Harley Davidson 2009 Dyna Models. Service manual — page 4

5.

Replace filler cap and screw in securely.

6.

Add oil, if required, to FULL mark (3). Do not overfill.

CHANGING OIL AND FILTER

TOOL NAME

PART NUMBER

OIL FILTER WRENCH

HD-42311

OIL FILTER WRENCH

HD-44067

NOTES

•

If the motorcycle is ridden hard, under dusty conditions,
or in cold weather, the oil and filter should be changed
more often.

•

All Dyna models are shipped from the factory with SAE
20W50 Harley-Davidson 360 Motor Oil.

•

All Dyna models come equipped from the factory with a
premium 5 micron synthetic media oil filter, Part No.
63798-99A (Chrome) or 63731-99A (Black). These are
the only recommended replacement filters.

1.

Ride motorcycle until engine is warmed up to normal
operating temperature.

2.

Unscrew and remove engine oil filler cap with attached
dipstick.

3.

See

Figure 1-3

. Remove the engine oil drain plug with o-

ring. Allow oil to drain into a suitable container.

Use Harley-Davidson oil filter wrench for filter removal.
This tool can prevent damage to crankshaft position
sensor and/or sensor cable. (00192b)

4.

See

Figure 1-4

. Remove the oil filter using the OIL FILTER

WRENCH (Part No. HD-42311) or OIL FILTER
WRENCH (Part No. HD-44067) . Clean the oil filter mount
flange of any old gasket material.

NOTE

On vehicles equipped with forward controls, shift linkage may
have to be removed to provide enough clearance to remove
and install oil filter.

5.

See

Figure 1-5

. Lube the gasket on new oil filter with

engine oil and install new filter. Hand tighten oil filter 1/2
to 3/4 turn after gasket contacts filter mounting surface.
Do NOT use oil filter wrench for oil filter installation.

6.

See

Figure 1-3

. Install oil pan drain plug (1).

a.

Inspect o-ring for tears or damage. Replace if
required. Wipe any foreign material from plug.

b.

Install o-ring and drain plug. Tighten to 14-21 ft-lbs
(19.0-28.5 Nm).

7.

Fill oil pan with the correct amount of oil. Use the proper
grade of oil for the lowest temperature expected before
next oil change. Refer to

Table 1-5

.

a.

Use 2.5 quarts (2.4 liters) of engine oil for a wet
capacity refill.

b.

Use 3.0 quarts (2.7 liters) for a dry capacity refill.

NOTE

Use wet capacity for engines that have just had the oil
drained. Use dry capacity for engines that have been dis-
assembled, cleaned in solvent and dried.

8.

Check engine oil level using cold check procedure.

9.

Start engine and carefully check for oil leaks around drain
plug and oil filter.

10. Check engine oil level using hot check procedure.

om00727

Figure 1-3. Engine Oil Drain Plug (oil pan under

transmission, view from left side of vehicle)

om00154

Figure 1-4. Oil Filter Wrench (Part No. HD-42311)

HOME

2009 Dyna Service: Maintenance 1-13

sm01414

Figure 1-5. Lubricating New Oil Filter Gasket

HOME

1-14 2009 Dyna Service: Maintenance

1.6

BULB REQUIREMENTS

GENERAL

Use the table to identify the bulb location and part number.
Refer to

Table 1-6

.

NOTE

The speedometer, tachometer, odometer and indicator lamps
are illuminated with LEDs. LEDs are non-repairable. The entire
assembly must be replaced if an LED fails.

Table 1-6. Bulb Chart: 2009 Dyna Models

H-D

PART

NUMBER

CURRENT

DRAW

(AMPERAGE)

BULBS

REQUIRED

DESCRIPTION

LAMP

69838-08

5.0/4.58

2

High beam/low beam (FXDF, domestic)

Headlamp

68881-01

5.0/4.58

2

High beam/low beam (FXDF, international)

68329-03

5.0/4.58

1

High beam/low beam (all other models)

53436-97

0.32

1

Position lamp (FXDF, international)

53438-92

0.32

1

Position lamp (other models, international)

Illuminated with LEDs. Replace entire assembly
upon failure.

