Harley Davidson 2009 Dyna Models. Service manual — page 13
2.24
REAR FORK
REMOVAL
1.
Remove exhaust system. See
.
2.
Remove rear brake caliper. See
.
3.
Remove rear wheel. See
NOTE
Do not remove sprocket or brake disc unless they are damaged
and must be replaced.
4.
Remove lower shock absorber fasteners and swing shock
absorbers away from swingarm. See
5.
Remove the belt and debris guards. See
.
6.
Remove rear brake line clamp from rear fork.
7.
See
. Remove plug (2).
8.
Remove nut (3).
9.
Remove pivot shaft with attached nut (4). Support rear
fork (1) and pull assembly from frame.
4
2
1
9
12
11
10
7
6
8
5
3
sm02277
7.
1.
Left boss
Rear fork
2.
8.
Plug
Pivot bearing
9.
3.
Right spacer
Nut
4.
10.
Pivot shaft
Right boss
11.
5.
Dust shield
Retaining ring
6.
12.
Left spacer
Bushing
Figure 2-98. Rear Fork
2009 Dyna Service: Chassis 2-71
DISASSEMBLY
Carefully mark all components as they are removed, so com-
ponents may be easily returned to their original locations.
NOTE
The pivot bearing (8) is lifetime lubricated and will require no
further attention other than cleaning. Only disassemble com-
ponents from left boss of fork if they are damaged.
1.
See
. Remove retaining ring (5), push or with
a brass drift tap spacer (6) inboard to remove it from left
fork boss (7).
2.
From inboard side press or drive pivot bearing (8) from
left fork boss.
3.
Push or with a brass drift tap spacer (9) outboard to
remove it from right fork boss (10).
4.
Press pivot bushing (12) and dust shield (11) from fork
assembly.
CLEANING AND INSPECTION
See
. The pivot bearing (8) is lifetime lubricated
and will require no further attention other than cleaning. Clean
the bearing bore with a clean shop towel, removing any dirt or
grit adhering to the bearing surface.
1.
Carefully inspect all bearing components for wear and/or
corrosion. Replace any components that are damaged.
2.
Check that rear fork is not bent or twisted. Replace if
damaged.
ASSEMBLY
TOOL NAME
PART NUMBER
WHEEL BEARING GREASE
99855-89
1.
. If necessary, install new pivot bearing
(8) and press new bearing from outboard side until outer
race is seated against shoulder in left fork boss (7).
2.
Install retaining ring (5) and spacer (6). The spacer must
be inserted from the inboard side.
3.
If bushing (12) must be replaced, press the bushing and
dust shield (11) into the fork bore so dust shield is flush
to 0.060 in. (1.50 mm) above fork bore.
4.
Coat right side pivot spacer (9) with WHEEL BEARING
GREASE (Part No. 99855-89). Insert pivot spacer into
pivot bushing (12) with chamfered end facing outward.
INSTALLATION
1.
Coat pivot shaft with anti-seize lubricant.
2.
Slide rear fork assembly into position on mounting boss
of transmission case.
3.
See
. Hold fork assembly in position and install
the pivot shaft with attached nut (4) from right side. Thread
nut (3) on threads of pivot shaft. Tighten nut to 71-75 ft-
lbs (96.3-101.7 Nm).
4.
Swing shock absorbers into position and install lower
shock absorber fasteners. See
5.
Install rear brake caliper. See
.
6.
Install rear brake line clamp to rear fork.
7.
Install rear wheel and adjust drive belt deflection. See
.
8.
Install the belt and debris guards. See
.
9.
Install exhaust system. See
.
2-72 2009 Dyna Service: Chassis
2.25
CLUTCH CONTROL
REMOVAL
1.
Loosen clutch adjuster so clutch cable is fully slack. See
.
NOTE
Use the appropriate size retaining ring pliers and the appro-
priate tip to remove or install the retaining ring. Verify that the
tip is in good condition.
2.
