Harley Davidson 2009 Dyna Models. Service manual — page 2
3.19 BOTTOM END OVERHAUL: ASSEMBLY
3.22 PUSH RODS, LIFTERS AND COVERS
Valve Guide Replacement. . . . . . . . . . . . 3-68
Removal. . . . . . . . . . . . . . . . . 3-68
Installation. . . . . . . . . . . . . . . . .3-69
Piston Rings. . . . . . . . . . . . . . . ..3-80
Installation Overview. . . . . . . . . . . . . . 3-84
3.26 CAM SUPPORT PLATE AND COVER
Removal Overview. . . . . . . . . . . . . . . 3-85
Camshafts. . . . . . . . . . . . . . . . . . 3-85
Removal. . . . . . . . . . . . . . . . . 3-85
Assembly. . . . . . . . . . . . . . . . ...3-85
Oil Pressure Relief Valve. . . . . . . . . . . . ..3-87
Cam Needle Bearings. . . . . . . . . . . . . ..3-87
Removal. . . . . . . . . . . . . . . . . 3-87
Installation. . . . . . . . . . . . . . . . .3-89
Cleaning and Inspection. . . . . . . . . . . . ...3-90
Oil Pressure Valve. . . . . . . . . . . . . .3-90
Cam Support Plate. . . . . . . . . . . . . 3-90
Installation Overview. . . . . . . . . . . . . . 3-90
Left Crankcase Half. . . . . . . . . . . . . . ..3-93
Sprocket Shaft Bearing Inner Race. . . . . . . . ..3-96
Removal. . . . . . . . . . . . . . . . . 3-96
Installation. . . . . . . . . . . . . . . . .3-97
Cylinder Studs. . . . . . . . . . . . . . . . ..3-98
Removal. . . . . . . . . . . . . . . . . 3-98
Installation. . . . . . . . . . . . . . . . .3-98
Pipe Plug and Oil Fittings. . . . . . . . . . . . .3-99
Removal. . . . . . . . . . . . . . . . . 3-99
Installation. . . . . . . . . . . . . . . . .3-99
3.29 FLYWHEEL AND CONNECTING RODS
TABLE OF CONTENTS VII
TABLE OF CONTENTS
Fastener Torque Values in this Chapter. . . . . . . ..4-1
4.2 SPECIFICATIONS: FUEL SYSTEM
Specifications. . . . . . . . . . . . . . . . . .4-3
4.3 ELECTRONIC FUEL INJECTION (EFI)
Troubleshooting. . . . . . . . . . . . . . . . ..4-4
General. . . . . . . . . . . . . . . . . . . ...4-5
Vapor Valve. . . . . . . . . . . . . . . ...4-11
4.7 THROTTLE POSITION SENSOR (TPS)
4.8 INTAKE AIR TEMPERATURE SENSOR
(IAT)
4.9 ENGINE TEMPERATURE SENSOR (ET)
4.12 MANIFOLD ABSOLUTE PRESSURE
SENSOR (MAP)
Installation. . . . . . . . . . . . . . . . . . 4-27
Procedure. . . . . . . . . . . . . . . . . . .4-39
4.19 EVAPORATIVE EMISSIONS CONTROL
(CA MODELS)
Removal. . . . . . . . . . . . . . . . . 4-41
Installation. . . . . . . . . . . . . . . . .4-42
Fastener Torque Values in this Chapter. . . . . . . ..5-1
Specifications. . . . . . . . . . . . . . . . . .5-2
VIII TABLE OF CONTENTS
TABLE OF CONTENTS
Removal. . . . . . . . . . . . . . . . . ..5-9
Installation. . . . . . . . . . . . . . . . ...5-9
Mainshaft Bearing Inner Race. . . . . . . . . . ..5-10
Removal. . . . . . . . . . . . . . . . . 5-10
Installation. . . . . . . . . . . . . . . . .5-11
Clutch Pack and Bearing. . . . . . . . . . . . ..5-16
Complete Disassembly. . . . . . . . . . . ..5-16
Assembly. . . . . . . . . . . . . . . . ...5-17
Fastener Torque Values in this Chapter. . . . . . . ..6-1
6.2 SPECIFICATIONS: TRANSMISSION
Power Flow. . . . . . . . . . . . . . . . . . .6-3
Adjustment. . . . . . . . . . . . . . . . . . .6-5
Assembly and Installation. . . . . . . . . . . . ...6-7
Installation. . . . . . . . . . . . . . . . . . 6-19
6.7 MAIN DRIVE GEAR AND BEARING
Needle Bearing Replacement. . . . . . . . ...6-22
Installation. . . . . . . . . . . . . . . . . . 6-23
Shifter Arm Assembly. . . . . . . . . . . . 6-29