Tail/stop lamp (FXDB)

Tail and stop lamp

68026-99

0.59/2.10

1

Tail/stop lamp (other models, domestic)

68167-04

0.59/2.10

1

Tail/stop lamp (other models, international)

68168-89A

2.25/0.59

2

Front/running

Turn signal lamp

68163-84

1.75

2

Front international

68168-89A

2.25

2

Rear (FXDB, domestic)

68572-64B

2.25

2

Rear (other models, domestic)

68163-84

1.75

2

Rear international

Illuminated with LEDs. Replace entire assembly
upon failure.

High beam indicator

Instrument panel indic-
ators

Oil pressure indicator

Neutral indicator

Turn signal indicators

All models use an LED built into the gauge.

Fuel Gauge

HOME

2009 Dyna Service: Maintenance 1-15

1.7

BRAKES

FLUID INSPECTION

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)

1.

See

Figure 1-6

. Check level in rear brake master cylinder

reservoir. Level should be 1/4 ± 1/8 in. (6.35 ± 3.18 mm)
below the gasket surface.

Do not allow dirt or debris to enter the master cylinder
reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)

2.

See

Figure 1-7

. Check level in front brake master cylinder

reservoir. Level should be 1/4 ± 1/8 in. (6.35 ± 3.18 mm)
below the gasket surface.

3.

Install gaskets and covers. Tighten reservoir cover screws
to 6-8 in-lbs (0.7-0.9 Nm).

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)

4.

Front brake hand lever and rear brake foot pedal must
have a firm feel when applied. If not, bleed system using
only D.O.T. 4 BRAKE FLUID. See

1.16 BLEEDING

BRAKES

.

1

sm02490

1.

Fluid level should be 1/8-1/4 in. (3.2-6.4 mm)
below gasket surface

Figure 1-6. Rear Brake Master Cylinder Reservoir

1

sm02491

1.

Fluid level should be 1/8-1/4 in. (3.2-6.4 mm)
below gasket surface

Figure 1-7. Front Brake Master Cylinder Reservoir

REAR PEDAL HEIGHT

The rear brake pedal should not require adjustment. If minor
pedal height adjustment is desired:

1.

See

Figure 1-8

. Brake rod (5) is threaded into push rod

(3) in rear brake master cylinder (1), and locked in place
with jam nut (4). Loosen jam nut.

When adjusting brake control rod, never allow more than
nine threads to be exposed between control rod and jam
nut. If more than nine threads are exposed, brake rod can
come apart resulting in loss of rear brake, which could
cause death or serious injury. (00306c)

2.

Using an open-end wrench on the push rod flats, turn the
push rod in the direction which will correct pedal height.
When correct pedal height is obtained, tighten jam nut.

3.

Verify that water drain hole in rubber boot (2), which covers
rear brake push rod, is positioned to bottom.

HOME

1-16 2009 Dyna Service: Maintenance

NOTE

Brake pedal freeplay is built into master cylinder and no
adjustment is required. When pedal is pushed down with hand,
a small amount of freeplay must be felt.

5

4

3

2

1

sm02847a

1.

Rear brake master cylinder

2.

Rubber boot

3.

Push rod

4.

Jam nut

5.

Brake rod

Figure 1-8. Rear Brake Pedal Height

HOME

2009 Dyna Service: Maintenance 1-17

1.8

AIR CLEANER AND EXHAUST SYSTEM

REMOVAL

1.

See

Figure 1-9

. Remove screw (1) and air cleaner cover

(2).

2.

See

Figure 1-10

. Gently pull both rubber breather tubes

(1) from the element.

3.

Slide clip-nut (2) to the left to allow access to third screw.
Remove three screws (3), bracket (4) and filter element
(5).

4.

Replace the filter element if damaged or if filter media
cannot be adequately cleaned.

Do not use gasoline or solvents to clean filter element.
Flammable cleaning agents can cause an intake system
fire, which could result in death or serious injury. (00101a)

5.

Gently pull the breather tubes from the breather bolts on
the backplate.

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)

6.

Clean filter element.

a.

Wash the paper/wire mesh air filter element and
breather tubes in lukewarm water with a mild deter-
gent. Do not strike filter element on a hard surface to
dislodge dirt.

b.

Allow filter to either air dry or blow it dry, from the
inside, with low pressure air. Do NOT use air cleaner
filter oil on the Harley-Davidson paper/wire mesh air
filter element.

c.