. Remove the clutch cable anchor pin (1)
from the hand lever. To remove anchor pin, it will be
necessary to remove the retaining ring (2) and pivot pin
(4).
3.
Drain transmission lubricant and remove fill plug dipstick.
Remove transmission side cover. See
4.
See
. Note position of retaining ring opening.
Retaining ring opening must be positioned in approximately
the same location during assembly. Remove retaining ring
(4).
5.
Pull inner ramp and ramp coupling (3) out of side cover.
Hold inner and outer ramps together to keep balls from
falling free.
6.
Rotate the inner ramp to a position which will allow the
coupling to be disconnected from the inner ramp lever
arm. Disconnect coupling from inner ramp. Disconnect
cable end (2) from coupling.
7.
Back out threaded cable fitting (1) from side cover.
3
1
4
2
sm02481
1.
Anchor pin
2.
Retaining ring
3.
Clevis
4.
Pivot pin
Figure 2-99. Clutch Cable Installation
INSTALLATION
1.
See
. Apply a drop of Loctite Threadlocker
243 (blue) to clutch cable fitting and screw fitting (with o-
ring) into clutch release cover. Do not tighten at this time.
2.
Connect cable end to ramp coupling (3). Rotate ramps for
best access and install coupling on inner ramp. Place ramp
assembly in position in side cover.
NOTE
Use the appropriate size retaining ring pliers and the appro-
priate tip to remove or install the retaining ring. Verify that the
tip is in good condition.
3.
Install retaining ring (4). Position retaining ring opening to
the right of the outer ramp tang (the stop that prevents
rotation).
4.
Place new gasket on side cover and install, fully tightening
the clutch cable fitting. See
.
5.
Place a few drops of oil inside cable housing.
NOTES
•
Anchor pin does not require lubrication.
•
When clutch cable is installed, the cable should be located
in front of the handlebars for all models except FXDB.
FXDB models should have the clutch cable installed so
that it is located behind the handlebars.
6.
Check that clutch cable is properly routed along left side
of steering head, behind the triple trees, and through the
clips on front frame crossmember.
7.
See
. Insert anchor pin (1) through handle and
clutch cable clevis end (3).
8.
Place handle in bracket and install pivot pin (4) and
retaining ring (2).
9.
Adjust clutch cable. See
.
3
5
4
1
2
sm02482
1.
Cable fitting
2.
Clutch cable end
3.
Ramp coupling
4.
Retaining ring
5.
Inner ramp
Figure 2-100. Clutch Cable Connection
2009 Dyna Service: Chassis 2-73
2.26
HANDLEBARS: ALL BUT FXDB/FXDF
REMOVAL
All Models
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
1.
Disconnect negative battery cable.
2.
Place blanket or protective cover over front of fuel tank to
protect against scratches and other damage.
3.
Remove front master cylinder assembly. See
.
4.
Remove two screws securing clutch control assembly to
left side of handlebar. See
5.
Remove right and left handlebar switch assemblies and
throttle. See
or
NOTE
Original equipment grip is glued in place and must be cut off
to remove. Remove grip only if necessary.
6.
Remove left handlebar grip.
FXD/FXDC Models
1.
. Remove speedometer cover fasteners
(5) and speedometer cover (4).
2.
Remove upper handlebar clamp fasteners (1).
a.
For FXD models, remove upper handlebar clamp and
speedometer assembly (2).
b.
For FXDC models, remove upper handlebar clamp
(3).
3.
Remove handlebar (6).
4.
If removing lower handlebar clamps (7), remove two lower
handlebar clamp fasteners (13), lockwashers (12), ground
cable (15) and ground cable washer (14) and lower
handlebar clamps from upper fork bracket (11). Replace
bushings (9) if necessary.
5
7
15
4
8
9
10
11
9
8
13
12
1
6
14
3
2
sm02280
1.
Upper handlebar clamp fastener (4)
2.
Upper handlebar clamp and speedometer
assembly (FXD)
3.
Upper handlebar clamp (FXDC)
4.
Speedometer cover (FXD)
5.
