Content .. 7 8 9 10 ..

Harley Davidson 2009 Dyna Models. Service manual - page 9

2.3

VEHICLE IDENTIFICATION NUMBER (V.I.N.)

GENERAL

See

Figure 2-1

. The full 17 digit serial, or Vehicle Identification

Number (V.I.N.) is stamped on the right side of the steering
head and on a label located on the right side down tube.

An abbreviated V.I.N. is stamped on the left side crankcase at
the base between the cylinders.

Sample V.I.N. as it appears on the steering head -
1HD1GN4178K111000

Sample abbreviated V.I.N. as it appears on the left crankcase
GP48300000

NOTE

Always give the full 17 digit Vehicle Identification Number when
ordering parts or making any inquiry about your motorcycle.

sm02716

Stamping

Label

Figure 2-1. V.I.N. Location

1 HD 1 GN 4 1 7 9 K 111000

om00921

Figure 2-2. Typical Harley-Davidson V.I.N.: 2009 Dyna Models

Table 2-8. Harley-Davidson 2009 Dyna Model V.I.N. Description

POSSIBLE VALUES

DESCRIPTION

ITEM

1=Originally manufactured for sale within the United States

Market designation

5=Originally manufactured for sale outside of the United States

HD=Harley-Davidson

Manufacturer and make

1=Heavyweight motorcycle 901 cc and larger

Motorcycle type

See model V.I.N. table

Model

4=Twin cam 96, 1584cc air cooled, fuel injected

Engine type

1=Regular

Introduction date

2=Mid-year
3=California/regular
4=Cosmetic changes and/or special introductory date
5=California/cosmetic changes and/or special introductory date
6=California/mid-year

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2009 Dyna Service: Chassis 2-7

Table 2-8. Harley-Davidson 2009 Dyna Model V.I.N. Description

POSSIBLE VALUES

DESCRIPTION

ITEM

Can be 0-9 or X

V.I.N. check digit

8=2009

Model year

K=Kansas City, MO., U.S.A.

Plant of manufacture

varies

Sequential number (last 6 digits)

Table 2-9. V.I.N. Model Codes: 2009 Dyna Models

MODEL

CODE

MODEL

CODE

FXDB Street Bob

™

FXD Dyna Super Glide

FXDF Fat Bob

™

FXDC Dyna Super Glide Custom

FXDL Dyna Low Rider

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2-8 2009 Dyna Service: Chassis

2.4

FRONT WHEEL

REMOVAL

NOTE

Care must be taken when removing and installing wheel to
prevent cosmetic damage to wheel. This is especially true with
wheels that feature painted surfaces.

Block motorcycle underneath frame so front wheel is raised
off the ground.

Inspect wheel bearing end play and service bearings if
necessary. See

2.6 SEALED WHEEL BEARINGS

See

Figure 2-3

. Remove mounting bolts (1, 2) and remove

brake caliper. Support caliper using a rubber bungee cord.

NOTE

Do not operate front brake lever with the front wheel removed
or the caliper piston may be forced out of piston bore.
Reseating the piston requires disassembly of the caliper.

Remove axle nut and washer (3).

See

Figure 2-4

. Loosen the slider cap screws (2) and pull

the axle (1) free.

Remove wheel from forks.

sm03766

Long mounting bolt

Short mounting bolt

Axle nut and washer

Figure 2-3. Front Caliper and Axle Mounting (Left Side)

sm03767

Axle

Slider cap screws and washers

Figure 2-4. Front Wheel Mounting (Right Side)

DISASSEMBLY

NOTE

To service tire or valve stem assembly, see

2.17 TIRES

Cast Wheel

See

Figure 2-5

. Remove spacers (2, 6) from left and right

sides.

If necessary, remove brake disc (8). On left side of wheel,
remove five screws (3) and washers (4) to detach brake
disc (8). Discard screws.

Cast Wheel, Dual Brakes

See

Figure 2-6

. Remove spacers (2, 9) from left and right

sides.

If necessary, remove brake discs (7). Remove five screws
(8) to detach each brake disc (7). Discard screws.

Laced Wheel

See

Figure 2-7

. Remove spacers (2, 9) from left and right

sides.