Fastener Torque Values in this Chapter. . . . . . . ..7-1
7.2 SPECIFICATIONS: ELECTRICAL
Specifications. . . . . . . . . . . . . . . . . .7-3
7.4 ELECTRONIC CONTROL MODULE (ECM)
TABLE OF CONTENTS IX
TABLE OF CONTENTS
Relays. . . . . . . . . . . . . . . . . . .7-9
Fuses. . . . . . . . . . . . . . . . . . ..7-9
Removal. . . . . . . . . . . . . . . . . 7-10
Installation. . . . . . . . . . . . . . . . .7-11
FXDC, FXDF Models (Ignition Switch Only). . . . . .7-13
7.9 BATTERY TRAY AND BATTERY CABLES
Battery Tray. . . . . . . . . . . . . . . . . ...7-14
Removal. . . . . . . . . . . . . . . . . 7-14
Installation. . . . . . . . . . . . . . . . .7-14
Battery Cables. . . . . . . . . . . . . . . . ..7-15
Routing. . . . . . . . . . . . . . . . . ..7-15
General. . . . . . . . . . . . . . . . . . . .7-16
Wiring Diagrams. . . . . . . . . . . . . . 7-16
Paint Touch-Up. . . . . . . . . . . . . . ..7-16
Drive Assembly. . . . . . . . . . . . . . . . .7-18
Installation. . . . . . . . . . . . . . . . . . 7-19
Solenoid Assembly. . . . . . . . . . . . . . ...7-20
Disassembly. . . . . . . . . . . . . . . ..7-20
Assembly. . . . . . . . . . . . . . . . ...7-20
Solenoid Plunger. . . . . . . . . . . . . . . ..7-20
Disassembly. . . . . . . . . . . . . . . ..7-20
Assembly. . . . . . . . . . . . . . . . ...7-20
Solenoid Contacts. . . . . . . . . . . . . . . 7-20
Disassembly. . . . . . . . . . . . . . . ..7-20
Assembly. . . . . . . . . . . . . . . . ...7-21
Single Bulb Headlamp. . . . . . . . . . . ...7-23
Dual Bulb Headlamp. . . . . . . . . . . . .7-24
7.14 TURN SIGNALS AND RUNNING LIGHTS
7.15 STOP-TAIL-TURN (STT) MODULE:
FXDB (DOMESTIC ONLY)
7.16 TURN SIGNAL AND SECURITY
MODULE (TSM/TSSM/HFSM)
7.17 CRANK POSITION SENSOR (CKP)
Removal. . . . . . . . . . . . . . . . . 7-39
Installation. . . . . . . . . . . . . . . . .7-39
FXD Models. . . . . . . . . . . . . . . . . ..7-39
Removal. . . . . . . . . . . . . . . . . . ...7-46
Speedometer. . . . . . . . . . . . . . . .7-46
Installation. . . . . . . . . . . . . . . . . . 7-46
Speedometer. . . . . . . . . . . . . . . .7-46
Removal. . . . . . . . . . . . . . . . . . ...7-47
Installation. . . . . . . . . . . . . . . . . . 7-47
X TABLE OF CONTENTS
TABLE OF CONTENTS
![](/vehicle/thin/gug/bltost/antahea.png)
6.
Refer to
. Install the push rods in their original
positions. Be sure to remove any tags that may have been
used for identification.
a.
. For example, if reassembling the
rear cylinder, slide the intake push rod (silver) through
the front hole in the rocker housing engaging the lifter
socket in the inside hole of the lifter cover.
b.
Slide the exhaust push rod (black) through the rear
hole in the rocker housing engaging the lifter socket
in the outside hole of the lifter cover.
Table 3-30. Push Rod/Lifter Locations
CYLINDER
HEAD/ROCKER
HOUSING
BORE
LIFTER BORE
COVER
COVER &
PUSH ROD
CYL-
INDER
Rear
Inside
Intake
Front
Front
Outside
Exhaust
Front
Inside
Intake
Rear
Rear
Outside
Exhaust
4
2
1
3
sm02346
1.
Cover
2.
Gasket
3.
Ribs on cover
4.
Anti-rotational pin
Figure 3-40. Installing Lifters
2
4
1
3
sm02181
1.
Front cylinder exhaust push rod
2.
Front cylinder intake push rod
3.
Rear cylinder intake push rod
4.
Rear cylinder exhaust push rod
Figure 3-41. Push Rod Locations
ROCKER ARM SUPPORT PLATE
Installing the rocker arms and rotating the engine with the valve
train loaded can result in bent push rods, damaged bushings
or a warped support plate.