Speedometer cover fastener (FXD, 2)
6.
Handlebar
7.
Lower handlebar clamp (2)
8.
Cup washer (4)
9.
Bushing (4)
10. Spacer (2)
11. Upper fork bracket
12. Lockwasher (2)
13. Lower handlebar clamp fastener (2)
14. Ground cable washer (right side only)
15. Ground cable (right side only)
Figure 2-101. Handlebars: FXD, FXDC
FXDL Models
1.
. Remove riser cover fastener (6) and
riser cover (3).
2.
Remove upper handlebar clamp fasteners (1).
3.
Remove upper handlebar clamp (2).
4.
Remove handlebar (4).
2-74 2009 Dyna Service: Chassis
5.
If removing risers (5), remove two riser fasteners (13),
lockwashers (12), ground cable (15) and ground cable
washer (14) and risers from upper fork bracket (11).
Replace bushings (9) if necessary.
1
6
5
2
3
8
9
10
11
9
8
12
13
14
15
4
7
sm02281
1.
Upper handlebar clamp fastener (4)
2.
Upper handlebar clamp
3.
Riser cover
4.
Handlebar
5.
Riser (2)
6.
Riser cover fastener
7.
Riser cover retainer
8.
Cup washer (4)
9.
Bushing (4)
10. Spacer (2)
11. Upper fork bracket
12. Lockwasher (2)
13. Riser fastener (2)
14. Ground cable washer (right side only)
15. Ground cable (right side only)
Figure 2-102. Handlebars: FXDL
INSTALLATION
FXD/FXDC Models
1.
See
. If lower handlebar clamps (7) were
removed, install lockwashers (12) on lower handlebar
clamp fasteners (13). Install ground cable (15) and ground
cable washer (14) on right-side fastener.
NOTE
In next step, make sure cup washers (8), bushings (9) and
spacers (10) are in position in upper fork bracket (11).
2.
Slide lower handlebar clamp fasteners through upper fork
bracket.
3.
Loosely install lower handlebar clamps to upper fork
bracket using lower handlebar clamp fasteners.
4.
Place handlebars (6) on lower handlebar clamps. Install
upper handlebar clamp (2 or 3). Install but do not tighten
clamp fasteners.
5.
Using knurled areas of handlebar as a guide, center
handlebars between lower handlebar clamps.
NOTE
On some models, knurled areas of handlebar will be completely
hidden by upper handlebar clamp and will not be visible at all
when handlebar is centered properly.
6.
Raise handlebars to normal riding position and hold in
position.
7.
Secure handlebars in clamp:
a.
Tighten two rear fasteners (1) until cast-in spacers
contact handlebar lower clamps (7).
b.
Tighten front fasteners to 12-16 ft-lbs (16.3-21.7 Nm).
c.
Final tighten rear fasteners to 12-16 ft-lbs (16.3-21.7
Nm). Slight gap between upper and lower clamps
should exist at front.
8.
Tighten lower handlebar clamp fasteners (13) to 30-40 ft-
lbs (40.7-54.2 Nm).
9.
Install speedometer cover (4) and speedometer cover
fasteners (5). Tighten fasteners to 50-60 in-lbs (5.6-6.8
Nm).
FXDL Models
1.
. If risers (5) were removed, install lock-
washers (12) on riser fasteners (13). Install ground cable
(15) and ground cable washer (14) on right-side fastener.
NOTE
In next step, make sure cup washers (8), bushings (9) and
spacers (10) are in position in upper fork bracket (11).
2.
Slide riser fasteners through upper fork bracket.
3.
Loosely install risers to upper fork bracket using riser
fasteners.
4.
Place handlebars (4) on risers. Install upper handlebar
clamp (2). Install but do not tighten clamp fasteners.
5.
Using knurled areas of handlebar as a guide, center
handlebars between lower handlebar clamps.
NOTE
On some models, knurled areas of handlebar will be completely
hidden by upper handlebar clamp and will not be visible at all
when handlebar is centered properly.
