Harley Davidson 2009 Dyna Models. Service manual - page 1

MAINTENANCE

1.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................1-1

1.2 GENERAL

Servicing a New Motorcycle...............................................1-3
Safe Operating Maintenance..............................................1-3
Shop Practices...................................................................1-3

Repair Notes...............................................................1-3
Safety..........................................................................1-3
Removing Parts...........................................................1-3
Cleaning......................................................................1-3
Disassembly and Assembly........................................1-4
Checking Torques on Fasteners..................................1-4
Magnetic Parts Trays...................................................1-4

Repair and Replacement Procedures................................1-4

Hardware and Threaded Parts....................................1-4
Threadlocking Agents..................................................1-4
Wiring, Hoses and Lines.............................................1-4
Instruments and Gauges.............................................1-4
Bearings......................................................................1-4
Bushings.....................................................................1-4
Gaskets.......................................................................1-4
Lip Type Seals.............................................................1-4
O-Rings (Preformed Packings)....................................1-5
Gears..........................................................................1-5
Shafts..........................................................................1-5
Part Replacement........................................................1-5
Exhaust System Leakage............................................1-5

Cleaning.............................................................................1-5

Part Protection............................................................1-5
Cleaning Process........................................................1-5
Rust or Corrosion Removal.........................................1-5
Bearings......................................................................1-5

Tool Safety..........................................................................1-5

Air Tools.......................................................................1-5
Wrenches....................................................................1-5
Pliers/Cutters/Pry bars................................................1-5
Hammers.....................................................................1-6
Punches/Chisels..........................................................1-6
Screwdrivers................................................................1-6
Ratchets and Handles.................................................1-6
Sockets........................................................................1-6
Storage Units...............................................................1-6

1.3 MAINTENANCE SCHEDULE

General...............................................................................1-7

1.4 FUEL AND OIL

Fuel..................................................................................1-10
Gasoline Blends...............................................................1-10
Engine Lubrication............................................................1-10
Winter Lubrication............................................................1-11

1.5 ENGINE OIL AND FILTER

Checking and Adding Oil..................................................1-12

Type of Oil.................................................................1-12
Checking with Cold Engine.......................................1-12
Checking with Warm Engine.....................................1-12

Changing Oil and Filter.....................................................1-13

1.6 BULB REQUIREMENTS

General.............................................................................1-15

1.7 BRAKES

Fluid Inspection................................................................1-16
Rear Pedal Height............................................................1-16

1.8 AIR CLEANER AND EXHAUST SYSTEM

Removal...........................................................................1-18
Installation........................................................................1-18
Exhaust System Leak Check............................................1-19

1.9 TIRES AND WHEELS

Tires.................................................................................1-20
Tire Replacement.............................................................1-20
Wheel Bearings................................................................1-21
Wheel Spokes..................................................................1-21

1.10 PRIMARY CHAIN

General.............................................................................1-22
Changing Primary Chaincase Lubricant...........................1-22

1.11 TRANSMISSION LUBRICANT

Changing Transmission Lubricant.....................................1-24

1.12 CLUTCH

Adjustment.......................................................................1-25

1.13 REAR BELT AND SPROCKETS

General.............................................................................1-27
Cleaning...........................................................................1-27
Inspection.........................................................................1-27

Sprockets..................................................................1-27
Rear Belt...................................................................1-27

1.14 REAR BELT DEFLECTION

Inspection.........................................................................1-29
Adjustment.......................................................................1-30

1.15 THROTTLE CABLES

Cable Inspection, Lubrication and Adjustment.................1-31

Inspection and Lubrication........................................1-31
Adjustment................................................................1-31

1.16 BLEEDING BRAKES

General.............................................................................1-32
Procedure.........................................................................1-32

1.17 BRAKE PADS AND DISCS

Inspection.........................................................................1-33

Brake Pads................................................................1-33
Brake Disc.................................................................1-33

Brake Pad Replacement...................................................1-33

Rear Brake Caliper....................................................1-33
Front Brake Caliper...................................................1-34