If necessary, remove brake disc(s) (8). On left side of
wheel, remove five screws (3) to detach brake disc (8).
Discard screws.

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2009 Dyna Service: Chassis 2-9

sm02230

Cast wheel

Axle

Right bearing spacer

Brake disc

Left bearing spacer

Screw (5)

10.

Washer (5)

Washer

11.

Axle nut

Bearing (2)

Sleeve

Figure 2-5. Cast Front Wheel

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2-10 2009 Dyna Service: Chassis

sm04025

Left bearing spacer

Axle

Right bearing spacer

Brake disc

Screw (5)

Bearing (2)

Sleeve

Washer

10.

Axle nut

Disc wheel

Figure 2-6. Cast Front Wheel Components (FXDF)

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2009 Dyna Service: Chassis 2-11

sm02231

10.

Washer

Axle

11.

Right bearing spacer

Hubcap (not on FXD)

12.

Axle nut

Screw (5)

13.

Screw (5)

Valve stem nut

14.

Valve cap

Bearing (2)

15.

Sleeve

Spoke and nipple kit

16.

Balance weight

Wheel hub

17.

Brake disc

Rim

18.

Laced wheel assembly

Left bearing spacer

Figure 2-7. Laced Front Wheel

CLEANING AND INSPECTION

Inspect all parts for damage or excessive wear.

Inspect brake rotor and pads. See

1.17 BRAKE PADS

AND DISCS

ASSEMBLY

Be sure that brake fluid or other lubricants do not contact
brake pads or discs. Such contact can adversely affect
braking ability, which could cause loss of control, resulting
in death or serious injury. (00290a)

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2-12 2009 Dyna Service: Chassis

Cast Wheel

See

Figure 2-5

. If necessary, install brake disc (8). Verify

that brake disc is clean.

On left side of wheel, install five new screws (3) and
washers (4) to attach brake disc (8). Tighten fasteners to
16-24 ft-lbs (21.7-32.5 Nm).

FXDF: Install second disc on right side of wheel. Tighten
fasteners to 16-24 ft-lbs (21.7-32.5 Nm).

Install spacers (2, 9) with largest chamfered end facing
away from wheel.

Verify that wheel and tire are true. See

2.11 CHECKING

CAST WHEEL RUNOUT

Laced Wheel

If hub and rim were disassembled, see

2.8 WHEEL

LACING: 19 INCH RIM

2.9 WHEEL LACING: 21 INCH

RIM

See

Figure 2-7

. If necessary, install brake disc (8). Verify

that brake disc is clean.

On left side of wheel, install five new screws (3) to attach
brake disc (8). Tighten fasteners to 16-24 ft-lbs (21.7-32.5
Nm).

Install spacers (2, 9) with largest chamfered end facing
away from wheel.

Verify that wheel and tire are true. See

2.10 TRUING

LACED WHEELS

INSTALLATION

Apply a light coat of LOCTITE ANTI-SEIZE LUBRICANT
to the axle, bearing bores, and the bore of the inner sleeve.

See

Figure 2-8

. Place wheel into front fork and install axle.

Verify that axle spacers (1) on right and left side are
properly installed.

See

Figure 2-9

. Install slider cap with cast-in spacer (1)

toward the rear of the vehicle. Do not tighten fasteners at
this time.

Install the washer, lockwasher, and axle nut. Tighten axle
nut to 60-65 ft-lbs (81.3-88.1 Nm). Hold axle stationary
with a steel rod or screwdriver inserted through hole on
right end of axle while tightening.

Tighten rear axle cap fastener (2) to 10-14 ft-lbs (13.6-
19.0 Nm), then tighten front axle cap fastener (3) to 10-14
ft-lbs (13.6-19.0 Nm).

sm02460

Spacer (2)

Axle nut, lockwasher and washer

Slider cap fasteners

Figure 2-8. Front Axle Assembly

See

Figure 2-3

. Install the brake caliper to the fork legs.

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

Install short mounting bolt (2) (metric) into bottom 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).

Whenever a wheel is installed and before moving the
motorcycle, pump brakes to build brake system pressure.
Insufficient pressure can adversely affect brake perform-
ance, which could result in death or serious injury.
(00284a)

Pump brake hand lever to move pistons out until they
contact both brake pads. Verify piston location against
pads.

