Harley Davidson 2009 Dyna Models. Service manual

Refer to

. Install the push rods in their original

positions. Be sure to remove any tags that may have been
used for identification.

. For example, if reassembling the

rear cylinder, slide the intake push rod (silver) through
the front hole in the rocker housing engaging the lifter
socket in the inside hole of the lifter cover.

Slide the exhaust push rod (black) through the rear
hole in the rocker housing engaging the lifter socket
in the outside hole of the lifter cover.

Table 3-30. Push Rod/Lifter Locations

CYLINDER

HEAD/ROCKER

HOUSING

BORE

LIFTER BORE

COVER

COVER &

PUSH ROD

CYL-
INDER

Rear

Inside

Intake

Front

Outside

Exhaust

Front

Inside

Intake

Rear

Outside

Exhaust

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Cover

Gasket

Ribs on cover

Anti-rotational pin

Figure 3-40. Installing Lifters

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Front cylinder exhaust push rod

Front cylinder intake push rod

Rear cylinder intake push rod

Rear cylinder exhaust push rod

Figure 3-41. Push Rod Locations

ROCKER ARM SUPPORT PLATE

Installing the rocker arms and rotating the engine with the valve
train loaded can result in bent push rods, damaged bushings
or a warped support plate.

To install the rocker arm support plate, both lifters of the
cylinder being serviced must be on the base circle (or
lowest position) of the cam. To rotate engine, see

3.17 TOP END OVERHAUL: ASSEMBLY, Rocker Arm
Support Plate

See

Figure 3-42

. Place the rocker arm support plate

assembly into the rocker housing. Loosely install the four
rocker arm support plate bolts with flat washers.

NOTE

If the engine was left in the chassis for service, final tighten
the rocker arm support plate bolt on the rear left side of the
rear cylinder using a 3/8 in. drive torque wrench with a 1/2 in.
flank drive "dog bone" torque adapter (Snap-on FRDH161).
Failure to properly use this combination will overtighten the
bolts causing distortion of the rocker housing.

Tighten rocker arm support plate bolts.

Following the sequence shown, alternately tighten
each of the four rocker arm support plate bolts just
1/4 turn. Continue turning the bolts in these incre-
ments until snug.

Following the same sequence, tighten the bolts to 18-
22 ft-lbs (24.4-29.8 Nm).

Lift up lower push rod covers and verify that both push
rods spin freely.

NOTE

Always service each cylinder separately. After the first cylinder
is serviced the engine must be rotated to find the base circle
on the second cam. Service on the remaining cylinder can then
proceed.

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2009 Dyna Service: Engine 3-43

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Figure 3-42. Rocker Arm Torque Sequence

Complete installation of the push rod covers.

Verify that the o-ring ends of the upper and lower
push rod covers fit snugly into the cylinder head and
lifter cover bores.

Insert the upper edge of spring cap retainer into the
cylinder head bore leaving the bottom edge free.

Insert blade of small screwdriver between bottom
edge of spring cap retainer and top of spring cap.

NOTE

For best results, be sure that screwdriver, spring cap and
spring cap retainer are free of grease and oil.

See

Figure 3-43

. While simultaneously depressing

spring cap with tip of screwdriver, use forefinger to
slide bottom edge of spring cap retainer down shaft
towards tip of screwdriver blade. As spring cap
reaches its full length of travel, spring cap retainer
should be in approximate position against upper push
rod cover.

Verify that spring cap retainer is seated tightly against
upper push rod cover.

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Figure 3-43. Install Spring Cap Retainers

BREATHER ASSEMBLY

NOTE

For breather assembly service procedures, see

3.20 BREATHER ASSEMBLY

See

Figure 3-45

. Alternately tighten the two bolts to secure

breather assembly to 90-120 in-lbs (10.2-13.6 Nm).

See

Figure 3-44

. Install a new rocker cover gasket with

indent facing forward on the rocker housing flange. Place
the rocker cover into position aligning the holes in the
cover with those in the gasket.

NOTE

If the engine was left in the chassis for service, final tighten
the three rocker cover bolts on the left side of the rear cylinder
using a 3/8 in. drive torque wrench with a 7/16 in. flank drive
"dog bone" torque adapter (Snap-on FRDH141). Failure to
properly use this combination will overtighten the bolts causing
distortion of the rocker cover.

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3-44 2009 Dyna Service: Engine