Harley Davidson 2009 Dyna Models. Service manual — page 7

1.17

BRAKE PADS AND DISCS

INSPECTION

Check brake pads and discs:

•

At every scheduled service interval.

•

Whenever the components are removed during service
procedures.

Brake Pads

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

See

Figure 1-33

. Replace brake pads (3) if brake pad friction

material on either the front or rear caliper is worn to 0.04 in.
(1.02 mm) or less above the backing plate (4). Always replace
both pads in a caliper as a set. See

1.17 BRAKE PADS AND

DISCS, Brake Pad Replacement

When checking the brake pads and discs, inspect the brake
hoses for correct routing and any signs of damage.

Brake Disc

•

The minimum brake disc (2) thickness is stamped on the
side of the disc.

•

Maximum brake disc lateral runout and warpage is 0.008
in. (0.2 mm) when measured near the outside diameter.

Replace disc if badly scored or warped. See

2.4 FRONT

WHEEL

2.5 REAR WHEEL

sm02217

Front brake caliper (viewed from below)

Brake disc

Brake pads

Backing plate

Rear brake caliper (viewed from above)

Figure 1-33. Brake Pad Inspection

BRAKE PAD REPLACEMENT

Rear Brake Caliper

If present, remove right saddlebag.

Remove the rear master cylinder reservoir cap. As the
pistons are pushed back into the caliper, fluid level may
rise above the recommended 1/4 ± 1/8 in. (6.35 ± 3.18
mm) below the gasket surface. You may have to remove
fluid to allow for this.

See

Figure 1-34

. Loosen, but do not remove, pad pin (1)

(metric).

Pry the outside pad back until the pistons are completely
retracted. Use steady pressure to prevent scoring the
brake disc. Pry between the pad and the brake disc in
order to push the caliper pistons back into their bores.

HOME

2009 Dyna Service: Maintenance 1-33

Once the pistons have been fully retracted into their bores,
pull pad pin part way until the inside pad drops free. Note
the pad's original orientation for replacement purposes.

Continue to remove the pin until the outer pad drops free.

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

Inspect pad pin for grooving and wear. Measure the pad
pin diameter in an unworn area, and then in the area of
any grooving or wear. If wear is more than 0.015 in. (0.38
mm), replace pin.

Install new outer brake pad using the same orientation as
the pad previously removed. Curved portion of pad must
face up and tab must engage slot (2) in caliper housing.

Partially install pad pin until it retains the outer pad.

10. Install the inner pad and ensure tab engages slot in caliper

housing. Finish installing pad pin and tighten to 80-120
in-lbs (9.0-13.6 Nm).

After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)

11. Pump brake pedal to move pistons out until they contact

both brake pads. Verify piston location against pads.

12. Check brake fluid level in master cylinder. Fill to proper

level if necessary using D.O.T. 4 BRAKE FLUID. Install
master cylinder reservoir cap. Tighten reservoir cap screws
to 6-8 in-lbs (0.7-0.9 Nm).

13. Install right saddlebag if necessary.

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

14. Test brake system.

Turn ignition switch ON. Pump brake pedal to verify
operation of the brake lamp.

Test ride the motorcycle. If the brakes feel spongy,
bleed the system. See

1.16 BLEEDING BRAKES

NOTE

Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.

sm03757

Pad pin

Tab slot

Figure 1-34. Pad Retaining Pin (Rear Caliper Shown)

Front Brake Caliper

Remove the front master cylinder reservoir cap. As the
pistons are pushed back into the caliper, fluid level may
rise above the recommended 1/4 ± 1/8 in. (6.35 ± 3.18
mm) below the gasket surface. Fluid may need to be
removed to allow for this.

See

Figure 1-35

. Loosen, but do not remove bridge

bolt/pad pin (3) (metric).

Remove both caliper mounting bolts (1, 2) (metric). Detach
caliper from front forks and brake disc.

Pry the pads back to force all four caliper pistons into their
bores.

NOTE

The brake pads have tabs that are clipped onto the pad springs.
Disengage the tabs from the pad springs as you remove the
pads.

With the pistons retracted, remove the bridge bolt/pad pin
and remove brake pads.

Inspect bridge bolt/pad pin for grooving and wear. Measure
the pad pin diameter in an unworn area, and then in the
area of any grooving or wear. If wear is more than 0.015
in. (0.38 mm), replace the pin.

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

NOTES

•

See

Figure 1-36

. Ensure the pad spring tabs (1) on brake

pad engage the pad springs in the pistons.

