ELECTRICAL SYSTEM
369
5. To remove the tachometer, perform the follow-
ter and tachometer to the underside of the
ing:
console.
a. Remove the two screws securing the
d. Depress the tab and disconnect the 12-pin
backplate (B, Figure 147) and take it off.
electrical connector from the back of the
b. Depress the tab and disconnect the 6-pin elec-
speedometer.
trical connector from the back of the tachom-
e. Carefully remove the speedometer and gasket
eter.
out through the front of the console.
c. Carefully push the tachometer and front gas-
f. Remove the gasket from the speedometer.
ket (B, Figure 148) out through the front of
5. To remove the tachometer, perform the follow-
the meter housing.
ing:
d. Remove the front gasket from the tachometer.
a. Perform Steps 4a-4c of speedometer removal.
6. Store the meters in a safe place.
b. Remove the T15 Torx screw securing the wir-
7. Remove the rear gasket(s) from the meter hous-
ing harness clip to the backside of the ta-
ing. They are identical with the same part number.
chometer.
NOTE
c. Gently pry on each end of the 6-pin electrical
If necessary, apply alcohol or glass
connector and disconnect it from the backside
cleaner to the gasket surfaces to ease
of the tachometer.
installation of the meters.
d. Carefully remove the tachometer and gasket
out through the front of the console.
8. If removed, install the front gasket onto the me-
8
ter and install it into the meter housing. Press firmly
e. Remove the gasket from the tachometer.
until the meter is correctly seated.
6. If removed, install the gasket onto the perimeter
9. Connect the electrical connector to the backside
of the console where it mounts onto the fuel tank.
of the meter. Route the electrical wiring through the
7. To install the speedometer, perform the follow-
slot in the backside of the meter housing.
ing:
10. Install the rear gasket onto the meter and hous-
a. Install the gasket onto the console.
ing.
b. Install the speedometer onto the console and
11. Install the backplate and tighten the screws se-
gasket. Make sure the speedometer is seated
curely.
correctly onto the gasket.
12. On models so equipped, install the windshield
c. Connect the 12-pin electrical connector onto
or front fairing.
the back of the speedometer.
8. To install the tachometer, perform the following:
Removal/Installation
a. Install the gasket onto the console.
(FXDL)
b. Install the tachometer onto the console and
gasket. Make sure the tachometer is seated
Refer to Figure 149.
correctly onto the gasket.
1. Remove the seat as described in Chapter Thir-
c. Install and push down and install the 6-pin
teen.
electrical connector onto the back of the ta-
2. Disconnect the negative battery cable as de-
chometer.
scribed in this chapter.
3. Cover the fuel tank surrounding the instrument
d. Install the wire harness and clip to the back-
assembly with towels to protect the finish.
side of the tachometer. Install the T15 Torx
screw securing the wiring harness clip and
4. To remove the speedometer, perform the follow-
tighten securely.
ing:
a. Remove the two Allen screws securing the
9. Install the mounting bracket to the underside of
console assembly to the fuel tank.
the console. Align the bolt holes in the mounting
b. Lift the console assembly up, turn it over and
bracket and the speedometer and tachometer.
place it on the fuel tank towels.
10. Install the four Allen screws securing the
c. Remove the four Allen screws and remove
mounting bracket to the backside of the speedome-
the mounting bracket securing the speedome-
ter and tachometer.
370
CHAPTER EIGHT
11. Check that there will be no binding with the
150
INSTRUMENTS (FXDWG)
wiring harness and the bracket after the console is
installed onto the fuel tank.
12. Carefully turn the console assembly over and
position it on the fuel tank aligning the screw holes.
13. Install the two Allen screws securing the con-
sole assembly to the fuel tank and tighten securely.
14. Connect the negative battery cable as described
in this chapter.
15. Install the seat.
Removal/Installation
(FXDWG)
Refer to Figure 150.
1. Remove the seat as described in Chapter Thir-
teen.
2. Disconnect the negative battery cable as de-
scribed in this chapter.