6.
Raise handlebars to normal riding position and hold in
position.
2009 Dyna Service: Chassis 2-75
7.
Secure handlebars in clamp:
a.
Tighten two rear fasteners (1) until cast-in spacers
contact risers.
b.
Tighten front fasteners to 12-16 ft-lbs (16.3-21.7 Nm).
c.
Final tighten rear fasteners to 12-16 ft-lbs (16.3-21.7
Nm). Slight gap between upper and lower clamps
should exist at front.
8.
Tighten riser fasteners to 30-40 ft-lbs (40.7-54.2 Nm).
9.
Install riser cover (3) riser cover fastener (6). Tighten
fastener to 50-60 in-lbs (5.6-6.8 Nm).
All Models
1.
Install left handlebar grip.
2.
Install right and left handlebar switch assemblies. Do not
tighten at this time. See
3.
Install clutch control assembly. See
4.
Install front brake master cylinder. See
5.
Connect battery negative cable. Tighten to 60-69 in-lb
(6.8-10.9 Nm)
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
6.
Test front brake lever for pressure and operation.
7.
Test for correct operation. Adjust as required. See
8.
Turn the Ignition/Light Key Switch to IGNITION and test
switches for proper operation.
9.
Operate brake lever to test stop light lamp.
2-76 2009 Dyna Service: Chassis
2.27
HANDLEBARS: FXDB/FXDF
REMOVAL
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
1.
Disconnect negative battery cable.
2.
Remove instrument panel. See
or
3.
Unplug fuel gauge connector.
4.
Remove fuel tank fasteners, vent, fuel supply fitting and
slide fuel tank back. See
5.
Place blanket or protective cover over front of fuel tank to
protect against scratches and other damage.
6.
Disconnect all left and right side hand control connectors
from connectors on main harness.
NOTE
Make note of wire colors and locations in connector before
removal. This will verify proper wire location in connector during
installation.
7.
Identify wire leads and remove terminals from hand control
connector housings (left hand control connector [24], right
hand control connector [22]). See
8.
Remove terminals from turn signal multilock connector.
See
.
9.
Remove front master cylinder assembly. See
.
10. Remove clutch control assembly from handlebar. See
11. Separate right handlebar switch assembly and remove
throttle. See
.
NOTE
Original equipment grip is glued in place and must be cut off
to remove. Remove grip only if necessary.
12. Remove left handlebar grip.
13. Remove switch housings, turn signals and wiring from
handlebars.
FXDB
1.
See
. Remove handlebar clamp fasteners
(1).
2.
Remove upper handlebar clamps (2).
3.
Remove handlebar (3).
2
1
3
4
sm03775
1.
Upper handlebar clamp fastener (4)
2.
Upper handlebar clamp (2)
3.
Handlebar
4.
Upper fork bracket
Figure 2-103. Handlebars: FXDB
FXDF
1.
. Remove upper handlebar clamp
fasteners (1) and upper handlebar clamp (2). Remove
handlebar.
2.
If removing lower handlebar clamps (4), remove two lower
handlebar clamp fasteners (10), lockwashers (9), ground
cable (12) and ground cable washer (11) and lower
handlebar clamps from upper fork bracket (8). Replace
bushings (6) if necessary.
2009 Dyna Service: Chassis 2-77
1
11
4
7
2
5
6
8
12
6
5
9
10
3
sm02282
1.
Upper handlebar clamp fastener (4)
2.
Upper handlebar clamp
3.
Handlebar
4.
Lower handlebar clamp (2)
5.
Cup washer (4)
6.
Bushing (4)
7.
Spacer (2)
8.
Upper fork bracket
9.
Lockwasher (2)
10. Lower handlebar clamp fastener (2)
11. Ground cable washer (right side only)
12. Ground cable (right side only)
Figure 2-104. Handlebars: FXDF
INSTALLATION
NOTE
The turn signal wires enter the switch housings through a relief
grommet in the housing. The turn signals must be supported
throughout this procedure to prevent pulling the grommet or
the turn sign wires out of the housing.
