Harley Davidson 2009 Dyna Models. Service manual

1.25

CRITICAL FASTENERS

INSPECTION

Inspect critical fasteners at the scheduled service intervals.

Replace any fasteners that are damaged or missing.

Checking Torques on Fasteners

Refer to

Table 1-16

. Attempt to turn the fastener using a torque

wrench set to the minimum torque specification for that
fastener. If the fastener does not rotate, the fastener torque

has been maintained. If the fastener rotates, remove it to
determine if it has a locking agent.

If it has a locking agent, clean all locking material from the
threaded hole. Replace the fastener with a new one or clean
the original fastener threads and apply the appropriate locking
agent (see appropriate procedure). Install and tighten the
fastener to specification.

If the fastener does not have a locking agent, install and tighten
to specification.

Table 1-16. Critical Fasteners: Dyna

TORQUE

FASTENER

SYSTEM

3.9-5.1 Nm

35-45 in-lbs

Upper and lower switch housing screws

Hand controls

6.8-9.0 Nm

60-80 in-lbs

Clutch lever handlebar clamp screws

6.8-9.0 Nm

60-80 in-lbs

Master cylinder handlebar clamp screws

28.5-33.9 Nm

21-25 ft-lbs

Banjo bolts

Brakes

38.0-51.5 Nm

28-38 ft-lbs

Front brake caliper mounting bolts

20.3-22.6 Nm

15-16 ft-lbs

Front brake pad pin/bridge bolt

13.6-18.9 Nm

10-14 ft-lbs

Rear brake caliper mounting bolts

9.0-13.6 Nm

80-120 in-lbs

Rear brake pad pin

21.7-32.5 Nm

16-24 ft-lbs

Brake disc screws, front

40.7-61.0 Nm

30-45 ft-lbs

Brake disc screws, rear

0.7-0.9 Nm

6-8 in-lbs

Reservoir cover screws

40.7-54.2 Nm

30-40 ft-lbs

Rear master cylinder mounting nut

84.1-90.1 Nm

62-67 ft-lbs

Front axle

Axle nuts

128.1-142.4 Nm

95-105 ft-lbs

Rear axle

40.7-47.5 Nm

30-35 ft-lbs

Lower fork pinch bolts

Front fork

13.6-19.0 Nm

10-14 ft-lbs

Axle cap fasteners

40.7-47.5 Nm

30-35 ft-lbs

Upper bracket pinch bolts

16.3-21.7 Nm

12-16 ft-lbs

Handlebar clamp mounting screw

HOME

2009 Dyna Service: Maintenance 1-49

1.26

ENGINE MOUNTS

INSPECTION

See

Figure 1-49

. Check for cracks or tears in the isolator

rubber.

Check stabilizer links for wear.

Check that all engine mount bolts are tight.

Check that all engine mount rivets are not sheared.

Check that the mounts are supporting the weight of the
motor.

sm02288

12.

Bolt

13.

Lockwasher

14.

Washer

15.

Front isolator

Bolt

16.

Spacer

Bolt

17.

Flange nut

Washer (3)

18.

Stabilizer link

Washer

19.

Rear isolator

Washer

20.

Bolt

10.

21.

Flange nut

Bolt

11. Washer

Figure 1-49. Engine Mounts

HOME

1-50 2009 Dyna Service: Maintenance

1.27

STORAGE

GENERAL

If the motorcycle will not be operated for several months, such
as during the winter season, there are several things which
should be done to protect parts against corrosion, to preserve
the battery and to prevent the buildup of gum and varnish in
the fuel system.

This work should be performed following Service Manual pro-
cedures.

PLACING IN STORAGE

TOOL NAME

PART NUMBER

STORAGE COVER

98716-87A

Do not store motorcycle with gasoline in tank within the
home or garage where open flames, pilot lights, sparks or
electric motors are present. Gasoline is extremely flam-
mable and highly explosive, which could result in death
or serious injury. (00003a)

Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)

Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)

Prepare the fuel system by filling fuel tank and adding a
gasoline stabilizer. Use one of the commercially available
gasoline stabilizers following the manufacturer's instruc-
tions.

Run motorcycle until engine is at normal operating temper-
ature. Stop the engine then drain the oil pan, install a new
oil filter, and fill oil pan with the proper grade oil. Check
the transmission lubricant level.

Remove the spark plugs, inject a few squirts of engine oil
into each cylinder and crank the engine 5-6 revolutions.
Install spark plugs.