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2009 Dyna Service: Chassis 2-13

sm03769

Cast in spacer

Rear axle cap fastener

Front axle cap fastener

Gap

Figure 2-9. Axle Cap Installation

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2-14 2009 Dyna Service: Chassis

2.5

REAR WHEEL

REMOVAL

NOTE

Care must be taken when removing and installing wheel to
prevent cosmetic damage to wheel. This is especially true with
wheels that feature painted surfaces.

Block motorcycle underneath frame so rear wheel is raised
off the ground.

Remove three screws to detach the debris deflector from
rear fork. See

2.21 DEBRIS DEFLECTOR

Inspect wheel bearing end play and service bearings if
necessary. See

2.6 SEALED WHEEL BEARINGS

See

Figure 2-10

. Remove retaining ring (3), axle nut (2),

and washer from left side of axle.

Loosen adjuster on each side several turns to remove belt
tension.

See

Figure 2-11

. Loosen, but do not remove, left and right

upper mounting nuts (1).

Remove left and right lower shock mounting screws (2).

Allow rear fork and wheel to lower.

Remove belt guard. See

2.20 BELT GUARD

10. Pry brake pads away from rotor and remove retaining pin

and brake pads. See

1.17 BRAKE PADS AND DISCS

NOTE

Caliper to rear wheel clearance is minimal. To prevent damage
to surfaces, be careful when removing caliper from rear fork.

11. Remove caliper assembly from caliper mount. Support

caliper with an elastic cord. See

2.16 REAR BRAKE

CALIPER

NOTE

Spacer and caliper mount may fall out when axle is removed.

12. Remove axle from wheel.

13. Move wheel forward and slip belt off sprocket.

14. Pull wheel and belt sprocket from rear fork.

NOTE

Do not operate rear brake pedal with the rear wheel removed
or the caliper piston may be forced out of piston bores.
Reseating the piston requires disassembly of the caliper.

sm03754

Axle adjuster

Axle nut

Retaining ring

Figure 2-10. Axle Adjusters (Left Side Shown)

sm03770

Upper mounting nut (2)

Lower mounting screw (2)

Figure 2-11. Rear Shock Mount

DISASSEMBLY

NOTE

With the exception of the sprocket cover, component parts for
cast and laced rear wheels are identical.

See

Figure 2-12

. Remove spacers (2, 10) from left and

right sides.

If necessary, remove brake disc and/or rear sprocket.

On left side of wheel, remove five screws (14) and
washers (15) to detach rear sprocket (9). Discard
screws.

On right side of wheel, remove five screws (3) to
remove rear brake disc (4).Discard screws.

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2009 Dyna Service: Chassis 2-15

15 14

sm02233

Rear sprocket

Axle

10.

Right bearing spacer

Left bearing spacer

11.

Washer

Screw (5)

12.

Rear brake disc

Axle nut

13.

Retaining ring

Bearing (2)

14.

Sleeve

Screw (5)

15.

Washer (5)

Cast wheel

Laced wheel hub and rim

Figure 2-12. Rear Wheel/Hub

CLEANING AND INSPECTION

Inspect all parts for damage or excessive wear.

Inspect brake disc and pads. See

1.17 BRAKE PADS AND

DISCS

Inspect rear belt and sprocket. See

1.13 REAR BELT AND

SPROCKETS

ASSEMBLY

Do not re-use sprocket mounting screws. Re-using
sprocket mounting screws can result in torque loss and
damage to the sprocket and/or belt assembly. (00480b)

If hub and rim were disassembled, see

. Using new screws (3), install brake disc

(4) on wheel if removed.

Tighten screws to 30-45 ft-lbs (40.7-61.0 Nm).

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2-16 2009 Dyna Service: Chassis

Using new screws (14), install belt sprocket (9) if removed.

Tighten screws to 55-65 ft-lbs (74.6-88.1 Nm).

Verify that wheel and tire are true.

For laced wheels, see

2.10 TRUING LACED

WHEELS

For cast wheels, see

2.11 CHECKING CAST WHEEL

RUNOUT

INSTALLATION

Apply a light coat of LOCTITE ANTI-SEIZE LUBRICANT
to the axle, bearing bores, and the bore of the inner sleeve.