1.
Repair or replace switches, turn signal switches, wires
and grommets as necessary.
NOTE
For handlebar switch repair procedures, see
.
2.
Wrap wire ends and open ends of conduit with electrical
tape.
3.
Cut a length of mechanics wire to use as a leader.
4.
Lay mechanics wire along the wire harnesses so a few
inches overlap and secure using electrical tape.
Grommets in each of the wiring holes in the handlebar
must remain in position after routing the wiring through
the handlebar. Operation without the grommets in place
can damage wires, causing a short circuit which could
result in death or serious injury. (00416d)
5.
If necessary, replace grommets on handlebars wire
openings.
6.
Lubricate wire conduits with glass cleaner.
7.
. Thread the wire leaders through the
handlebar grommets and to the center hole.
8.
Pull wire bundles through to the handlebar center hole.
9.
Loosely install left and right switch housings.
10. Pull slack from wire harnesses and remove the tape and
mechanics wire.
sm02483
Figure 2-105. Wire Leader in Handlebars (Handlebars
Removed from Motorcycle)
2-78 2009 Dyna Service: Chassis
11. FXDF models: see
. Install handlebars as
follows:
a.
If lower handlebar clamps (4) were removed, install
lockwashers (9) on lower handlebar clamp fasteners
(10). Install ground cable (12) and ground cable
washer (11) on right-side fastener.
b.
If removed, install cup washers (5), bushings (6) and
spacers (7) in upper fork bracket (8).
c.
Slide lower handlebar clamp fasteners (10) through
upper fork bracket.
d.
Loosely install lower handlebar clamps (4) to upper
fork bracket using lower handlebar clamp fasteners.
e.
Place handlebars (3) on lower handlebar clamps.
Install upper handlebar clamps (2). Install but do not
tighten clamp fasteners (1).
12. FXDB models: see
. Place handlebars (3)
on risers. Install upper handlebar clamps (2). Install but
do not tighten clamp fasteners.
13. Insert wires into proper locations in wire connector hous-
ings. See
B.2 WIRING DIAGRAMS, 2009 Dyna Wiring
14. Connect left and right hand control connectors [22, 24].
15. Connect turn signal connector [31].
NOTE
When clutch control is installed on handlebars, the cable should
be located in front of the handlebars for all models except
FXDB. FXDB models should have the clutch cable installed
so that it is located behind the handlebars.
16. Install clutch control and front master cylinder. Align
housings and tighten fasteners. See
or
2.13 FRONT BRAKE MASTER CYLINDER
17. Slide fuel tank into position and install fuel tank fasteners.
Connect vent hose and fuel supply fitting. See
18. Connect fuel gauge connector [117].
19. Install instrument console. See
or
20. Using knurled areas of handlebar as a guide, center
handlebars between lower handlebar clamps.
NOTE
On some models, knurled areas of handlebar will be completely
hidden by upper handlebar clamp when handlebar is centered
properly.
21. Raise handlebars to normal riding position and hold in
position.
NOTE
FXDF models: gap between upper and lower clamps should
be equal front and rear.
22. FXDF models: see
. Tighen handlebar
clamps as follows:
a.
Tighten front and rear upper handlebar clamp
fasteners (1) to 12-16 ft-lbs (16.3-21.7 Nm).
b.
Remove one lower handlebar clamp fastener (10).
Apply LOCTITE HIGH STRENGTH THREADLOCKER
271 (red) to fastener threads.
c.
Install fastener and tighten to 30-40 ft-lbs (40.7-54.2
Nm). Repeat for other fastener.
23. FXDB models: see
. Tighten handlebar
clamps as follows:
a.
Tighten two front fasteners (1) until cast-in spacers
contact risers.
b.
Tighten two rear fasteners (2) to 12-16 ft-lbs (16.3-
21.7 Nm).
c.