Hold the filter element up to a strong light source. If
light is uniformly visible through the element, it is
sufficiently clean.

7.

Inspect seal ring on cover for cracks or tears. Verify that
it seals tightly to backplate. Replace as required.

8.

Inspect breather tubes for tears, cuts, holes or other
damage. Replace as necessary.

NOTE

The breather tubes allow crankcase vapors to be directed into
the air filter element. By providing effective recirculation of
crankcase vapor, the tubes serve to eliminate the pollutants
normally discharged from the crankcase. Air cleaner mounting
without installation of the breather tubes, or with breather tubes
that are not air tight, allows crankcase vapors to be vented into
the atmosphere in violation of legal emissions standards. This
will also negatively affect the engine's breather system as it
will cause the umbrella valve to flutter.

9.

Wipe inside of air cleaner cover and backplate with damp
cloth to remove dust.

10. On California models only, make sure trap door swings

freely.

1

2

sm03762

1.

Cover screw

2.

Air cleaner cover

Figure 1-9. Air Cleaner Cover

2

3

4

5

1

1

sm03761

1.

Breather tubes

2.

Clip-nut

3.

Screw (3)

4.

Bracket

5.

Filter element

Figure 1-10. Air Cleaner Element

INSTALLATION

1.

See

Figure 1-11

. Position new gasket on filter element.

Make sure gasket holes are aligned with screw holes.

2.

See

Figure 1-10

. Attach breather tubes (1) to breather

screws on backplate.

HOME

1-18 2009 Dyna Service: Maintenance

3.

Install air filter element (5) and bracket (4) using three
screws (3). Tighten to 40-60 in-lbs (4.5-6.8 Nm). Slide
clip-nut (2) to the right and into place.

4.

Insert breather tubes (1) into holes in filter element.

5.

See

Figure 1-9

. Install air filter cover (2).

a.

Apply a drop of LOCTITE THREADLOCKER 243
(blue) to threads of air cleaner cover screw (1).

b.

Install air cleaner cover and tighten screw to 36-60
in-lbs (4.1-6.8 Nm).

sm03763

Figure 1-11. Element Gasket

EXHAUST SYSTEM LEAK CHECK

Check the exhaust system for leaks at every scheduled service
interval as follows:

1.

Check entire exhaust system for loose or missing
fasteners, broken pipe clamps or brackets, and obvious
signs of leakage (carbon tracks at pipe joints, etc.).

2.

Check for loose or broken heat shields. Repair or replace
as necessary.

3.

Start engine, cover muffler ends with clean, dry shop
towels and listen for audible signs of exhaust leakage.

4.

Correct any leaks detected. See

4.17 EXHAUST SYSTEM

for exhaust system removal and installation procedures.

HOME

2009 Dyna Service: Maintenance 1-19

1.9

TIRES AND WHEELS

TIRES

Match tires, tubes, air valves and caps to the correct wheel
rim. Contact a Harley-Davidson dealer. Mismatching can
result in damage to the tire bead, allow tire slippage on
the rim or cause tire failure, which could result in death
or serious injury. (00023a)

Use only Harley-Davidson approved tires. See a Harley-
Davidson dealer. Using non-approved tires can adversely
affect stability, which could result in death or serious
injury. (00024a)

Use inner tubes on laced (wire spoked) wheels. Using
tubeless tires on laced wheels can cause air leaks, which
could result in death or serious injury. (00025a)

NOTES

•

Tubeless tires fitted with the correct size inner tubes may
be used on all Harley-Davidson laced (wire spoked)
wheels. Protective rubber rim strips must be used with

tubeless tires (fitted with correct size inner tubes) when
mounted on laced (wire spoked) wheels.

•

Inner tubes must not be used in radial tires and radial tires
must not be used on laced (wire spoked) wheels.

•

Tubeless tires are used on all Harley-Davidson cast and
disc wheels.

•

Tire sizes are molded on the tire sidewall. Inner tube sizes
are printed on the tube.

•

New tires should be stored on a horizontal tire rack. Avoid
stacking new tires in a vertical stack. The weight of the
stack compresses the tires and closes down the beads.

Check tire pressure and tread:

•

As part of the pre-ride inspection.

•

At every scheduled service interval.

1.

Inspect each tire for punctures, cuts and breaks.