•

If the directional tab (2) does not face down when caliper
is installed, brake noise may develop.

Install new pads into caliper. The directional tab (2) must
face down when caliper is installed.

Loosely install the center bridge bolt/pad pin.

HOME

1-34 2009 Dyna Service: Maintenance

Attach caliper to front fork.

See

Figure 1-35

. Place caliper over brake disc with

bleeder valve facing upward.

Loosely install long mounting bolt (1) (metric) into
upper hole on fork leg.

Install short mounting bolt (2) (metric) into lower hole
on fork leg. Tighten bottom mounting bolt to 28-38 ft-
lbs (38.0-51.5 Nm).

Final tighten the top mounting bolt to 28-38 ft-lbs
(38.0-51.5 Nm).

Final tighten center bridge bolt/pad pin (3) to 15-16
ft-lbs (20.3-22.6 Nm).

10. Pump brake hand lever to move pistons out until they

contact both brake pads. Verify piston location against
pads. If the front wheel is off the ground, rotate wheel to
check for excessive brake pad drag.

11. Check brake fluid level in master cylinder. Fill to proper

level if necessary using D.O.T. 4 BRAKE FLUID. Install
master cylinder reservoir cap. Tighten reservoir cap screws
to 6-8 in-lbs (0.7-0.9 Nm).

12. Test brake system.

Turn ignition switch ON. Pump brake hand lever to
verify operation of the brake lamp.

Test ride the motorcycle. If the brakes feel spongy,
bleed the system. See

1.16 BLEEDING BRAKES

NOTE

Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.

sm03758

Long mounting bolt (metric)

Short mounting bolt (metric)

Pad pin (metric)

Figure 1-35. Front Brake Caliper (Left Side Shown)

sm04031

Pad spring tabs

Directional tab

Figure 1-36. Front Brake Pad

HOME

2009 Dyna Service: Maintenance 1-35

1.18

BATTERY MAINTENANCE

GENERAL

Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHILDREN.
(00063a)

Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury. (00064a)

Batteries, battery posts, terminals and related accessories
contain lead and lead compounds, and other chemicals
known to the State of California to cause cancer, and birth
defects or other reproductive harm. Wash hands after
handling. (00019e)

All AGM batteries are permanently sealed, maintenance-free,
valve-regulated, lead/calcium and sulfuric acid batteries. The
batteries are shipped pre-charged and ready to be put into
service. Do not attempt to open these batteries for any reason.

NOTE

For charging information, see

1.18 BATTERY MAINTENANCE,

Charging Battery

. For testing information, see ELECTRICAL

DIAGNOSTIC MANUAL.

is00249

Figure 1-37. AGM Battery with Warning Label

sm02241

Keep flames away

Contents are corrosive

Wear safety glasses

Read instructions

Keep away from children

Contents are explosive

Figure 1-38. Battery Warning label

HOME

1-36 2009 Dyna Service: Maintenance

Table 1-12. Antidotes for Battery Acid

TREATMENT

CONTACT

Flush with water.

External

Drink large quantities of milk or water, followed
by milk of magnesia, vegetable oil or beaten
eggs. Get immediate medical attention.

Internal

Flush with water. Get immediate medical
attention.

Eyes

CLEANING AND INSPECTION

Battery top must be clean and dry. Dirt and electrolyte on
top of the battery can cause battery to self-discharge.
Clean battery top with a solution of baking soda (sodium
bicarbonate) and water (5 teaspoons baking soda per
quart or liter of water). When the solution stops bubbling,
rinse off the battery with clean water.

Clean cable connectors and battery terminals using a wire
brush or sandpaper. Remove any oxidation.

Inspect the battery screws, clamps and cables for
breakage, loose connections and corrosion. Clean clamps.

Check the battery posts for melting or damage caused by
overtightening.

Inspect the battery for discoloration, raised top or a warped
or distorted case, which might indicate that the battery has
been frozen, overheated or overcharged.

Inspect the battery case for cracks or leaks.

VOLTMETER TEST

Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury. (00064a)

Voltmeter Test

Refer to

Table 1-13

. The voltmeter test provides a general

indicator of battery condition. Check the voltage of the battery
to verify that it is in a 100% fully charged condition. If the open
circuit (disconnected) voltage reading is below 12.6V, charge
the battery and then recheck the voltage after the battery has
set for one to two hours. If the voltage reading is 12.7V or
above, perform a load test. See the ELECTRICAL DIA-
GNOSTIC MANUAL for the load test procedure.