Tighten two front fasteners (1) to 12-16 ft-lbs (16.3-
21.7 Nm).
24. Connect negative battery cable to battery.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
25. Test front brake lever for pressure and operation.
26. Test throttle for correct operation. Adjust as required. See
27. Turn the Ignition/Light Key Switch to IGNITION and test
switches for proper operation.
28. Operate brake lever to test stop light lamp.
2009 Dyna Service: Chassis 2-79
2.28
FRONT FENDER
REMOVAL
1.
. Remove both fender mounting screws
(2) and nuts (3) on each side.
2.
Carefully remove fender being careful not to scratch the
fender paint.
INSTALLATION
1.
Carefully position fender and align mounting holes.
2.
. Ensure the fender mounting brackets
are resting against the machined bosses of the forks and
install screws (2) through fender mounting holes in fork
legs. Thread nuts (3) onto screws.
3.
Tighten fender mounting nuts to 15-21 ft-lbs (20.3-28.5
Nm).
2
3
1
sm02283
1.
Front fender
2.
Screw (2)
3.
Nut (2)
Figure 2-106. Front Fender
2-80 2009 Dyna Service: Chassis
2.29
REAR FENDER
GENERAL
This topic is split by vehicle type. However, the following steps
are common to all models.
Removal
1.
Remove seat.
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2.
Disconnect negative battery cable.
3.
Detach rear electrical harness.
a.
Follow the tail light and rear turn signal wire harness
to the eight pin connector under the seat.
b.
Separate the eight pin connector.
c.
If necessary, remove the six wires and the attached
socket terminals from the connector. See the electrical
diagnostic manual and
for
more information.
4.
Cut cable strap securing harness to frame. Pull harness
through fender opening.
5.
Continue with the steps for your specific vehicle.
Tail Lamp/Turn Signal Harness Routing
NOTE
If you are replacing the existing conduit, it may be necessary
to remove remaining adhesive. Do NOT use solvents or harsh
chemicals to remove adhesive as damage to painted sur-
faces may occur.
1.
Thoroughly clean inside surface of fender with soap and
water until it is free of dirt, oil, or other debris.
NOTE
For typical wiring harness/conduit placement, see
2.
Dry the surface, then wipe the area where conduit will be
placed with Isopropyl Alcohol. Allow to dry completely.
3.
Slide tail lamp wiring harness through conduit and plug
connectors into appropriate sockets. See the electrical
diagnostic manual and
for more
information.
4.
Remove protective strip covering adhesive on conduit (see
.) and lightly position the conduit in place.
2
1
sm02485
1.
Conduit
2.
Protective strip
Figure 2-107. Removing Protective Strip from Conduit
2
1
sm02486
1.
Conduit
2.
Wallpaper corner roller
Figure 2-108. Purging Air Between Adhesive and Fender
5.
. Using a wallpaper corner roller (avail-
able at most home improvement stores), roll along conduit
to purge the air from between the adhesive and the fender.
NOTES
•
Do NOT rub the conduit to make it adhere to the fender.
This will not do an adequate job of purging the air from
between the adhesive and fender.
•
Once the adhesive is in place, it requires 72 hours to fully
cure. Do NOT pull or try to reposition the conduit during
this period.
6.
Continue with the installation steps for your specific
vehicle.
Installation
After attaching fender, perform the following steps on all
models.
1.
Route harness through opening in fender.
2.
Install socket terminals back into connector. See the
electrical diagnostic manual and
for more information.
2009 Dyna Service: Chassis 2-81
3.
Connect negative battery cable.
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
4.
Install seat.
FXDF
Removal
1.
Remove rear turn signal lamps. See
2.
See
. Remove screws (1) from holes in cover
(2), fender support (3) and mounting bracket (4).
3.
Remove remaining screws (1) from left side of fender and
carefully remove fender.
1
3
4
2
sm02284
1.
Screw (4)
2.
Cover, right
3.
Fender support
4.
Mounting bracket (inside fender)
Figure 2-109. Rear Fender (FXDF)
Installation
1.