1.
To install the rocker arm support plate, both lifters of the
cylinder being serviced must be on the base circle (or
lowest position) of the cam. To rotate engine, see
3.17 TOP END OVERHAUL: ASSEMBLY, Rocker Arm
Support Plate
.
2.
See
. Place the rocker arm support plate
assembly into the rocker housing. Loosely install the four
rocker arm support plate bolts with flat washers.
NOTE
If the engine was left in the chassis for service, final tighten
the rocker arm support plate bolt on the rear left side of the
rear cylinder using a 3/8 in. drive torque wrench with a 1/2 in.
flank drive "dog bone" torque adapter (Snap-on FRDH161).
Failure to properly use this combination will overtighten the
bolts causing distortion of the rocker housing.
3.
Tighten rocker arm support plate bolts.
a.
Following the sequence shown, alternately tighten
each of the four rocker arm support plate bolts just
1/4 turn. Continue turning the bolts in these incre-
ments until snug.
b.
Following the same sequence, tighten the bolts to 18-
22 ft-lbs (24.4-29.8 Nm).
4.
Lift up lower push rod covers and verify that both push
rods spin freely.
NOTE
Always service each cylinder separately. After the first cylinder
is serviced the engine must be rotated to find the base circle
on the second cam. Service on the remaining cylinder can then
proceed.
2009 Dyna Service: Engine 3-43
![](/vehicle/thin/gug/bltost/qusean.png)
3
2
1
4
2
3
4
1
sm02386
Figure 3-42. Rocker Arm Torque Sequence
5.
Complete installation of the push rod covers.
a.
Verify that the o-ring ends of the upper and lower
push rod covers fit snugly into the cylinder head and
lifter cover bores.
b.
Insert the upper edge of spring cap retainer into the
cylinder head bore leaving the bottom edge free.
c.
Insert blade of small screwdriver between bottom
edge of spring cap retainer and top of spring cap.
NOTE
For best results, be sure that screwdriver, spring cap and
spring cap retainer are free of grease and oil.
d.
See
. While simultaneously depressing
spring cap with tip of screwdriver, use forefinger to
slide bottom edge of spring cap retainer down shaft
towards tip of screwdriver blade. As spring cap
reaches its full length of travel, spring cap retainer
should be in approximate position against upper push
rod cover.
e.
Verify that spring cap retainer is seated tightly against
upper push rod cover.
sm02347
Figure 3-43. Install Spring Cap Retainers
BREATHER ASSEMBLY
NOTE
For breather assembly service procedures, see
.
1.
. Alternately tighten the two bolts to secure
breather assembly to 90-120 in-lbs (10.2-13.6 Nm).
2.
See
. Install a new rocker cover gasket with
indent facing forward on the rocker housing flange. Place
the rocker cover into position aligning the holes in the
cover with those in the gasket.
NOTE
If the engine was left in the chassis for service, final tighten
the three rocker cover bolts on the left side of the rear cylinder
using a 3/8 in. drive torque wrench with a 7/16 in. flank drive
"dog bone" torque adapter (Snap-on FRDH141). Failure to
properly use this combination will overtighten the bolts causing
distortion of the rocker cover.
3-44 2009 Dyna Service: Engine
![](/vehicle/thin/gug/bltost/dosonu.png)
3.
. Install rocker cover bolts.
a.
Apply a small dab of LOCTITE THREADLOCKER
243 (blue) to threads of six rocker cover bolts.
b.
Loosely install bolts in the rocker cover.
c.
Following the sequence shown, tighten bolts to 15-18
ft-lbs (20.3-24.4 Nm).
4.
Complete motorcycle assembly.
a.
If engine was left in the chassis for service, see
3.13 ASSEMBLING MOTORCYCLE AFTER SER-
VICE
.
b.
If engine was removed for service, see
3.15 INSTALLING ENGINE IN CHASSIS
sm02398
Figure 3-44. Rocker Cover Gasket Indent (Front Cylinder
Shown)
6
2
4
3
1
5
4
2
6
5
1
3
sm02326
1.
Short bolt, 1.0 in. (25.4 mm)
2.
Long bolt, 1.75 in. (44.5 mm)
3.
Short bolt, 1.0 in. (25.4 mm)
4.
Long bolt, 1.75 in. (44.5 mm)
5.
Short bolt, 1.0 in. (25.4 mm)
6.
Long bolt, 1.75 in. (44.5 mm)
Figure 3-45. Rocker Cover Bolts Torque Sequence
2009 Dyna Service: Engine 3-45
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