Table 1-13. Voltmeter Test For Battery Charge Conditions

STATE OF CHARGE

VOLTAGE (OCV)

100%

12.7 V

75%

12.6 V

50%

12.3 V

25%

12.0 V

11.8 V

CHARGING BATTERY

Safety Precautions

Never charge a battery without first reviewing the instructions
for the charger being used. In addition to the manufacturer's
instructions, follow these general safety precautions:

•

Always wear eye, face and hand protection.

•

Always charge batteries in a well-ventilated area.

•

Turn the charger off before connecting the leads to the
battery to avoid dangerous sparks.

•

Never try to charge a visibly damaged or frozen battery.

•

Connect the charger leads to the battery; red positive (+)
lead to the positive (+) terminal and black negative (-) lead
to the negative (-) terminal. If the battery is still in the
vehicle, connect the negative lead to the chassis ground.
Be sure that the ignition and all electrical accessories are
turned off.

•

Make sure that the charger leads to the battery are not
separated, frayed or loose.

•

If the battery gets hotter than 110° F (43° C) during char-
ging, discontinue charger and allow the battery to cool.

•

Always turn the charger off before removing charger leads
from the battery to avoid dangerous sparks.

Using a Battery Charger

Charge the battery if any of the following conditions exist:

•

Vehicle lights appear dim.

•

Electric starter sounds weak.

•

Battery has not been used for an extended period of time.

Explosive hydrogen gas, which escapes during charging,
could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks
and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

If battery releases an excessive amount of gas during
charging, decrease the charging rate. Overheating can
result in plate distortion, internal shorting, drying out or
damage. (00413b)

HOME

2009 Dyna Service: Maintenance 1-37

Perform a voltmeter test to determine the state of charge.
See the ELECTRICAL DIAGNOSTIC MANUAL. If battery
needs to be charged, proceed to the next step.

NOTE

The figures listed in the table assume that the battery is char-
ging at room temperature. If warmer than room temperature,
use a slightly shorter charging time. If colder, use a slightly
longer charging time.

Table 1-14. Battery Charging Rates/Times (Approximate)

20 AMP CHARGER

10 AMP CHARGER

6 AMP CHARGER

3 AMP CHARGER

STATE OF CHARGE

BATTERY

AMP

HOUR

% OF

CHARGE

VOLTAGE

100%

12.7

15 minutes

30 minutes

50 minutes

1.75 hours

75%

12.6

30 minutes

1 hour

1.75 hours

3.5 hours

50%

12.3

45 minutes

1.5 hours

2.5 hours

5 hours

25%

12.0

1 hour

2 hours

3 hours, 20 minutes

6 hours, 40 minutes

11.8

NOTE

The use of constant current chargers to charge sealed main-
tenance-free batteries is not recommended. Any overcharge
will cause dry-out and premature battery failure. If a constant
current charger is the only type available, do not exceed the
charge times listed above and do not continue charging the
battery if it gets hot. When charging, never exceed 15 volts for
more than 30 minutes.

Unplug or turn OFF battery charger before connecting
charger cables to battery. Connecting cables with charger
ON can cause a spark and battery explosion, which could
result in death or serious injury. (00066a)

Do not reverse the charger connections described in the
following steps or the charging system of the motorcycle
could be damaged. (00214a)

Connect red battery charger lead to the positive (+) ter-
minal of the battery.

Connect black battery charger lead to the negative (-)
terminal of the battery.

NOTE

If the battery is still in the vehicle, connect the negative lead
to the chassis ground. Be sure that the ignition and all electrical
accessories are turned off.

Step away from the battery and turn on the charger. See
the charging instructions in

Table 1-14

Unplug or turn OFF battery charger before disconnecting
charger cables from battery. Disconnecting clamps with
charger ON can cause a spark and battery explosion, which
could result in death or serious injury. (00067a)

After the battery is fully charged, disconnect the black
battery charger lead to the negative (-) terminal of the
battery.

Disconnect the red battery charger lead to the positive (+)
terminal of the battery.

Mark the charging date on the battery.

Perform either a conductance test or load test to determine
the condition of the battery. See the ELECTRICAL DIA-
GNOSTIC MANUAL.

If charging battery because voltmeter test reading was
below 12.6 V, perform voltmeter test. See the ELEC-
TRICAL DIAGNOSTIC MANUAL.

DISCONNECTION AND REMOVAL

Remove seat.

Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)

See

Figure 1-39

. Remove lower fastener (1).

Pivot cover (2) outward and lift to disengage slots on cover
from projections on battery tray (3).