Inspect rear belt deflection. See

1.14 REAR BELT

DEFLECTION

Inspect rear belt and sprockets. See

1.13 REAR BELT

AND SPROCKETS

Inspect air cleaner filter. See

1.8 AIR CLEANER AND

EXHAUST SYSTEM

Lubricate controls. See

1.23 CABLE AND CHASSIS

LUBRICATION

Inspect operation of all electrical equipment and switches.

Check tire inflation and inspect tires for wear and/or
damage. See

1.9 TIRES AND WHEELS

. If the motorcycle

will be stored for an extended period of time, securely
support the motorcycle under the frame so that all weight
is off the tires.

10. Wash painted and chrome-plated surfaces. Apply a light

film of oil to exposed unpainted surfaces.

Unplug or turn OFF battery charger before connecting
charger cables to battery. Connecting cables with charger
ON can cause a spark and battery explosion, which could
result in death or serious injury. (00066a)

Explosive hydrogen gas, which escapes during charging,
could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks
and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

11. Remove battery from vehicle. Charge battery until the

correct voltage is obtained. Charge the battery every other
month if it is stored at temperatures below 60° F (16° C).
Charge battery once a month if it is stored at temperatures
above 60° F (16° C). See

1.18 BATTERY MAINTENANCE

Unplug or turn OFF battery charger before disconnecting
charger cables from battery. Disconnecting clamps with
charger ON can cause a spark and battery explosion, which
could result in death or serious injury. (00067a)

12. If the motorcycle is to be covered, use a material that will

breathe, such as STORAGE COVER (Part No. 98716-
87A) or light canvas. Plastic materials that do not breathe
promote the formation of condensation, which leads to
corrosion.

REMOVAL FROM STORAGE

The clutch failing to disengage can cause loss of control,
which could result in death or serious injury. Prior to
starting after extended periods of storage, place transmis-
sion in gear and push vehicle back and forth several times
to assure proper clutch disengagement. (00075a)

Charge and install the battery.

Remove and inspect the spark plugs. Replace if neces-
sary.

Clean the air cleaner element.

If fuel tank was drained, fill fuel tank with fresh gasoline.

HOME

2009 Dyna Service: Maintenance 1-51

1.28

TROUBLESHOOTING

GENERAL

The Troubleshooting section of this manual is a guide to
diagnose problems. Read the appropriate sections of this
manual before performing any work. Improper repair and/or
maintenance could result in death or serious injury.
(00528b)

The following check list of possible operating troubles and their
probable causes will be helpful in keeping a motorcycle in good
operating condition. More than one of these conditions may
be causing the trouble and all should be carefully checked.

NOTE

For further troubleshooting information, see the ELECTRICAL
DIAGNOSTIC MANUAL.

ENGINE

Starter Motor Does Not Operate or Does Not
Turn Engine Over

Ignition switch not in ON position.

Engine run switch in OFF position.

Discharged battery, loose or corroded connections
(solenoid chatters).

Starter control circuit, relay, or solenoid faulty.

Electric starter shaft pinion gear not engaging or overrun-
ning clutch slipping.

TSM/TSSM/HFSM Bank Angle Sensor tripped and ignition
switch not cycled OFF then ON.

Engine Turns Over But Does Not Start

Fuel tank empty.

Fouled spark plugs.

Discharged battery, loose or broken battery terminal con-
nections.

Engine lubricant too heavy (winter operation).

NOTE

For cold weather starts, always disengage clutch.

Spark plug cables in bad condition and shorting, cable
connections loose or cables connected to incorrect cylin-
ders.

Loose wire connection at coil, battery or ECM connector.

Ignition timing incorrect due to faulty coil, ECM or sensors
(MAP, CKP and/or TSM/TSSM/HFSM).

Starts Hard

Spark plugs in bad condition or have improper gap or are
partially fouled.

Spark plug cables in bad condition.

Battery nearly discharged.

Loose wire connection at one of the battery terminals, coil
or ECM connector.

Water or dirt in fuel system.

Intake air leak.

Fuel tank vent hose and vapor valve plugged.

Engine lubricant too heavy (winter operation).

NOTE

For cold weather starts, always disengage clutch.

Ignition not functioning properly (possible sensor failure).

10. Faulty ignition coil.

11. Valves sticking.

Starts But Runs Irregularly or Misses

Spark plugs in bad condition or partially fouled.

Spark plug cables in bad condition and leaking.

Spark plug gap too close or too wide.

Faulty ignition coil, ECM, or sensor.

Battery nearly discharged.