Before installing fender, install tail lamp/turn signal harness
and conduit to underside of fender.
2.
. Apply LOCTITE THREADLOCKER 243
(blue) to the threads of screws (1). Place fender and
covers (2) into position. Tighten screws (1) to 12-18 ft-lbs
(16.3-24.4 Nm).
3.
Install rear turn signals. See
.
4.
Finish with installation instructions under
.
FXD, FXDC, AND FXDL MODELS
Removal
1.
Remove rear turn signal lamps. See
AND RUNNING LIGHTS, Rear Lamp Housing Replace-
ment
2.
See
. Remove screws (1) that hold fender in
place and carefully remove fender and covers (3).
Installation
1.
Before installing fender, install tail lamp/turn signal harness
and conduit to underside of fender. See Tail Lamp/Turn
Signal Harness Routing instructions under
for procedure.
2.
. Apply LOCTITE THREADLOCKER 243
(blue) to the threads of screws (1). Place fender and
covers (3) into position. Tighten screws (1) to 12-18 ft-lbs
(16.3-24.4 Nm).
3.
Install rear turn signals. See
RUNNING LIGHTS, Rear Lamp Housing Replacement
.
4.
Finish with installation instructions under
1
2
4
3
1
5
sm02285
1.
Screw (4)
2.
Fender
3.
Covers (2)
4.
Fender support
5.
Mounting bracket (inside fender)
Figure 2-110. Rear Fender (FXD, FXDC, and FXDL)
FXDB MODELS
Removal
1.
Remove rear turn signal lamps. See
AND RUNNING LIGHTS, Bulb Replacement: Bullet Style
2.
See
. Remove screws (1) that hold fender in
place and carefully remove fender from supports (2).
2-82 2009 Dyna Service: Chassis
Installation
1.
Before installing fender, install tail lamp/turn signal harness
and conduit to underside of fender. See Tail Lamp/Turn
Signal Harness Routing instructions under
for procedure.
2.
. Apply LOCTITE THREADLOCKER 243
(blue) to the threads of screws (1). Place fender and
covers (3) into position. Tighten screws (1) to 12-18 ft-lbs
(16.3-24.4 Nm).
3.
Install rear turn signals. See
RUNNING LIGHTS, Bulb Replacement: Bullet Style
.
4.
Finish with installation instructions under
.
1
2
3
sm05842
1.
Screw (2)
2.
Fender support
3.
Mounting bracket (inside fender)
Figure 2-111. Rear Fender (FXDB)
2009 Dyna Service: Chassis 2-83
2.30
SEAT
REMOVAL
NOTE
. There is a nylon retaining clip between the
rear seat bracket and the fender. DO NOT lose this clip, sub-
stitute a clip of different material or install the seat without this
clip. Any of the above actions will result in scratched fender
paint. The nylon retaining clip secures the seat screw nut.
1.
. Remove screw (1) from rear seat
bracket (2). (Nylon clip remains with fender assembly.)
NOTE
•
There is a bracket at the front of the seat that slips under
a u-shaped frame bracket.
•
There is no need to remove the seat bracket and its
fasteners from the seat pan.
•
The strap is secured to the fender under the seat by a nut
(4) and washer (5).
2.
Slide seat to the rear of the motorcycle and lift seat.
3.
Remove nut (4) and washer (5).
4.
Remove seat strap.
2
6
1
7
5
3
8
4
11
10
9
sm02287
7.
1.
Screw
Screw
2.
8.
Bracket
Seat, FXDC, FXDF
9.
3.
Seat, FXDL
Seat strap
4.
10.
Nut
Solo seat, FXD
11.
5.
Solo seat, FXDB
Washer
6.
Plastic nut (retains strap screw)
Figure 2-112. Seat
INSTALLATION
1.
. Install seat strap.
a.
Fasten nut (4) and washer (5) above seat strap on
frame.
b.
Tighten nut (4) to 60-90 in-lbs (6.78-10.17 Nm).
2.
Slide back of seat through seat strap loop.