3. Cover the fuel tank surrounding the instrument
assembly with towels to protect the finish.
4. Remove the acorn nut securing the console as-
sembly to the set screw on the fuel tank.
5. Lift the console assembly up, turn it over and
place it on the fuel tank towels.
6. Depress the tab and disconnect the
12-pin
electrical connector from the back of the speed-
ometer.
7. Unscrew the rubber boot from the reset switch
on the left side of the console.
8. Remove the reset switch from the side of the
console.
9. Carefully pry and raise the three tabs and the
speedometer to release the back clamp from the
speedometer.
1.
Speedometer
2.
Gasket
10. Remove the speedometer and gasket out
3.
Trim plate
through the front of the console.
4.
Indicator light bezel
11. Remove the gasket from the speedometer.
5.
Acorn nut
12. Install the gasket onto the speedometer.
6.
Console
7.
Boot
13. Install the speedometer into the console.
8.
Reset switch
14. Press on the three tabs and push onto the back-
9.
Set screw
side of the speedometer until they are engaged.
10.
Clip
11.
Trim piece
15. Insert the reset switch through the side in the
12.
Ignition switch and key
console and install the rubber boot.
13.
Cage nut
16. Connect the 12-pin electrical connector onto
14.
Clamp
the back of the speedometer.
15.
Cable strap
17. Carefully turn the console assembly over and
16.
Screw
17.
Indicator light panel
position it on the fuel tank aligning the set screw
with the console hole.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
ELECTRICAL SYSTEM
371
151
Police accessory1
Instruments
Siren1
F
E
D
C
B
A
2
Security
Ignition
Pursuit
L
K
J
I
H
G
Accessories
Lights
P&A1
U
S
R
P
O
15A
M
8
1. FXDP Dyna Police models only.
2. FXDP turn signal use only. Security not
available on FXDP models.
varies, depending on the model. The fuse ratings are
152
listed in Table 1. Refer to Figure 151 for fuse loca-
tion on the panel.
All fuses are located on a single panel within the
electrical panel. If there is an electrical failure, first
check for a blown fuse. A blown fuse will have a
break in the element (Figure 152).
Whenever the fuse blows, find out the reason for
the failure before replacing the fuse. Usually, the
trouble is a short circuit in the wiring. This may be
caused by worn-through insulation or a discon-
nected wire shorted to ground. Check the circuit the
fuse protects.
18. Install the acorn nut securing the console as-
sembly to the fuel tank and tighten securely.
19. Connect the negative battery cable as described
Fuse Replacement
in this chapter.
20. Install the seat.
1. Remove the seat as described in Chapter Thir-
teen.
FUSES
NOTE
Always disarm the optional TSSM se-
All models are equipped with a series of fuses to
curity system prior to disconnecting
protect the electrical system. The number of fuses
the battery or the siren will sound.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
372
CHAPTER EIGHT
2. Disconnect the negative battery cable as de-
scribed in this chapter.
153
3. Remove the electrical panel cover as described
in this chapter.
4. Locate the blown fuse (Figure 153) and install a
new one of the same amperage.
NOTE
Always carry spare fuses.
CIRCUIT BREAKER
All models use a single circuit breaker to protect
the electrical circuits. Table
1 lists the circuit
154
breaker rating for the different models.
Whenever a failure occurs in any part of the
electrical system, the circuit breaker is
self-resetting and will automatically return power
to the circuit when the electrical fault is found and
corrected.
CAUTION
If the electrical fault is not found and
corrected, the circuit breaker will cycle
on and off continuously. This will cause
the motorcycle to run erratically.
2.
Disconnect
the
negative
battery
cable
as
de-
Usually the trouble to a short circuit is found in
scribed in this chapter.
the wiring connected to the circuit breaker.
3. Remove the electric panel cover and inner panel
The circuits protected by the circuit breaker can
as described in this chapter.
be determined by following the wiring diagrams at
NOTE
the end of the book.