Damaged wire or loose connection at battery terminals,
coil or ECM connector.

Intermittent short circuit due to damaged wire insulation.

Water or dirt in fuel system.

Fuel tank vent system plugged.

10. Air leak at intake manifold or air cleaner.

11. Loose or dirty ECM connector.

12. Faulty Sensor(s): Manifold Absolute Pressure (MAP),

Crank Position (CKP) or Oxygen (O2).

13. Incorrect valve timing.

14. Weak or broken valve springs.

15. Damaged intake or exhaust valve.

Spark Plug Fouls Repeatedly

Fuel mixture too rich.

Incorrect spark plug for the kind of service.

Piston rings badly worn or broken.

Valve guides or seals badly worn.

Pre-Ignition or Detonation (Knocks or Pings)

Fuel octane rating too low.

Faulty spark plugs.

Incorrect spark plug for the kind of service.

Excessive carbon deposit on piston head or in combustion
chamber.

HOME

2009 Dyna Service: Maintenance 1-53

Ignition timing advanced due to faulty sensors (MAP and/or
CKP).

Overheating

Insufficient oil supply or oil not circulating.

Insufficient air flow over engine.

Heavy carbon deposit.

Ignition timing retarded due to faulty sensor(s): Manifold
Absolute Pressure (MAP) and/or Crank Position (CKP).

Leaking valve.

Valve Train Noise

Low oil pressure caused by oil feed pump not functioning
properly or oil passages obstructed.

Faulty hydraulic lifters.

Bent push rod(s).

Incorrect push rod length.

Rocker arm binding on shaft.

Valve sticking in guide.

Chain tensioner or shoe worn.

Excessive Vibration

Wheels and/or tires worn or damaged.

Engine/transmission/rear wheel not aligned properly.

Primary chain badly worn or links tight as a result of
insufficient lubrication or misalignment.

Engine to transmission mounting bolts loose.

Upper engine mounting bracket loose.

Ignition timing advanced due to faulty sensor inputs (MAP
and/or CKP)/poorly tuned engine.

Internal engine problem.

Broken frame.

Check Engine Light Illuminates During
Operation

Fault detected. For diagnostic information see the Electrical
Diagnostic Manual.

LUBRICATION SYSTEM

Oil Does Not Return To Oil Pan

Oil pan empty.

Oil pump not functioning.

Restricted oil lines or fittings.

Restricted oil filter.

Oil pump misaligned or in poor condition.

O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).

Engine Uses Too Much Oil Or Smokes
Excessively

Oil pan overfilled.

Restricted oil return line to pan.

Restricted breather operation.

Restricted oil filter.

Oil pump misaligned or in poor condition.

Piston rings badly worn or broken.

Valve guides or seals worn.

O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).

Plugged crankcase scavenge port.

Engine Leaks Oil From Cases, Push Rods,
Hoses, Etc.

Loose parts.

Imperfect seal at gaskets, push rod cover, washers, etc.

Restricted breather hose to air cleaner.

Restricted oil filter.

Oil pan overfilled.

Lower rocker housing gasket installed incorrectly (upside
down).

Restricted oil return line to tank.

Low Oil Pressure

Oil pan underfilled.

Faulty low oil pressure switch.

Oil pump O-ring damaged or missing.

Bypass valve stuck in open position.

Ball missing or leaking in cam support plate.

High Oil Pressure

Oil pan overfilled.

Bypass valve stuck in closed position.

ELECTRICAL SYSTEM

NOTE

For diagnostic information see the ELECTRICAL DIAGNOSTIC
MANUAL.

Alternator Does Not Charge

Voltage regulator module not grounded.

Engine ground wire loose or broken.

Faulty voltage regulator module.

Loose or broken wires in charging circuit.

Faulty stator and/or rotor.

HOME

1-54 2009 Dyna Service: Maintenance

Alternator Charge Rate Is Below Normal

Weak or damaged battery.

Loose connections.

Faulty voltage regulator module.

Faulty stator and/or rotor.

Speedometer Operates Erratically

Contaminated vehicle speed sensor (remove sensor and
clean off metal particles).

Loose connections.

TRANSMISSION

Shifts Hard

Primary chaincase overfilled with lubricant.

Clutch not fully disengaging.

Transmission lubricant too heavy (winter operation).

Shifter return spring (inside transmission) bent or broken.

Bent shifter rod.

Shifter forks (inside transmission) sprung.

Corners worn off shifter clutch dog rings (inside transmis-
sion).

Jumps Out Of Gear

Shifter rod improperly adjusted.