Unthread and remove battery negative cable from negative
battery terminal (4).

Unbolt and remove battery positive cable from positive (+)
battery terminal (5).

Remove battery strap (6).

Remove battery from tray.

HOME

1-38 2009 Dyna Service: Maintenance

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Battery tray

Negative battery terminal

Positive battery terminal

Battery strap

Figure 1-39. Battery Assembly

STORAGE

TOOL NAME

PART NUMBER

GLOBAL BATTERY CHARGER

99863-01A

Do not allow battery to completely discharge. The electro-
lyte in a discharged battery will freeze. The more dis-
charged a battery is, the more easily it can freeze and crack
the battery case. (00218a)

If the motorcycle is to be stored with the security system armed,
connect a GLOBAL BATTERY CHARGER (Part No. 99863-
01A) to maintain battery charge.

If the motorcycle is to be stored with the battery installed, a
GLOBAL BATTERY CHARGER unavailable, and with the
security system not armed, unplug the main fuse.

If the motorcycle will not be operated for several months, such
as during the winter season, remove the battery from the
motorcycle and fully charge.

See

Figure 1-40

. Self-discharge is a normal condition and

occurs continuously at a rate that depends on the ambient
temperature and the battery's state of charge. Batteries dis-
charge at a faster rate at higher ambient temperatures. To
reduce the self-discharge rate, store battery in a cool (not
freezing), dry place.

Charge the battery every month if stored at temperatures below
60° F (16° C). Charge the battery more frequently if stored in
a warm area above 60° F (16° C).

NOTES

•

The GLOBAL BATTERY CHARGER (Part No. 99863-01A)
may be used to maintain battery charge for extended
periods of time without risk of overcharging or boiling.

•

When returning a battery to service after storage, see
ELECTRICAL DIAGNOSTIC MANUAL.

50 %

75 %

100 %

105 °F (40.5 °C)

77 °F (25 °C)

sm02838

Capacity

Months of non-use

Figure 1-40. Battery Self-Discharge Rate

INSTALLATION AND CONNECTION

Do not over-tighten bolts on battery terminals. Use
recommended torque values. Over-tightening battery ter-
minal bolts could result in damage to battery terminals.
(00216a)

Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)

NOTE

Check that battery is fully charged before installation.

See

Figure 1-39

. With battery terminals facing outward,

place battery in battery tray and install battery strap.

Insert fastener through battery positive cable terminal and
into threaded hole of battery positive (+) terminal (5).
Tighten fastener to 60-70 in-lbs (6.8-7.9 Nm). Place bat-
tery terminal cover over positive battery terminal.

Insert fastener through battery negative cable terminal
into threaded hole of battery negative (-) terminal (4).
Tighten fastener to 60-70 in-lbs (6.8-7.9 Nm).

Apply a light coat of petroleum jelly or corrosion retardant
material to both battery terminals.

HOME

2009 Dyna Service: Maintenance 1-39

Place slots on battery cover (2) on projections on battery
tray (3). Install screw (1) to secure cover.

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)

Install seat.

HOME

1-40 2009 Dyna Service: Maintenance

1.19

SUSPENSION ADJUSTMENTS

REAR SHOCK PRELOAD ADJUSTMENT

TOOL NAME

PART NUMBER

SPANNER WRENCH

HD-94700-52C

Be sure both shock absorbers are adjusted to same pre-
load position. Improper adjustment can adversely affect
stability and handling, which could result in death or ser-
ious injury. (00036a)

The rear shock absorber springs can be adjusted to five posi-
tions to compensate for various loads.

•

For heavy loads, the springs should be compressed.

•

For lighter loads the springs should be extended.

See

Figure 1-41

. To adjust the rear shock absorber, turn spring

adjusting cam to desired position with a SPANNER
WRENCH (Part No. HD-94700-52C). Both spring adjusting
cams must be adjusted to the same position. When returning
to off-cam position, cams should be backed off in opposite
direction.

sm02453

Figure 1-41. Rear Shock Absorber Spring Adjustment

(Typical)

om01113

Figure 1-42. Spanner Wrench (HD-94700-52C)

HOME

2009 Dyna Service: Maintenance 1-41

1.20

SPARK PLUGS

INSPECTION

Disconnecting spark plug cable with engine running can
result in electric shock and death or serious injury.
(00464b)

After the engine has cooled to room temperature, discon-
nect cables from both spark plugs.

Remove spark plugs. If a plug has eroded electrodes,
heavy deposits or a cracked insulator, discard it.