3.
Slide bracket below front seat under the u-shaped frame
bracket.
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
4.
Install screw (1) and bracket (2) to fender. Verify nylon
retaining clip is in position on fender.
2-84 2009 Dyna Service: Chassis
2.31
JIFFY STAND
CLEANING
The jiffy stand locks when placed in the full forward (down)
position with vehicle weight on it. If the jiffy stand is not
in the full forward (down) position with vehicle weight on
it, the vehicle can fall over which could result in death or
serious injury. (00006a)
Always park motorcycle on a level, firm surface. An
unbalanced motorcycle can fall over, which could result
in death or serious injury. (00039a)
Be sure jiffy stand is fully retracted before riding. If jiffy
stand is not fully retracted, it can contact the road surface
causing a loss of vehicle control, which could result in
death or serious injury. (00007a)
1.
Block motorcycle underneath frame so both wheels are
raised off the ground.
2.
See
. Inspect top of catch (6 or 8). If covered
with dirt, wipe dirt off with a shop towel and spray catch
and mating surface with LOCTITE AEROSOL ANTI-SEIZE.
3.
Move jiffy stand leg (13) forward and back to infuse anti-
seize into mating parts.
4.
If catch is covered with mud/grime, remove bolt (7) and
catch (6 or 8).
5.
Clean catch (6 or 8) and pivot block mating surface (10).
6.
Spray LOCTITE AEROSOL ANTI-SEIZE on shaft of jiffy
stand leg and pin (16) to lubricate the mating surface
between pin and pivot block (10). Move leg back and forth
and downward while spraying lubricant.
7.
Assemble the catch so it engages the flats on the shaft of
the jiffy stand leg and secure with bolt (7).
8.
Tighten bolt (7) to 19 ft-lbs (25.8 Nm).
9.
Check that jiffy stand operates correctly before using.
SENSOR (HDI MODELS)
1.
. Make a note of harness routing for ease
of assembly. Disconnect sensor connector located under
the seat.
2.
Remove cable anchors (2).
3.
Remove screw (4) and remove sensor (3).
4.
If necessary, remove screw (1) and remove sensor bracket
(5).
5.
Installation is in reverse of removal. Tighten screws (1, 4)
to 96-144 in-lbs (10.8-16.3 Nm).
NOTE
. Ensure the sensor harness is routed to the
inside of the left-lower frame and under the rear engine mount
casting.
. Route the sensor harness in the same
retainer cavity (3) as the vent tube (2).
sm03864
Figure 2-113. Jiffy Stand Sensor Harness Routing
2009 Dyna Service: Chassis 2-85
1
3
2
sm03931
1.
Wire harness retainer
2.
Vent line
3.
Retainer cavity
Figure 2-114. Harness Retainer
REMOVAL
Block vehicle under frame such that vehicle will not fall
when jiffy stand is removed. Failure to properly block
vehicle could result in death or serious injury. (00462b)
1.
Block motorcycle underneath frame so both wheels are
raised off the ground.
2.
. Remove cotter pin (12) and washer
(11) from pin (16). Discard cotter pin.
3.
Detach spring (14) from jiffy stand and anchor plate (17).
4.
Pull pin (16) from between frame tubes. Jiffy stand and
pivot block components will drop as an assembly.
18
2
1
3
4
5
6
7
8
9
10
17
16
15
13
14
12
11
sm03871
1.
Sensor bracket screw (HDI)
2.
Harness retainer (2) (HDI)
3.
Sensor (HDI)
4.
Sensor screw (HDI)
5.
Sensor bracket (HDI)
6.
Catch (replaces item 8 on HDI)
7.
Bolt
8.
Catch
9.
Threaded spacer
10. Pivot block
11. Washer
12. Pretzel pin
13. Jiffy stand leg
14. Spring
15. Screw
16. Pin (secures pivot block)
17. Anchor plate
18. Bumper
Figure 2-115. Jiffy Stand
2-86 2009 Dyna Service: Chassis
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