Shifter drum (inside transmission) improperly adjusted or
damaged/worn.

Shifter engaging parts (inside transmission) badly worn
and rounded.

Shifter forks bent.

Damaged gears.

Clutch Slips

Clutch controls improperly adjusted.

Insufficient clutch spring tension.

Worn friction discs.

Clutch Drags Or Does Not Release

Lubricant level too high in primary chaincase.

Clutch controls improperly adjusted.

Primary chain badly misaligned or too tight.

Insufficient clutch spring tension.

Clutch discs warped.

Clutch Chatters

Friction discs or steel discs worn or warped.

HANDLING

Irregularities

Improperly loaded motorcycle. Non-standard equipment
on the front end such as heavy radio receivers, extra
lighting equipment or luggage tends to cause unstable
handling.

Damaged tire(s) or improper front-rear tire combination.

Irregular or peaked front tire tread wear.

Incorrect tire pressure.

Shock absorber not functioning normally.

Loose wheel axle nuts. Tighten to recommended torque
specification.

Excessive wheel hub bearing play.

Rear wheel out of alignment with frame and front wheel.

Steering head bearings improperly adjusted. Correct
adjustment and replace pitted or worn bearings and races.

10. Loose spokes (laced wheel vehicles only).

11. Tire and wheel unbalanced.

12. Rims and tires out-of-round or eccentric with hub.

13. Rims and tires out-of-true sideways.

14. Rear fork pivot.

BRAKES

Brake Does Not Hold Normally

Master cylinder reservoir low on fluid, system leaking or
pads worn.

Brake system contains air bubbles.

Master cylinder or caliper piston seals worn or parts
damaged.

Brake pads contaminated with grease or oil.

Brake pads badly worn.

Brake disc badly worn or warped.

Brake drags - insufficient brake pedal or hand lever free-
play, caliper piston worn or damaged, or excessive brake
fluid in reservoir.

Brake fades due to heat build up - brake pads dragging
or excessive braking.

Brake fluid leak when under pressure.

HOME

2009 Dyna Service: Maintenance 1-55

4.1

FASTENER TORQUE VALUES

FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

NOTES

TORQUE VALUE

FASTENER

4.5 AIR CLEANER ASSEMBLY, Installation

4.5-6.8 Nm

40-60 in-lbs

Air cleaner cover bracket screw

4.5 AIR CLEANER ASSEMBLY, Installation

4.1-6.8 Nm

36-60 in-lbs

Air cleaner cover screw

4.5 AIR CLEANER ASSEMBLY, Installation/metric

29.8-32.5 Nm

22-24 ft-lbs

Breather bolts

4.9 ENGINE TEMPERATURE SENSOR
(ET), Installation/Hand start 2-3 turns

13.6-20.3 Nm

10-15 ft-lbs

Engine temperature sensor

4.17 EXHAUST SYSTEM, Installation: All but FXDF

11.3-13.6 Nm

100-120 in-lbs

Exhaust flange nut (lower front cylinder)

4.17 EXHAUST SYSTEM, Installation: FXDF

11.3-13.6 Nm

100-120 in-lbs

Exhaust flange nut (lower front cylinder)

4.17 EXHAUST SYSTEM, Installation: All but FXDF

11.3-13.6 Nm

100-120 in-lbs

Exhaust flange nut (lower rear cylinder)

4.17 EXHAUST SYSTEM, Installation: FXDF

11.3-13.6 Nm

100-120 in-lbs

Exhaust flange nut (lower rear cylinder)

4.17 EXHAUST SYSTEM, Installation: All but FXDF

11.3-13.6 Nm

100-120 in-lbs

Exhaust flange nut (upper front cylinder,
final torque)

4.17 EXHAUST SYSTEM, Installation: FXDF

11.3-13.6 Nm

100-120 in-lbs

Exhaust flange nut (upper front cylinder,
final torque)

4.17 EXHAUST SYSTEM, Installation: All but FXDF

1-2 Nm

9-18 in-lbs

Exhaust flange nut (upper front cylinder,
initial torque)

4.17 EXHAUST SYSTEM, Installation: FXDF

1-2 Nm

9-18 in-lbs

Exhaust flange nut (upper front cylinder,
initial torque)

4.17 EXHAUST SYSTEM, Installation: All but FXDF

11.3-13.6 Nm

100-120 in-lbs

Exhaust flange nut (upper rear cylinder,
final torque)