2.

Inspect each tire for wear. Replace tires before they reach
the tread wear indicator bars.

NOTE

Missing indicator wear bars represent less than 1/32 in. (0.8
mm) tread pattern depth remaining.

3.

Check for proper front and rear tire pressures when tires
are cold. Compare results against

Table 1-7

.

Table 1-7. Tire Pressures: 2009 Dyna Models

TIRE PRESSURE (COLD)

LOAD

MODEL

REAR

FRONT

kPa

PSI

kPa

PSI

248

36

206

30

Solo rider

All models except FXDF

275

40

206

30

Rider and passenger

248

36

248

36

Solo rider

FXDF

275

40

248

36

Rider and passenger

TIRE REPLACEMENT

See

Figure 1-12

. Arrows on tire sidewalls pinpoint location of

wear bar indicators.

See

Figure 1-13

. Tread wear indicator bars appear on tire tread

surfaces when 1/32 in. (0.8 mm) or less tire tread
remains.Always remove tires from service before they reach
the tread wear indicator bars, indicating 1/32 in. (0.8 mm) tread
pattern depth remaining.

New tires are needed if any of the following conditions exist:

•

Tire wear indicator bars become visible on the tread sur-
faces.

•

Tire cords or fabric become visible through cracked side-
walls, snags or deep cuts.

•

A bump, bulge or split in the tire is found.

•

Puncture, cut or other damage to the tire that cannot be
repaired.

HOME

1-20 2009 Dyna Service: Maintenance

Table 7-8. Tail Lamp Wires: FXDB Only

CAVITY

WIRE COLOR

TYPE

NO.

FUNCTION

1

Not used

4-pin Deutsch

[93]

Tail lamp

2

R/Y

3

O/W

4

BK

HOME

2009 Dyna Service: Electrical 7-29

7.14

TURN SIGNALS AND RUNNING LIGHTS

BULB REPLACEMENT: BULLET STYLE

1.

Locate latch slot on circumference of turn signal lamp lens.
Press in with small screw driver or coin to remove lens.

2.

Push bulb in and rotate 1/4 turn counterclockwise to
remove.

3.

Inspect contacts in socket. If necessary, clean contacts
with a small wire brush and electrical contact cleaner.

4.

Evenly apply dielectric grease to the contacts and bottom
of the new bulb.

5.

Push and rotate new bulb into socket.

6.

Snap-in and rotate lens to position latch slot on bottom.

NOTE

If after replacing a bulb, the turn signal or running lamp will not
light, check the wiring, the ground at the socket and/or the
switch.

FRONT LAMP HOUSING REPLACEMENT

NOTE

On FXDF and FXDB models, the turn signal wiring is routed
through the lower switch housings. On FXDB and FXDF
models, the turn signal wires are routed through the handlebars.
See

2.27 HANDLEBARS: FXDB/FXDF

or

7.32 HANDLEBAR

SWITCH ASSEMBLIES

for more information.

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

1.

Disconnect the negative battery cable.

NOTE

Before removing turn signal wires, carefully note wire routing.
In particular, pay close attention to the locations of cable straps
which must be replaced.

2.

Remove fuel tank fasteners, vent, fuel supply fitting and
slide fuel tank back. See

4.6 FUEL TANK

.

3.

Unplug fuel gauge connector [117].

4.

Disconnect turn signal connector and cut cable straps
around turn signal wire conduit.

5.

Remove turn signal lamp wires from multilock connector.
See

A.1 AMP MULTILOCK CONNECTORS

for connector

information.

NOTE

To aid in installing new turn signal wires, attach thin wire to
terminals on old turn signal wires before pulling old wires out
of conduit or handlebars. This thin wire can then be used to
guide new wires back through conduit or handlebars.

7

10

5

4

3

11

12

9

8

7

5

4

3

2

1

9

8

13

6

sm02564

1.

Lockwasher

2.

Ball receptacle

3.

Ball stud

4.

Ball stud clamp

5.

Jam nut

6.

Left lamp housing

7.

Socket assembly

8.

Bulb

9.

Lens

10. Right lamp housing
11. Retainer
12. Lockwasher
13. Acorn nut

Figure 7-32. Front Turn Signals

HOME

7-30 2009 Dyna Service: Electrical