Roll wheel into rear fork and position brake caliper mount
between wheel and fork. Ensure notch in caliper mount is
engaged with tab on fork.

Slide drive belt over drive sprocket. Make sure brake disc
is centered between brake pads.

Install axle:

From right side, carefully insert axle through right rear
fork and rear caliper bracket.

Continue sliding axle through wheel hub sleeve,
sprocket, left side spacer and left rear fork.

NOTE

Caliper to rear wheel clearance is minimal. To prevent damage
to surfaces, be careful when installing caliper.

Install caliper assembly to rear fork. See

2.16 REAR

BRAKE CALIPER

Install brake pads and retaining pin. See

. Attach rear shocks.

Apply two or three drops of LOCTITE THREAD-
LOCKER 243 (blue) to threads of lower shock
mounting screws (2).

Lift rear fork and install both shock absorbers with
lower shock mounting screws (2).

Tighten upper shock nuts to 30-40 ft-lbs (40.7-54.2
Nm).

Tighten lower shock fasteners to 30-40 ft-lbs (40.7-
54.2 Nm).

Check wheel bearing end play after tightening axle nut to
specified torque. Excessive end play can adversely affect
stability and handling. Insufficient end play can cause
bearing seizure. Either condition can cause loss of control,
which could result in death or serious injury. (00285a)

Do not exceed specified torque when tightening axle nut.
Exceeding torque can cause wheel bearings to seize during
vehicle operation, which could result in death or serious
injury. (00408e)

See

Figure 2-10

. Install washer and axle nut (2) on left

side of axle.

Tighten axle nut to 95-105 ft-lbs (128.8-142.4 Nm).

Install retaining ring (1).

Install debris deflector using three screws. Tighten to 40-60
in-lbs (4.5-6.8 Nm). See

2.21 DEBRIS DEFLECTOR

10. Install belt guard. See

2.20 BELT GUARD

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

both brake pads. Verify piston location against pads.

12. Verify correct axle alignment. See

2.12 VEHICLE ALIGN-

MENT

13. Check belt deflection. See

1.14 REAR BELT DEFLEC-

TION

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2009 Dyna Service: Chassis 2-17

2.6

SEALED WHEEL BEARINGS

INSPECTION

Block motorcycle underneath frame, so that the wheel is
raised off the ground.

Turn the wheel through several rotations.

See

Figure 2-13

. Mount a magnetic base dial indicator to

the brake disc with the dial contact point on the end of the
axle.

Move the wheel from side to side to check end play.

Bearing passes inspection if the end play is less than
0.002 in. (0.051 mm).

Replace the bearings if end play is not within specific-
ation, or if there is drag, rough rotation, abnormal
noise or anything unusual.

sm02234

Figure 2-13. Wheel Bearing Inspection (Front Wheel

Shown)

REMOVAL

TOOL NAME

PART NUMBER

25 MM COLLET

HD-44060-10

WHEEL BEARING
INSTALLER/REMOVER

HD-44060A

Remove wheel from motorcycle. See

2.4 FRONT WHEEL

If present, remove hub plate from wheel on opposite side
of front brake disc.

NOTE

See

Figure 2-15

. Some wheel hubs may not provide adequate

support for the puller bridge. In these cases center a used
brake disc over the hub to support the puller bridge while
removing the bearings.

See

Figure 2-14

. Obtain WHEEL BEARING

INSTALLER/REMOVER (Part No. HD-44060A) and

assemble using 25 MM COLLET (Part No. HD-44060-10)
(6).

Sparingly apply graphite lubricant to threads of forcing
screw (1) to prolong service life and provide smooth
operation.

Install nut (2), washer (3) and Nice bearing (4) on
screw. Insert assembly through hole in bridge (5).

Drop ball bearing inside 25 mm collet (6). Fasten
collet and ball bearing to forcing screw.

Hold end of forcing screw and turn collet to expand edges
of collet.

See

Figure 2-16

. When expanded collet has gripped

bearing edges, hold end of forcing screw and turn the nut
to remove bearing from wheel.

Remove spacer from inside wheel hub.