1.18 BATTERY MAINTENANCE

General.............................................................................1-36
Cleaning and Inspection...................................................1-37
Voltmeter Test...................................................................1-37

Voltmeter Test............................................................1-37

Charging Battery..............................................................1-37

Safety Precautions....................................................1-37
Using a Battery Charger............................................1-37

Disconnection and Removal.............................................1-38
Storage.............................................................................1-39
Installation and Connection..............................................1-39

III

T

ABLE OF CONTENTS

1.19 SUSPENSION ADJUSTMENTS

Rear Shock Preload Adjustment......................................1-41

1.20 SPARK PLUGS

Inspection.........................................................................1-42
Spark Plug Cable Inspection............................................1-42

1.21 STEERING HEAD BEARINGS

Adjustment.......................................................................1-44

Bearing Adjustment (Fall Away)................................1-44

Lubrication........................................................................1-44

1.22 FRONT FORK OIL

Replacing Fork Oil............................................................1-45

1.23 CABLE AND CHASSIS LUBRICATION

General.............................................................................1-46
Cables and Hand Levers..................................................1-46
Jiffy Stand.........................................................................1-46

1.24 HEADLAMP ALIGNMENT

Headlamp Alignment........................................................1-47
Adjustment.......................................................................1-47

All Models..................................................................1-47

1.25 CRITICAL FASTENERS

Inspection.........................................................................1-49

Checking Torques on Fasteners................................1-49

1.26 ENGINE MOUNTS

Inspection.........................................................................1-50

1.27 STORAGE

General.............................................................................1-51
Placing in Storage............................................................1-51
Removal from Storage......................................................1-51

1.28 TROUBLESHOOTING

General.............................................................................1-53
Engine..............................................................................1-53

Starter Motor Does Not Operate or Does Not Turn Engine
Over...........................................................................1-53
Engine Turns Over But Does Not Start......................1-53
Starts Hard................................................................1-53
Starts But Runs Irregularly or Misses........................1-53
Spark Plug Fouls Repeatedly....................................1-53
Pre-Ignition or Detonation (Knocks or Pings)............1-53
Overheating...............................................................1-54
Valve Train Noise.......................................................1-54
Excessive Vibration...................................................1-54
Check Engine Light Illuminates During Operation.....1-54

Lubrication System...........................................................1-54

Oil Does Not Return To Oil Pan.................................1-54
Engine Uses Too Much Oil Or Smokes Excessively...1-54
Engine Leaks Oil From Cases, Push Rods, Hoses,
Etc.............................................................................1-54
Low Oil Pressure.......................................................1-54
High Oil Pressure......................................................1-54

Electrical System..............................................................1-54

Alternator Does Not Charge......................................1-54

Alternator Charge Rate Is Below Normal..................1-55
Speedometer Operates Erratically............................1-55

Transmission.....................................................................1-55

Shifts Hard................................................................1-55
Jumps Out Of Gear...................................................1-55
Clutch Slips...............................................................1-55
Clutch Drags Or Does Not Release..........................1-55
Clutch Chatters..........................................................1-55

Handling...........................................................................1-55

Irregularities..............................................................1-55

Brakes..............................................................................1-55

Brake Does Not Hold Normally.................................1-55

CHASSIS

2.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................2-1

2.2 SPECIFICATIONS

Specifications.....................................................................2-4

Chassis Specifications................................................2-4
Tire Specifications.......................................................2-5

2.3 VEHICLE IDENTIFICATION NUMBER
(V.I.N.)

General...............................................................................2-7

2.4 FRONT WHEEL

Removal.............................................................................2-9
Disassembly.......................................................................2-9

Cast Wheel..................................................................2-9
Cast Wheel, Dual Brakes............................................2-9
Laced Wheel...............................................................2-9

Cleaning and Inspection...................................................2-12
Assembly..........................................................................2-12

Cast Wheel................................................................2-13
Laced Wheel.............................................................2-13

Installation........................................................................2-13