Record the number of wires and
Do not consider a tripped circuit breaker as just a
their color and to which terminal
minor annoyance; it indicates that something is
they are connected. The wires must
wrong in the electrical system that must be cor-
be reinstalled onto the correct termi-
rected immediately.
nal.
4. Remove the nuts and wire connections at the cir-
Replacement
cuit breaker (Figure 154).
5. Remove the circuit breaker from the mounting
The circuit breaker is located inside the electrical
bracket on the inner panel.
panel.
6. Install the circuit breaker by reversing these
1. Remove the seat as described in Chapter Thir-
steps.
teen.
NOTE
DIAGNOSTIC TROUBLE CODES
Always disarm the optional TSSM se-
curity system prior to disconnecting
Refer to Ignition System in Chapter Two to re-
the battery or the siren will sound.
trieve the diagnostic trouble codes.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
ELECTRICAL SYSTEM
373
Table 1 ELECTRICAL SPECIFICATIONS
Battery
12 volts, 19 amp hour
Alternator
AC voltage output
16-20 VAC per 1000 rpm
Stator coil resistance
0.1-0.2 ohm
Regulator
Voltage output @ 3600 rpm
14.3-14.7 @ 75° F (24° C)
Amperes at 3600 rpm
32 amp
Ignition coil
Primary resistance
0.5-0.7 ohm
Secondary resistance
5500-7500 ohms
Spark plug cable resistance
Front cylinder cable
4700-11230 ohms
Rear cylinder cable
1812-4375 ohms
Circuit breaker
FXDP
40 amp
All models except FXDP
30 amp
Fuses
Ignition fuse
15 amp
Lighting fuse
15 amp
Accessory fuse
15 amp
Instrument fuse
15 amp
Security system*
15 amp
8
*Models so equipped.
Table 2 MAINTENANCE FREE BATTERY VOLTAGE READINGS
State of Charge
Voltage reading
100%
13.0-13.2
75%
12.8
50%
12.5
25%
12.2
0%
12.0 volts or less
Table 3 BATTERY CHARGING RATES/TIMES (APPROXIMATE)
% of
3 amp
6 amp
10 amp
20 amp
Voltage
Charge
Charger
Charger
Charger
Charger
12.8
100%
-
-
-
-
12.6
75%
1.75 hours
50 minutes
30 minutes
15 minutes
12.3
50%
3.5 hours
1.75 hours
1 hour
30 minutes
12.0
25%
5 hours
2.5 hours
1.5 hours
45 minutes
11.8
0%
6 hours and
3 hours and
2 hours
1 hour
40 minutes
20 minutes
Table 4 STARTER MOTOR SPECIFICATIONS
Minimum free speed
3000 rpm @ 11.5 volts
Maximum free current
90 amp @ 11.5 volts
Cranking current
200 amp maximum @ 68° F (20° C)
Brush length (minimum)
0.433 in. (11.0 mm)
Commutator diameter (minimum)
1.141 in. (28.98 mm)
-------------------------------------------------------------------------------------------------------------------------------------------------------------
374
CHAPTER EIGHT
Table 5 REPLACEMENT BULBS
Item
Size (all 12 volt) × quantity
Headlamp
55/60
Position lamp*
3.9
Indicator lamps
FXDL
1.1 x 4
FXDP
2.1 x 4
All models except FXDL and FXDP
2.2 x 3
Fuel gauge
FXDL, FXDWG
2.7
FXD, FXDX, FXDX-CONV, FXDXT
3.7
FXDP
NA
Front turn signal/running light
27/7 x 2
Front turn signal*
21 x 2
Rear turn signal
27 x 2
Rear turn signal*
21 x 2
Tail/brake lamp
7/27
Tail/brake lamp*
5/21
*Indicates bulb specification for HD International models.
Table 6 ELECTRICAL SYSTEM TORQUE SPECIFICATIONS
Item
ft.-lb.
in.-lb.
