the
primary chaincase.

NOTE

Support the bearing support area on clutch side while pressing
bearing into bore. The force needed to press bearing into
position may force and unsupported primary chain case to
become damaged.

Apply a thin film of oil to outer diameter of bearing

Applying pressure to the outer race, press new bearing
letter side up, into bore until it makes solid contact with
the bearing support area.

See

Figure 5-20

. Retaining ring (1) must be oriented as

shown to prevent blocking of oil passage (2). Install
retaining ring to lock position of bearing in bore. Verify that
the ring is fully seated in the groove and is in proper orient-
ation.

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2009 Dyna Service: Drive 5-9

NOTES

•

The lip garter spring side of the oil seal is also identified
by the words "OIL SIDE".

•

Install oil seal with a seal driver that will press only against
outer rim of oil seal, NOT against the inner area.

•

The minimum allowable depth of the seal is reached when
the outer edge of the seal carrier is flush with the machined
surface of the primary housing. The maximum allowable
depth of the seal is reached when the seal carrier contacts
the mainshaft bearing snap ring.

Install mainshaft oil seal:

Lubricate the O.D. of the new seal with clean engine
oil.

See

Figure 5-21

. With the lip garter spring side

(stamped "oil side") facing toward the bearing, press
squarely on the outer edge of oil seal until outer edge
of seal is flush with machined surface of inner primary
housing.

Lubricate the bearing and seal lip with multi-purpose
grease or clean engine oil.

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Retaining ring

Oil passage

Figure 5-20. Retaining Ring Orientation

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Figure 5-21. Oil Seal

MAINSHAFT BEARING INNER RACE

TOOL NAME

PART NUMBER

MAINSHAFT BEARING INNER RACE
REMOVER/INSTALLER

HD-34902-C

Removal

NOTE

The bearing inner race must be positioned on the shaft a pre-
cise distance to properly align with the bearing outer race in
the primary chaincase. To remove and install the bearing inner
race, use the combination MAINSHAFT BEARING INNER
RACE REMOVER/INSTALLER (Part No. HD-34902-C).

See

Figure 5-22

. Install end cap (2) into end of mainshaft.

Position puller (3) around mainshaft, under bearing inner
race.

Turn forcing screw (4) clockwise while holding puller to
remove bearing.

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Bearing inner race

End cap

Puller

Forcing screw

Figure 5-22. Pulling Mainshaft Inner Bearing Race

HOME

5-10 2009 Dyna Service: Drive

Installation

See

Figure 5-24

. Slide bearing inner race (1), chamfered

edge first, onto mainshaft.

NOTE

Extension shaft has left-hand threads.

Thread extension shaft (2) onto end of mainshaft .

Position installer sleeve (4) over extension shaft and
against bearing inner race. Apply graphite lubricant to
threads of extension shaft.

Place two washers (5) over threaded portion of extension
shaft and install nut.

Tighten nut (6) while holding extension shaft stationary
with wrench on flats (3) at end of screw threads. Press
race onto shaft so inside edge is 0.100-0.125 in. (2.540-
3.180 mm) from main drive gear.

Lubricate race with primary chaincase lubricant.

sm03454

Figure 5-23. Mainshaft Bearing Inner Race Installer

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Bearing inner race

Extension shaft

Wrench flat

Installer sleeve

Washers

Nut

Figure 5-24. Installing Bearing Race

SHIFTER SHAFT BUSHING

See

Figure 5-25

. Press out old bushing from clutch side

of housing. Inspect the bushing bore to verify that it is
clean and smooth.

Press new bushing into bore from transmission side of
housing. Installed bushing must be flush to 0.020 in. (0.51
mm) below edge of bore.

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2009 Dyna Service: Drive 5-11

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Figure 5-25. Shifter Shaft Bushing

INSTALLATION

NOTE

Cover mainshaft clutch hub splines with tape to prevent the
splines damaging the inner primary cover oil seal.

Verify pivot shaft torque. See

2.24 REAR FORK, Installa-

tion

NOTE

See

Figure 5-26

. In next step, be sure dowels (1) in crankcase

gasket (2) engage holes in crankcase.

See

Figure 5-27

. Place crankcase gasket in place on

gasket surface (2). Be sure dowels in gasket engage dowel
holes (3).

Spread a thin film of oil on mainshaft oil seal lip and rubber
portion of crankcase gasket. Be careful not to damage
mainshaft seal when installing chaincase over the primary
bearing inner race on the mainshaft.

See

Figure 5-28

. Insert new sealing fasteners.

See

Figure 5-29

. Tighten fasteners in sequence shown to

25-27 ft-lbs (33.9-36.6 Nm).

Install the primary chain, clutch, and compensating
sprocket as an assembly. See

5.4 DRIVE COMPONENTS,

Installation

Install chain tensioner assembly.

Install starter. See

7.10 STARTER, Installation

NOTE

The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks .

Install primary chaincase cover. See

5.3 PRIMARY

CHAINCASE COVER, Installation

10. Fill primary chaincase with lubricant. See

1.10 PRIMARY

CHAIN, Changing Primary Chaincase Lubricant

11. Adjust rear belt tension.

12. Connect negative battery cable.

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Dowel

Crankcase gasket

Figure 5-26. Crankcase Gasket