2.5 REAR WHEEL

Removal...........................................................................2-15
Disassembly.....................................................................2-15
Cleaning and Inspection...................................................2-16
Assembly..........................................................................2-16
Installation........................................................................2-17

2.6 SEALED WHEEL BEARINGS

Inspection.........................................................................2-18
Removal...........................................................................2-18
Installation........................................................................2-19

2.7 WHEEL LACING: 17 INCH RIM

General.............................................................................2-21
Procedure.........................................................................2-21

2.8 WHEEL LACING: 19 INCH RIM

Procedure.........................................................................2-24

2.9 WHEEL LACING: 21 INCH RIM

General.............................................................................2-28

IV TABLE OF CONTENTS

TABLE OF CONTENTS

Procedure.........................................................................2-28

2.10 TRUING LACED WHEELS

General.............................................................................2-31
Lateral Truing....................................................................2-31
Radial Truing.....................................................................2-32

2.11 CHECKING CAST WHEEL RUNOUT

General.............................................................................2-34
Lateral Runout..................................................................2-34
Radial Runout...................................................................2-34

2.12 VEHICLE ALIGNMENT

Inspection.........................................................................2-35

2.13 FRONT BRAKE MASTER CYLINDER

General.............................................................................2-37
Removal and Disassembly...............................................2-37
Cleaning and Inspection...................................................2-39
Assembly and Installation.................................................2-39

2.14 FRONT BRAKE CALIPER

Removal...........................................................................2-41
Disassembly.....................................................................2-41
Cleaning, Inspection and Repair......................................2-43
Assembly..........................................................................2-44
Installation........................................................................2-44

2.15 REAR BRAKE MASTER CYLINDER

General.............................................................................2-46
Removal...........................................................................2-46
Disassembly.....................................................................2-47
Cleaning and Inspection...................................................2-48
Assembly..........................................................................2-48
Installation........................................................................2-48

2.16 REAR BRAKE CALIPER

Removal...........................................................................2-50
Disassembly.....................................................................2-50
Cleaning, Inspection and Repair......................................2-52
Assembly..........................................................................2-53
Installation........................................................................2-53

2.17 TIRES

General.............................................................................2-55
Removal...........................................................................2-55
Cleaning, Inspection and Repair......................................2-56
Installation........................................................................2-56

Tube Type Tires.........................................................2-56
Tubeless Tires...........................................................2-57

2.18 FRONT FORK

Removal...........................................................................2-58
Disassembly.....................................................................2-58
Cleaning and Inspection...................................................2-61
Assembly..........................................................................2-61
Installation........................................................................2-62

2.19 STEERING HEAD

Removal...........................................................................2-63

Inspection.........................................................................2-64
Disassembly.....................................................................2-64

Steering Head Bearing Race Removal ....................2-64

Assembly..........................................................................2-65
Installation........................................................................2-65

2.20 BELT GUARD

Removal...........................................................................2-66
Installation........................................................................2-66

2.21 DEBRIS DEFLECTOR

Removal...........................................................................2-67
Installation........................................................................2-67

2.22 THROTTLE CONTROL

Removal/Disassembly......................................................2-68
Cleaning and Inspection...................................................2-68
Assembly/Installation........................................................2-68
Throttle Cable Routing......................................................2-68

2.23 REAR SHOCK ABSORBERS

General.............................................................................2-70
Removal...........................................................................2-70
Inspection.........................................................................2-70
Installation........................................................................2-70

2.24 REAR FORK

Removal...........................................................................2-71
Disassembly.....................................................................2-72
Cleaning and Inspection...................................................2-72
Assembly..........................................................................2-72
Installation........................................................................2-72

2.25 CLUTCH CONTROL

Removal...........................................................................2-73
Installation........................................................................2-73

2.26 HANDLEBARS: ALL BUT FXDB/FXDF

Removal...........................................................................2-74

All Models..................................................................2-74
FXD/FXDC Models....................................................2-74
FXDL Models.............................................................2-74

Installation........................................................................2-75

FXD/FXDC Models....................................................2-75
FXDL Models.............................................................2-75
All Models..................................................................2-76