Repeat procedure for opposite side bearing. Discard all
bearings upon removal.

sm02235

Forcing screw

Nut

Washer

Nice bearing

Bridge

Collet with ball bearing inside

Figure 2-14. Removal Tool

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2-18 2009 Dyna Service: Chassis

SM03870

Figure 2-15. Brake Disk as Puller Aid

sm02236

Forcing screw

Nut

Figure 2-16. Remove Bearing

INSTALLATION

TOOL NAME

PART NUMBER

WHEEL BEARING
INSTALLER/REMOVER

HD-44060A

NOTE

Install first bearing on primary brake disc side of hub, which is
identified by having one or two grooves cut into the disc
mounting surface.

Obtain WHEEL BEARING INSTALLER/REMOVER (Part
No. HD-44060A) and assemble.

Sparingly apply graphite lubricant to threads of
threaded rod to prolong service life and verify smooth
operation.

See

Figure 2-17

. Place threaded rod through support

plate. Insert assembly through wheel.

See

Figure 2-18

. Place the new bearing (6) on rod

(1) with lettered side facing away from wheel center-
line.

Install pilot (5), Nice bearing (4), washer (3) and nut
(2) over rod.

Hold hex end of threaded rod (1) and turn nut (2) to install
bearing (6) into primary side of hub. Bearing will be fully
seated when nut can no longer be turned. Remove tool.

Install spacer inside wheel hub.

Reverse tool and install opposite side bearing until bearing
contacts inner spacer.

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2009 Dyna Service: Chassis 2-19

sm02237

Figure 2-17. Installation Tool Support Plate

sm02238

Threaded rod

Nut

Washer

Nice bearing

Pilot

Wheel bearing

Figure 2-18. Installing Bearing

sm02239

Bridge, Part No. HD-44060-5

Steel ball, Part No. 12547

Forcing screw, Part No. HD-44060-4

Nut, Part No. 10210

Washer, Part No. 12004

Nice bearing, Part No. 217801

Lubricant, Part No. J-23444A

Collet, 3/4 in., Part No. HD-44060-3A

Collet (ABS), 25 mm, Part No. HD-44060-11

10. Collet, 1.0 in., Part No. HD-44060-7
11. Collet, 25 mm, Part No. HD-44060-10
12. Pilot, 1.0 in., Part No. HD-44060-8
13. Support plate, Part No. HD-44060-1
14. Pilot, 3/4 in., Part No. HD-44060-6
15. Threaded rod, Part No. 280856

Figure 2-19.Wheel Bearing Installer/Remover Components

NOTES

•

Parts 1-7 are common to removal and installation.

•

Parts 8-10 are used for removal only.

•

Parts 11-15 are used for installation only.

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2-20 2009 Dyna Service: Chassis

2.7

WHEEL LACING: 17 INCH RIM

GENERAL

If only rim is to be replaced, tape spokes together to hold pos-
ition on hub and remove spokes from rim. Install taped
hub/spoke assembly to new rim and tighten spokes. Then
remove tape and true wheels.

sm02259

Narrow flange (brake side)

Wide flange (sprocket side)

Figure 2-20. Rim, Hub and Spoke Nipple

PROCEDURE

NOTE

The primary brake disc side of the hub can be identified by
having one or two grooves cut into the disc mounting surface.

See

Figure 2-21

. Place the hub on table with primary brake

disc side up. Insert a spoke in each hole of the lower row.
Angle spokes clockwise.

Center the rim over the hub assembly with the valve stem
hole facing upward.

See

Figure 2-22

. Using any lower row spoke, place the

first spoke into the rim hole to the left of the valve stem
hole on the upper half of the rim centerline.

See

Figure 2-23

. Install the rest of lower row spokes in

every fourth hole.

See

Figure 2-24

. Place the first upper row spoke into the

hub as shown below. Angle the spoke counterclockwise
crossing four lower row spokes. The spoke must enter the
hole to the left of the valve stem hole.

See

Figure 2-25

. Install the remaining nine upper row

spokes into every fourth remaining hole above the rim
centerline.

sm02261

Figure 2-21. Hub: Primary Brake Disc Side Up

sm02262

Figure 2-22. Brake Side Up: Start First Spoke of Bottom

Row

sm02260

Figure 2-23. Brake Side Up: Bottom Row of Spokes Laced

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