N·m
Alternator stator
Torx screws
-
30-40
3-5
Camshaft position sensor
(1999-2000)
Inspection cover screws
-
20-30
2-3
Sensor screw
-
20-30
2-3
Crankshaft position
sensor (CKP)
Allen screw
-
90-120
10-14
Fuel gauge sending unit
plate screws
-
17
2
Fuel tank
Console nut
-
80-100
9-11
Mounting bolt
10-18
-
14-24
Handlebar switch
housing screw
-
35-45
4-5
Headlight
Mounting block bolt
25-30
-
34-41
Mounting nut
-
120-180
14-20
Mounting screw
25-30
-
34-41
Shade bolt
-
120-144
14-16
Horn mounting nut
-
110
12
Ignition coil bolts
-
24-72
3-8
Ignition module screw
-
15-21
2-3
Instrument cluster bolt
12-18
-
16-24
Jackshaft lockplate bolt
-
84-108
9-12
MAP sensor screw
-
20-30
2-3
Speedometer sensor
mounting bolt
-
84-108
9-12
Starter
Mounting bolts
13-20
-
18-27
Positive terminal nut
-
65-80
7-9
(continued)
-------------------------------------------------------------------------------------------------------------------------------------------------------------
ELECTRICAL SYSTEM
375
Table 6 ELECTRICAL SYSTEM TORQUE SPECIFICATIONS (continued)
Item
ft.-lb.
in.-lb.
N·m
Starter jackshaft bolt
-
84-108
9-12
Switches
Neutral
-
120-180
14-20
Oil pressure
-
96-120
11-14
Rear stop light
-
96-120
11-14
Tail/brake light
Base screws
-
40-48
4-5
Lens screws
-
20-24
2-3
Voltage regulator screws
-
60-80
7-9
Table 7 TURN SIGNAL SPEED AND DISTANCE TEST
Range
1
2
3
4
MPH
0-34
35-44
45-60
61+
KMH
0-56
56-71
72-97
98+
Feet
221
339
680
1051
Miles
0.04
0.06
0.13
0.20
Meters
67
103
207
320
8
Table 8 TURN SIGNAL SPEED AND TIME TEST
Constant speed
Signal ON time
MPH
KMH
in seconds
25
40
5-7
38
61
5-7
52
84
8-10
65
105
10-12
-------------------------------------------------------------------------------------------------------------------------------------------------------------
CHAPTER NINE
WHEELS, HUBS AND TIRES
This chapter describes disassembly and repair of
the front and rear wheels, hubs and tire service. For
1
routine maintenance, see Chapter Three.
Tables 1-3 are at the end of the chapter.
MOTORCYCLE STANDS
Many procedures in this chapter require that the
front or rear wheel be lifted off the ground. To do
this, a quality motorcycle front end stand (Figure
1), swing arm stand, or suitable size jack is required.
Before purchasing or using a stand, check the man-
ufacturer’s instructions to make sure the stand will
work with the Dyna Glide model being worked on.
If any adjustments or accessories are required for
the motorcycle and/or stand, perform the necessary
adjustments or install the correct parts before lifting
-------------------------------------------------------------------------------------------------------------------------------------------------------------
WHEELS, HUBS AND TIRES
377
2
6
the motorcycle. When using the motorcycle stand,
3
have an assistant standing by to help. Some means
to tie down one end of the motorcycle may also be
required. After lifting the motorcycle on a stand,
make sure the motorcycle is properly supported be-
fore walking away from it.
FRONT WHEEL
Removal
9
1. Support the motorcycle with the front wheel off
the ground. See Motorcycle Stands in this chapter.
4
NOTE
On models with dual front calipers,
both calipers must be removed to re-
move the front wheel.
2A. On 1999 models, remove the caliper mounting
bolts (Figure 2) and remove the caliper(s) as de-
scribed in Chapter Twelve.
2B. On 2000-on models, remove the caliper mount-
ing bolts (Figure 3) and remove the caliper(s) as de-
scribed in Chapter Twelve.
NOTE
Place a plastic or wooden spacer be-
5
tween the brake pads in place of the
disc. Then, if the brake pedal is inad-
vertently depressed, the pistons will
not be forced out of the caliper. If this
occurs, disassemble the caliper to re-
seat the pistons.