2.27 HANDLEBARS: FXDB/FXDF

Removal...........................................................................2-77

FXDB.........................................................................2-77
FXDF.........................................................................2-77

Installation........................................................................2-78

2.28 FRONT FENDER

Removal...........................................................................2-80
Installation........................................................................2-80

2.29 REAR FENDER

General.............................................................................2-81

Removal....................................................................2-81

TABLE OF CONTENTS  V

TABLE OF CONTENTS

Tail Lamp/Turn Signal Harness Routing....................2-81
Installation.................................................................2-81

FXDF................................................................................2-82

Removal....................................................................2-82
Installation.................................................................2-82

FXD, FXDC, and FXDL Models........................................2-82

Removal....................................................................2-82
Installation.................................................................2-82

FXDB Models...................................................................2-82

Removal....................................................................2-82
Installation.................................................................2-83

2.30 SEAT

Removal...........................................................................2-84
Installation........................................................................2-84

2.31 JIFFY STAND

Cleaning...........................................................................2-85
Sensor (HDI Models)........................................................2-85
Removal...........................................................................2-86
Installation........................................................................2-87

2.32 ENGINE MOUNTS

Removal...........................................................................2-88

Front Isolator.............................................................2-88
Rear Isolator..............................................................2-88

Installation........................................................................2-88

Front Isolator.............................................................2-88
Rear Isolator..............................................................2-88

ENGINE

3.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................3-1

3.2 SPECIFICATIONS

Specifications.....................................................................3-3

3.3 SERVICE WEAR LIMITS

General...............................................................................3-5

3.4 ENGINE OIL FLOW

Oil Feed..............................................................................3-7
Top End..............................................................................3-7
Bottom End.........................................................................3-9
Oil Return.........................................................................3-11

3.5 OIL PUMP OPERATION

General.............................................................................3-13
Operation..........................................................................3-13

3.6 BREATHER OPERATION

General.............................................................................3-15

3.7 OIL PRESSURE

Oil Pressure Indicator Lamp.............................................3-16
Checking Oil Pressure......................................................3-16

3.8 TROUBLESHOOTING

Diagnosing Valve Train Noise...........................................3-17

Compression Test.............................................................3-17
Cylinder Leakdown Test....................................................3-17
Diagnosing Smoking Engine or High Oil Consumption.....3-18

Check Prior To Cylinder Head Removal....................3-18
Check After Cylinder Head Removal.........................3-18

3.9 HOW TO USE THIS SECTION

Top End Repair.................................................................3-19
Bottom End Repair...........................................................3-19
Typical Symptoms.............................................................3-19

3.10 TOP END SERVICE

Engine in Chassis.............................................................3-20
Engine Removed from Chassis........................................3-21

3.11 BOTTOM END SERVICE

Engine in Chassis.............................................................3-22
Engine Removed From Chassis.......................................3-23

3.12 STRIPPING MOTORCYCLE FOR
SERVICE

Procedure.........................................................................3-24

3.13 ASSEMBLING MOTORCYCLE AFTER
SERVICE

Procedure.........................................................................3-25

3.14 REMOVING ENGINE FROM CHASSIS

Procedure.........................................................................3-26

3.15 INSTALLING ENGINE IN CHASSIS

Procedure.........................................................................3-27

3.16 TOP END OVERHAUL: DISASSEMBLY

General.............................................................................3-29
Rocker Covers..................................................................3-29
Rocker Arm Support Plate................................................3-29
Push Rods, Lifters and Covers.........................................3-31
Cylinder Head...................................................................3-32
Cylinder............................................................................3-33
Piston...............................................................................3-33

3.17 TOP END OVERHAUL: ASSEMBLY

General.............................................................................3-35
Piston...............................................................................3-35
Cylinder............................................................................3-36
Cylinder Head...................................................................3-38
Push Rods, Lifters and Covers.........................................3-42
Rocker Arm Support Plate................................................3-43
Breather Assembly...........................................................3-44

3.18 BOTTOM END OVERHAUL:
DISASSEMBLY

General.............................................................................3-46
Cam Support Plate and Cover..........................................3-46

Prepare Engine.........................................................3-46
Cam Chain and Sprockets........................................3-46
Cam Support Plate....................................................3-47

Crankcase........................................................................3-48

VI TABLE OF CONTENTS

TABLE OF CONTENTS

2

1

sm02295

1.