4.17 EXHAUST SYSTEM, Installation: FXDF

11.3-13.6 Nm

100-120 in-lbs

Exhaust flange nut (upper rear cylinder,
final torque)

4.17 EXHAUST SYSTEM, Installation: All but FXDF

1-2 Nm

9-18 in-lbs

Exhaust flange nut (upper rear cylinder,
initial torque)

4.17 EXHAUST SYSTEM, Installation: FXDF

1-2 Nm

9-18 in-lbs

Exhaust flange nut (upper rear cylinder,
initial torque)

4.14 FUEL INJECTORS, Installation

10.2-12.4 Nm

90-110 in-lbs

Fuel supply tube fastener

4.6 FUEL TANK, Installation/Front and rear

20.3-27.1 Nm

15-20 ft-lbs

Fuel tank mounting fasteners

4.8 INTAKE AIR TEMPERATURE SENSOR
(IAT), Installation

1.7-2.3 Nm

15-20 in-lbs

Intake air temperature sensor fastener

4.10 INDUCTION MODULE, Installation

10.8-16.3 Nm

96-144 in-lbs

Intake manifold mounting screws

4.17 EXHAUST SYSTEM, Installation: FXDF

20.3-25.8 Nm

15-19 ft-lbs

Muffler bracket bolt

4.17 EXHAUST SYSTEM, Installation: FXDF

20.3-25.8 Nm

15-19 ft-lbs

Muffler bracket flange nuts

4.17 EXHAUST SYSTEM, Installation: All but FXDF

51.6-58.4 Nm

38-43 ft-lbs

Muffler clamp nuts

4.17 EXHAUST SYSTEM, Installation: FXDF

51.6-58.4 Nm

38-43 ft-lbs

Muffler clamp nuts

4.17 EXHAUST SYSTEM, Installation: FXDF

20.3-25.8 Nm

15-19 ft-lbs

Muffler mounting bolt

4.17 EXHAUST SYSTEM, Installation: All but FXDF

20.3-25.8 Nm

15-19 ft-lbs

Muffler support bracket nuts

4.13 OXYGEN SENSOR, Installation

39.3-59.7 Nm

29-44 ft-lbs

Oxygen sensor

4.11 IDLE AIR CONTROL (IAC), Installation

2.3-4.0 Nm

20-35 in-lbs

Throttle cable bracket fasteners

4.12 MANIFOLD ABSOLUTE PRESSURE
SENSOR (MAP), Installation/Use new screws

2.3-4.0 Nm

20-35 in-lbs

Throttle cable bracket fasteners

4.7 THROTTLE POSITION SENSOR
(TPS), Installation

2.0 Nm

18 in-lbs

Throttle position sensor fasteners

HOME

2009 Dyna Service: Fuel System 4-1

2.1

FASTENER TORQUE VALUES

FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

NOTES

TORQUE VALUE

FASTENER

2.4 FRONT WHEEL, Installation

13.6-19.0 Nm

10-14 ft-lbs

Axle cap fastener

2.4 FRONT WHEEL, Installation

13.6-19.0 Nm

10-14 ft-lbs

Axle cap fastener

2.20 BELT GUARD, Installation

13.6-20.3 Nm

10-15 ft-lbs

Belt guard fastener

2.20 BELT GUARD, Installation

13.6-20.3 Nm

10-15 ft-lbs

Belt guard fastener

2.5 REAR WHEEL, Assembly

74.6-88.1 Nm

55-65 ft-lbs

Belt sprocket screws

2.14 FRONT BRAKE CALIPER, Assembly

20.3-22.6 Nm

15-16 ft-lbs

Brake bridge bolt/pad pin, front caliper

2.13 FRONT BRAKE MASTER CYL-
INDER, Assembly and Installation

23.1-29.9 Nm

17-22 ft-lbs

Brake caliper/master cylinder banjo bolt

2.14 FRONT BRAKE CALIPER, Assembly

9.0-11.3 Nm

80-100 in-lbs

Brake caliper bleeder valve

2.16 REAR BRAKE CALIPER, Assembly

9.0-11.3 Nm

80-100 in-lbs

Brake caliper bleeder valve

2.14 FRONT BRAKE CALIPER, Assembly

38.0-51.5 Nm

28-38 ft-lbs

Brake caliper bridge bolt, front

2.4 FRONT WHEEL, Installation

38.0-51.5 Nm

28-38 ft-lbs

Brake caliper mounting bolt, front

2.4 FRONT WHEEL, Installation

38.0-51.5 Nm

28-38 ft-lbs

Brake caliper mounting bolt, front

2.16 REAR BRAKE CALIPER, Installation