See

Figure 1-43

. Compare your observations of the plug

deposits with the descriptions provided below.

A wet, black and shiny deposit on plug base, elec-
trodes and ceramic insulator tip indicates an oil fouled
plug. The condition may be caused by one or more
of the following: worn pistons, worn piston rings, worn
valves, worn valve guides, worn valve seals, a weak
battery or a faulty ignition system.

A dry, fluffy or sooty black deposit indicates an air-
fuel mixture that is too rich.

A light brown, glassy deposit indicates an overheated
plug. This condition may be accompanied by cracks
in the insulator or by erosion of the electrodes and is
caused by an air-fuel mixture that is too lean, a hot-
running engine, valves not seating or improper ignition
timing. The glassy deposit on the spark plug is a
conductor when hot and may cause high-speed mis-
firing. A plug with eroded electrodes, heavy deposits
or a cracked insulator must be replaced.

A plug with a white, yellow, tan or rusty brown
powdery deposit indicates balanced combustion.
Clean off spark plug deposits at regular intervals.

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

If the plugs require cleaning between tune-ups, proceed
as follows:

Degrease firing end of spark plug using ELECTRICAL
CONTACT CLEANER. Dry plug with compressed air.

Use a thin file to flatten spark plug electrodes. A spark
plug with sharp edges on its electrodes requires 25-
40% less firing voltage than one with rounded edges.

If the plugs cannot be cleaned, replace with new
spark plugs.

Check electrode gap with a wire-type feeler gauge. Bend
the outside of the electrode so only a slight drag on the
gauge is felt when passing it between electrodes. Proper
gap measurement is 0.038-0.043 in. (0.97-1.09 mm).

Check condition of threads on cylinder head and plug. If
necessary to remove deposits, apply penetrating oil and
clean out with a thread chaser.

Apply LOCTITE ANTI-SEIZE to the spark plug threads.
Install and tighten to 12-18 ft-lbs (16.3-24.4 Nm).

Connect spark plug cables. Rear cylinder plug cable
attaches to top coil terminal. Verify that cables are securely
connected to coil and spark plugs.

sm01640

Figure 1-43. Typical Spark Plug Deposits

SPARK PLUG CABLE INSPECTION

Inspect spark plug cables. Replace cables that are worn
or damaged.

Check for cracks or loose terminals.

Check for loose fit on ignition coil and spark plugs.

Check cable boots/caps for cracks or tears. Replace
boots/caps that are worn or damaged.

See

Figure 1-44

. Check spark plug cable resistance with

an ohmmeter. Compare values from test with

Table 1-15

Replace cables not meeting resistance specifications.

Table 1-15. Spark Plug Cable Resistance Values: Dyna

RESISTANCE

VALUE

(OHMS)

LENGTH

DESCRIPTION

In.

4750-12,675

483

19.00

Front cable

1813-4833

184

7.25

Rear cable

HOME

1-42 2009 Dyna Service: Maintenance

sm02659

Ohmmeter positive lead

Ohmmeter negative lead

Spark plug cable

Ohmmeter

Figure 1-44. Testing Resistance

HOME

2009 Dyna Service: Maintenance 1-43

1.21

STEERING HEAD BEARINGS

ADJUSTMENT

TOOL NAME

PART NUMBER

HUBCAP REMOVER AND INSTALLER

HD-41494

Bearing Adjustment (Fall Away)

Support motorcycle in an upright position so the front end
is completely suspended and the vehicle is level.

Remove all accessory weight, such as a windshield, that
may influence the way the front end swings. If clutch cable
is routed so it pulls the front end one way or the other,
disconnect it.

Place a suitable marking material, such as masking tape,
over the fender tip.

Install a pointer so the base is stationary on the floor and
the pointer indicates the center of the fender. The front
end should be straight ahead, however the balance point
may be slightly off center.

Check steering head bearing tension.

Tap the fender on one side until the front end begins
to "fall-away" by itself. Label this point on the marking
material.

Repeat the previous step in the other direction.

Measure distance between marks.

The distance between the "fall-away" marks must be 3.0-
4.0 in (76.2-101.6 mm).

NOTES

•

If distance measured is 3.0-4.0 in. (76.2-101.6 mm) no
bearing adjustment is needed.

•

If distance measured is outside the range given, bearing
adjustment is needed.

See

Figure 1-45

. With HUBCAP REMOVER AND

INSTALLER (Part No. HD-41494) unscrew and remove
stem cap (3).

Loosen fork stem nut (5).