Cylinder

2.

Dowel pin

Figure 3-34. Cylinder Dowel Pins

3

4

2

1

4

3

1

2

sm02349

1.

Short bolt

2.

Short bolt

3.

Long bolt

4.

Long bolt

Figure 3-35. Cylinder Head Bolt Torque Sequence (Top:

Front Cylinder Head, Bottom: Rear Cylinder Head)

NOTE

Improperly tightened cylinder head bolts may result in gasket
leaks, stud failure and distortion of the cylinder and/or cylinder
head.

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2009 Dyna Service:  Engine  3-39

5.

Tighten the four cylinder head bolts.

a.

Following sequence shown, alternately turn each
cylinder head bolt until finger tight.

b.

Following the same sequence, tighten the cylinder
head bolts to 120-144 in-lbs (13.5-16.2 Nm).

c.

Continuing the same sequence, tighten each bolt to
15-17 ft-lbs (20.3-23.0 Nm).

d.

See 

Figure 3-36

. Using a grease pencil, mark a

straight line on the cylinder head bolt continuing the
line over onto the cylinder head.

e.

Using the marks as a guide, turn each bolt 1/4 turn
or 90 degrees. Be sure to tighten the cylinder head
bolts in the sequence shown in 

Figure 3-35

.

sm02395

Figure 3-36. Final Tightening for Cylinder Head Bolts

NOTES

•

For best results, use SNAP-ON TORQUE ANGLE GAUGE
TA360.

•

Even though all bolt holes (rocker housing, rocker arm
support plate and breather assembly) may appear to be
in alignment, the rocker housing gasket may be installed
upside down. An upside down gasket will result in an open
breather channel causing a major oil leak when the vehicle
is started, possibly resulting in engine and/or property
damage.

•

On front cylinder head, install side of gasket marked "front"
facing up. On rear cylinder head, install side of gasket
marked "rear" facing up.

6.

See 

Figure 3-37

. Install a new rocker housing gasket on

the cylinder head. Verify that the rocker housing gasket
covers the breather channel.

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3-40  2009 Dyna Service:  Engine

2

1

sm02350

1.

CORRECT: Breather channel covered

2.

INCORRECT: Breather channel exposed

Figure 3-37. Install Rocker Housing Gasket (Rear Cylinder Shown)

7.

See 

Figure 3-39

. With the indent (1) facing forward, place

the rocker housing into position aligning the holes in the
housing with those in the gasket.

8.

See 

Figure 3-38

. Apply a small dab of LOCTITE

THREADLOCKER 243 (blue) to threads of six rocker
housing bolts. Loosely install the rocker housing bolts.
Place two long bolts on the left side of the engine and four
intermediate bolts in the interior. Alternately tighten the
bolts to 120-168 in-lbs (13.6-19.0 Nm) in the sequence
shown.

NOTES

•

If the engine was left in the chassis for service, final tighten
the rear left rocker housing bolt (rear cylinder) using a
torque wrench with a 1/4 in. drive.

•

O-rings that are missing, distorted, pinched or otherwise
damaged will result in either oil leakage or low oil pressure.
Use of the wrong o-ring will have the same results. Since
many o-rings are similar in size and appearance, always
use new o-rings, keeping them packaged until use to avoid
confusion.

9.

See 

Figure 3-39

. Apply a very thin film of clean H-D 20W50

engine oil to new baffle hole o-ring (2). Install new o-ring
in groove around breather baffle hole in rocker housing.

NOTE

Do not confuse breather baffle hole o-ring (Part No. 11270,
large inner diameter) with the top push rod o-ring (Part No.
11293, small inner diameter).

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2009 Dyna Service:  Engine  3-41