13.6-18.9 Nm

10-14 ft-lbs

Brake caliper mounting bolt, rear

2.4 FRONT WHEEL, Assembly

21.7-32.5 Nm

16-24 ft-lbs

Brake disc screws, front

2.4 FRONT WHEEL, Assembly

21.7-32.5 Nm

16-24 ft-lbs

Brake disc screws, front

2.4 FRONT WHEEL, Assembly

21.7-32.5 Nm

16-24 ft-lbs

Brake disc screws, front

2.5 REAR WHEEL, Assembly

40.7-61.0 Nm

30-45 ft-lbs

Brake disc screws, rear

2.13 FRONT BRAKE MASTER CYL-
INDER, Assembly and Installation

0.7-0.9 Nm

6-8 in-lbs

Brake master cylinder reservoir cover
screws

2.16 REAR BRAKE CALIPER, Assembly

9.0-13.6 Nm

80-120 in-lbs

Brake pad pin, rear caliper

2.14 FRONT BRAKE CALIPER, Installation

0.7-0.9 Nm

6-8 in-lbs

Brake reservoir cover screws, front

2.15 REAR BRAKE MASTER CYLINDER, Installa-
tion

0.7-0.9 Nm

6-8 in-lbs

Brake reservoir cover screws, rear

2.5 REAR WHEEL, Installation

4.5-6.8 Nm

40-60 in-lbs

Debris deflector screws

2.21 DEBRIS DEFLECTOR, Installation

4.5-6.8 Nm

40-60 in-lbs

Debris deflector screws

2.32 ENGINE MOUNTS, Installation

28-36 Nm

21-27 ft-lbs

Engine mount bolt

2.32 ENGINE MOUNTS, Installation

28-36 Nm

21-27 ft-lbs

Engine mount flange nut

2.32 ENGINE MOUNTS, Installation

28-36 Nm

21-27 ft-lbs

Engine mount flange nut

2.32 ENGINE MOUNTS, Installation

28-36 Nm

21-27 ft-lbs

Engine mount flange nut

2.19 STEERING HEAD, Installation/Anti-seize

94.9-108.4 Nm

70-80 ft-lbs

Fork stem nut

2.18 FRONT FORK, Assembly

22-58 Nm

16-43 ft-lbs

Fork tube caps

2.4 FRONT WHEEL, Installation

81.3-88.1 Nm

60-65 ft-lbs

Front axle nut

2.14 FRONT BRAKE CALIPER, Installation

38.0-51.5 Nm

28-38 ft-lbs

Front brake caliper lower mounting bolt

2.14 FRONT BRAKE CALIPER, Installation

38.0-51.5 Nm

28-38 ft-lbs

Front brake caliper upper mounting bolt

2.14 FRONT BRAKE CALIPER, Installation

23.1-29.9 Nm

17-22 ft-lbs

Front caliper banjo bolt

2.28 FRONT FENDER, Installation

20.3-28.5 Nm

15-21 ft-lbs

Front fender nuts

2.18 FRONT FORK, Assembly

12-18 Nm

106-159 in-lbs

Front fork seat pipe screw

HOME

2009 Dyna Service: Chassis 2-1

NOTES

TORQUE VALUE

FASTENER

2.13 FRONT BRAKE MASTER CYL-
INDER, Assembly and Installation

6.8-9.0 Nm

60-80 in-lbs

Handlebar switch clamp screw

2.13 FRONT BRAKE MASTER CYL-
INDER, Assembly and Installation

4.0-5.1 Nm

35-45 in-lbs

Handlebar switch housing screw

2.12 VEHICLE ALIGNMENT, Inspection

33.9 Nm

25 ft-lbs

Isolator mounting bolts

2.31 JIFFY STAND, Cleaning

25.8 Nm

19 ft-lbs

Jiffy stand bolt

2.31 JIFFY STAND, Sensor (HDI Models)

10.8-16.3 Nm

96-144 in-lbs

Jiffy stand sensor screw

2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation

40.7-54.2 Nm

30-40 ft-lbs

Lower handlebar clamp fastener

2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation

40.7-54.2 Nm

30-40 ft-lbs

Lower handlebar clamp fastener

2.27 HANDLEBARS: FXDB/FXDF, Installation

40.7-54.2 Nm

30-40 ft-lbs

Lower handlebar clamp fastener

2.15 REAR BRAKE MASTER CYLINDER, Installa-
tion

28.5-33.9 Nm

21-25 ft-lbs

Master cylinder banjo bolt, rear

2.15 REAR BRAKE MASTER CYLINDER, Installa-
tion

40.7-54.2 Nm