3. On the left side, remove the axle nut (Figure 4),
lockwasher and flat washer (Figure 5).
4A. On all models except FXDWG, loosen the front
axle pinch bolt (A, Figure 6).
-------------------------------------------------------------------------------------------------------------------------------------------------------------
378
CHAPTER NINE
4B. On FXDWG models, loosen the nuts on the
fork slider cap.
7
NOTE
On some models, the wheel spacers
are different. Identify the spacers be-
fore removing them.
5. Prior to removing the front axle, note the loca-
tion of the right side spacer (Figure 7) and left side
spacer (Figure 8). The spacer must be reinstalled on
the correct side during installation.
6. Insert a drift or screwdriver into the hole (Figure
9) in the end of the front axle (B, Figure 6). With-
draw the front axle from the fork sliders and front
8
wheel. Remove the tool from the axle.
7. Pull the wheel away from the fork sliders and re-
move it.
CAUTION
Do not set the wheel down on the
brake disc surface, as it may be dam-
aged.
8. Inspect the front wheel assembly as described in
this chapter.
Installation
9
1. Clean the axle in solvent and dry thoroughly.
Make sure the axle bearing surfaces on both fork
sliders and the axle are free of burrs and nicks.
2. Apply an antiseize lubricant to the axle shaft
prior to installation.
3. If the oil seals or bearings were replaced, con-
firm front axle spacer alignment as described under
Front Hub in this chapter.
4. Install the left side and right side axle spacers in
the wheel. The left side axle spacer is longer than
the right side spacer.
5. Install the wheel between the fork sliders and in-
10
stall the axle from the right side (Figure 9).
6. Check that axle spacers are installed correctly.
Refer to Figure 7 for the right side and to Figure 8
for the left side.
7. Install the flat washer, lockwasher (Figure 5)
and axle nut (Figure 4) finger-tight. Check that axle
spacers are installed correctly.
8A. On all models except FXDWG, tighten the front
axle pinch bolt (A, Figure 6) to the specification in
Table 2.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
WHEELS, HUBS AND TIRES
379
8B. On FXDWG models, tighten the nuts on the
11
Axial
fork slider cap to the specification in Table 2.
9. Insert a drift or screwdriver into the hole (Figure
9) in the end of the front axle (B, Figure 6) to keep it
from rotating.
10. Tighten the front axle nut (Figure 4) to the
specification in Table 2.
11. Remove the tool used in Step 8 from the front
axle.
12. Check that the front wheel is centered between
the fork sliders. If not, check the position of the left
and right axle spacers.
13. On 1999 models, perform the Front Wheel
Radial
Bearing End Play Check in this chapter.
14. Install the front brake caliper(s) as described in
Chapter Twelve.
15. With the front wheel off the ground, rotate it
several times and apply the front brake to seat the
brake pads against the disc(s).
16. Remove the stand and lower the front wheel
onto the ground.
9
Inspection
Replace any worn or damaged parts as described
12
in this section.
1. On 1999 models, inspect the oil seals (Figure
10) for excessive wear, hardness, cracks or other
damage. If necessary, replace the seals as described
under Front and Rear Hubs in this chapter.
2. Turn each bearing inner race by hand. The bear-
ing must turn smoothly. Some axial play (end play)
is normal, but radial play (side play) must be negli-
gible. See Figure 11. If one bearing is damaged, re-
place both bearings as a set. Refer to Front and Rear
Hubs in this chapter.
3. Clean the axle and axle spacers in solvent to re-
move all grease and dirt. Make sure the axle contact
13
surfaces are clean and free of dirt and old grease.
4. Check the axle runout with a set of V-blocks and
dial indicator (Figure 12).
5. Check the spacers for wear, burrs and damage.
Replace as necessary.
6. Check the brake disc bolts (Figure 13) for tight-
ness. To service the brake disc, refer to Chapter
Twelve.
7. Check wheel runout and spoke tension as de-
scribed in this chapter.
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