Loosen lower triple clamp pinch bolts.

sm02477

Star nut

Upper triple clamp

Stem cap

Hardened flat washer

Stem nut

Pinch bolt (2)

Figure 1-45. Steering Head Components

10. Tighten or loosen the star nut (1) until the measurement

is within limits.

If the distance is more than 4.0 in. (101.6 mm), turn
the adjuster nut counter clockwise to loosen.

If the distance is less than 3.0 in. (76.2 mm), turn the
adjuster nut clockwise to tighten.

11. Remove the stem nut and lightly lubricate the threads with

anti-seize lubricant.

12. Install stem nut and tighten to 70-80 ft-lbs (95-108.5 Nm).

13. Check fall-away. If it is 3.0-4.0 in. (76.2-101.6 mm), tighten

lower triple clamp pinch bolts to 30-35 ft-lbs (40.7-47.5
Nm).

14. Repeat the "fall-away" procedure to be sure the adjustment

is correct.

15. Install and adjust clutch cable.

16. Test ride motorcycle.

LUBRICATION

Use SPECIAL PURPOSE GREASE (Part No. 99857-97) every
30,000 mile (48,280 km) service interval. For steering head
bearing lubrication, see

2.19 STEERING HEAD

HOME

1-44 2009 Dyna Service: Maintenance

1.22

FRONT FORK OIL

REPLACING FORK OIL

Fork assemblies must be removed to drain fork oil. See

2.18 FRONT FORK

HOME

2009 Dyna Service: Maintenance 1-45

1.23

CABLE AND CHASSIS LUBRICATION

GENERAL

Inspect and lubricate the following at scheduled service inter-
vals as specified in

1.3 MAINTENANCE SCHEDULE

•

Front brake hand lever

•

Clutch hand lever

•

Throttle control cables

•

Throttle control grip sleeve

•

Clutch cable

•

Foot shift lever pivot (if applicable)

•

Rear brake lever pivot

•

Steering head bearings

•

Jiffy stand

If service is on muddy or dusty roads, clean and lubricate at
shorter intervals.

CABLES AND HAND LEVERS

For throttle cables, see

1.15 THROTTLE CABLES

Use SUPER OIL (Part No. HD-94968-85TV) for hand levers
and cables.

JIFFY STAND

Clean and lubricate the jiffy stand. For more information, see

2.31 JIFFY STAND

HOME

1-46 2009 Dyna Service: Maintenance

1.24

HEADLAMP ALIGNMENT

The automatic-on headlamp feature provides increased
visibility of the rider to other motorists. Be sure headlamp
is on at all times. Poor visibility of rider to other motorists
can result in death or serious injury. (00030b)

NOTE

Vehicles with multiple beam headlamps that are individually
aimed should be adjusted so both lamps converge into one
pattern.

Verify that front and rear tire inflation pressures are correct
and that suspension is adjusted to the weight of the prin-
cipal rider. See

1.9 TIRES AND WHEELS

Fill fuel tank or add ballast to equal the weight of the fuel
needed.

NOTE

See

Figure 1-46

. To aid in properly placing the motorcycle, a

perpendicular line (1) can be drawn on the floor. For best res-
ults, choose an area with minimum light.

See

Figure 1-46

. Draw a vertical line (2) on the wall.

Position motorcycle so that front axle is 25 feet (7.6
meters) from wall.

NOTE

As the weight of the rider will compress the suspension slightly,
have a person whose weight is approximately the same as that
of the principal rider sit on the motorcycle.

With the vehicle laden and upright, point the front wheel
straight forward at wall and measure the distance (4) from
the floor to the center of the HIGH BEAM bulb.

Draw a horizontal line (5) through the vertical line on the
wall that is 2.1 in. (53.3 mm) lower than the measured bulb
centerline.

om00692

Perpendicular line

Vertical line

25 feet (7.6 meters)

High beam bulb centerline

Horizontal line 2.1 in. (53.3 mm) lower than bulb
centerline

Figure 1-46. Checking Headlamp Alignment

NOTE

As the weight of the rider will compress the suspension slightly,
have a person whose weight is approximately the same as that
of the principal rider sit on the motorcycle.

See

Figure 1-46

. Verify headlamp alignment. Turn the

ignition switch to IGNITION and set the headlamp switch
to HIGH beam.

The center of the hot spot (brightest area of light
beam) should be centered where the two lines inter-
sect.

Adjust headlamp alignment if necessary.

ADJUSTMENT

All Models

See

Figure 1-47

Figure 1-48

. Loosen horizontal