30-40 ft-lbs

Master cylinder mounting nut, rear

2.18 FRONT FORK, Installation

41-48 Nm

30-35 ft-lbs

Pinch bolts

2.24 REAR FORK, Installation

96.3-101.7 Nm

71-75 ft-lbs

Pivot shaft nut

2.5 REAR WHEEL, Installation

128.8-142.4 Nm

95-105 ft-lbs

Rear axle nut

2.16 REAR BRAKE CALIPER, Installation

28.5-33.9 Nm

21-25 ft-lbs

Rear caliper banjo bolt

2.29 REAR FENDER, FXDF

16.3-24.4 Nm

12-18 ft-lbs

Rear fender cover screw

2.29 REAR FENDER, FXD, FXDC, and FXDL
Models

16.3-24.4 Nm

12-18 ft-lbs

Rear fender screw

2.29 REAR FENDER, FXDB Models

16.3-24.4 Nm

12-18 ft-lbs

Rear fender screw

2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation

5.6-6.8 Nm

50-60 in-lbs

Riser cover fastener

2.30 SEAT, Installation

6.78-10.17 Nm

60-90 in-lbs

Seat strap nut

2.5 REAR WHEEL, Installation

40.7-54.2 Nm

30-40 ft-lbs

Shock mounting fastener, lower

2.23 REAR SHOCK ABSORBERS, Installation/Loc-
tite Threadlocker 343 (blue)

40.7-54.2 Nm

30-40 ft-lbs

Shock mounting fastener, lower

2.5 REAR WHEEL, Installation

40.7-54.2 Nm

30-40 ft-lbs

Shock mounting fastener, upper

2.23 REAR SHOCK ABSORBERS, Installation/Loc-
tite Threadlocker 343 (blue)

40.7-54.2 Nm

30-40 ft-lbs

Shock mounting fastener, upper

2.23 REAR SHOCK ABSORBERS, Installation

101.7-115.2 Nm

70-85 ft-lbs

Shock mounting stud nut, inner

2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation

5.6-6.8 Nm

50-60 in-lbs

Speedometer cover fastener

2.7 WHEEL LACING: 17 INCH RIM, Procedure

6.2 Nm

55 in-lbs

Spoke nipple

2.8 WHEEL LACING: 19 INCH RIM, Procedure

6.2 Nm

55 in-lbs

Spoke nipple

2.9 WHEEL LACING: 21 INCH RIM, Procedure

6.2 Nm

55 in-lbs

Spoke nipple

2.10 TRUING LACED WHEELS, Radial Truing

6.2 Nm

55 in-lbs

Spoke nipple

2.22 THROTTLE CONTROL, Assembly/Installation

4.0-5.1 Nm

35-45 in-lbs

Throttle housing screws

2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation

16.3-21.7 Nm

12-16 ft-lbs

Upper handlebar clamp fastener

2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation

16.3-21.7 Nm

12-16 ft-lbs

Upper handlebar clamp fastener

2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation

16.3-21.7 Nm

12-16 ft-lbs

Upper handlebar clamp fastener

2.26 HANDLEBARS: ALL BUT
FXDB/FXDF, Installation

16.3-21.7 Nm

12-16 ft-lbs

Upper handlebar clamp fastener

HOME

2-2 2009 Dyna Service: Chassis

2.2

SPECIFICATIONS

Chassis Specifications

Table 2-1. Dimensions: 2009 Dyna Models

FXDF

FXDB

FXDL

FXDC

FXD

ITEM

IN.

1619.76

63.77

1630.68

64.20

1640.89

64.60

1630.68

64.20

1630.68

64.20

Wheel base

2329.94

91.73

2357.12

92.80

2364.74

93.10

2359.66

92.90

2357.12

92.80

Overall length

889.76

35.03

952.50

37.50

922.02

36.30

988.06

38.90

932.18

36.70

Overall width

124.99

4.92

124.97

4.92

124.97

4.92

135.13

5.32

135.13

5.32

Road clearance

1131.82

44.56

1280.16

50.40

1193.80

47.00

1211.58

47.70

1188.72

46.80

Overall height

662.94

26.10

649.22

25.56

655.32

25.80

680.72

26.80

675.64

26.60

Saddle height*

*With 180 lb. (81.6 kg) rider on seat.

Table 2-2. Capacities: 2009 Dyna Models

FXDF

FXDB

FXDL

FXDC

FXD

ITEM

LITERS

U.S.

LITERS

U.S.

LITERS

U.S.

LITERS

U.S.

LITERS

U.S.

18.93

5.00 gal

18.17

4.80 gal

18.17

4.80 gal

18.93

5.00 gal

18.17

4.80 gal

Fuel tank (total)

2.84

3.00 qt.

2.84

3.00 qt.

2.84

3.00 qt.

2.84

3.00 qt.

2.84

3.00 qt.

Oil tank with filter

0.95

1.00 qt.

0.95

1.00 qt.

0.95

1.00 qt.

0.95

1.00 qt.

0.95

1.00 qt.

Transmission
(approximate)

0.95

1.00 qt.

0.95

1.00 qt.

0.95

1.00 qt.

0.95

1.00 qt.

0.95

1.00 qt.

Primary chaincase
(approximate)

3.41

0.90 gal

3.41

0.90 gal

3.41

0.90 gal

3.41

0.90 gal

3.41

0.90 gal

Low fuel warning
light on

Table 2-3. Weights: 2009 Dyna Models

FXDF

FXDB

FXDL

FXDC

FXD

ITEM

LB.

303.77

669.70

287.58

634.00

290.75

641.00

292.57

645.00

286.67

632.00

Weight (as shipped
from factory)

492.15

1085.00

492.15

1085.00

492.15

1085.00

492.15

1085.00

492.15

1085.00

GVWR

176.90

390.00

176.90

390.00

176.90

390.00

176.90

390.00

176.90

390.00

GAWR front

315.25

695.00

315.25

695.00

315.25

695.00

315.25

695.00

315.25

695.00

GAWR rear

NOTES

•

Gross vehicle weight rating (GVWR) (maximum allowable
loaded vehicle weight) and corresponding gross axle

weight rating (GAWR) are given on a label located on the
frame steering head.

•

For important information regarding tire data and tire
inflation, see

1.9 TIRES AND WHEELS

HOME

2-4 2009 Dyna Service: Chassis

Tire Specifications

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)

Tire sizes are molded on the sidewall. Refer to the tire fitment
tables below. Rim size and contour are cast or stamped into
the exterior surface of the rim.

Example: T19 x 2.15 MT DOT. "T" indicates that the rim con-
forms to Tire and Rim Association standards. The "19" is the
normal diameter of the rim in inches, measured at the bead
seat diameter. The "2.15" is the width of the bead seat meas-
ured in inches. "MT" designates the rim contour. "DOT" means
that the rim meets Department of Transportation Federal Motor
Vehicle Safety Standards.

Table 2-4. Tire Fitment - Tubeless Cast Wheels

Tire Size

Rim Valve Hole Dia.

Rim Size & Contour

Wheel Size & Position

Dunlop D427F

0.327 in.

E16 x 3.00 MT

16 in. - Front

130/90B16 73H

Dunlop D401F

0.327 in.

T19 x 2.5 MT

19 in. - Front

100/90-19 57H

Dunlop D427

0.333 in.

T16 x 5.0 MT

16 in. - Rear

180/70B16 77H

Dunlop K591

0.327 in.

T17 x 4.5 MT

17 in. - Rear

160/70B17 73V

Table 2-5. Tire Fitment - Tube Type Steel Laced Wheels

Tire Size

Tube Size
Center Valve Tube

Rim Size & Contour

Wheel Size & Position

Dunlop D401F

MJ/MM90-19

19M/C x MT2.5 T

19 in. - Front

100/90-19 57H

100/90-19

Dunlop D402F

MH90x21

21 M/C x MT2.15 T

21 in. - Front

MH90-21 54H

Dunlop K591

150-160/70-17

17M/C x MT4.5 T

17 in. - Rear

160/70B17 73V

Table 2-6. Tire Fitment - Tube Type Chrome Aluminum Profile Laced Wheels

Tire Size

Tube Size
Center Valve Tube

Rim Size & Contour

Wheel Size & Position

Dunlop D401F

MJ/MM90-19

T19 x 2.50 TLA

19 in. - Front

100/90-19 57H

100/90-19

Dunlop D402F

MH90x21

T21 x 2.15 TLA

21 in. - Front

MH90-21 54H

Dunlop K591

150-160/70-17

17M/C x MT4.5 T

17 in. - Rear

160/70B17 73V

HOME

2009 Dyna Service: Chassis 2-5

Harley Davidson 2009 Dyna Models. Service manual - page 8