Harley Davidson 2009 Dyna Models. Service manual

2.32

ENGINE MOUNTS

REMOVAL

Front Isolator

Support front of engine with jack.

See

Figure 2-116

. Remove bolts (1) lockwashers (2) and

washers (3) securing front isolator (4) to frame.

Remove bolts (5), flange nuts (6) and washers (7).
Remove front isolator (4).

NOTE

Motorcycle must be upright and level before performing this
procedure.

Rear Isolator

Remove left side footpeg and debris deflector.

Use a jack on the oil tank to support rear of transmission.

Use a long extension, from right side of motorcycle and a
wrench on the left side of rear isolator (8). Remove bolts
(9), flange nuts (10) and washers (11).

NOTE

You will have to vary the load on the mount to slip the bolts
out.

Remove bolts (12), lockwashers (13) and washers (14)
securing rear isolator to frame. Remove rear isolator.

INSTALLATION

Front Isolator

Support front of engine with jack.

See

Figure 2-116

. Place front isolator (4) in position on

frame and install bolts (1) lockwashers (2) and washers
(3). Tighten bolts to 21-27 ft-lbs (28-36 Nm).

Install bolts (5), flange nuts (6) and washers (7). Tighten
flange nuts to 21-27 ft-lbs (28-36 Nm).

NOTE

Be sure motorcycle is upright and level before performing this
procedure.

Rear Isolator

Use a jack on the oil tank to support rear of transmission.

NOTE

You will have to vary the load on the mount to slip the bolts in.

Place rear isolator (8) in position on frame and install bolts
(12), lockwashers (13) and washers (14). Torque bolts to
21-27 ft-lbs (28-36 Nm).

Use a long extension, from right side of motorcycle and a
wrench on the left side of rear isolator. Install bolts (9),
flange nuts (10) and washers (11). Tighten flange nuts to
21-27 ft-lbs (28-36 Nm).

Install left side footpeg and debris deflector.

HOME

2-88 2009 Dyna Service: Chassis

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 2-116. Engine Mounts

HOME

2009 Dyna Service: Chassis 2-89

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

See

Figure 6-37

. Install new retaining rings (1).

Install new o-ring (4) into groove in main drive gear.

sm03044

Figure 6-40. Pressing in Seal

sm02302

Figure 6-41. Installing Transmission Side Needle Bearing

in Main Driver Gear

INSTALLATION

TOOL NAME

PART NUMBER

INSTALLER CUP

HD-35316-12

CROSS PLATE

HD-35316-3A

8 IN. BOLT

HD-35316-4A

12 IN. BOLT

HD-35316-5

WASHER

HD-35316-7

BEARING DRIVER

HD-35316-8

INSTALLER

HD-47856-1

PILOT

HD-47856-2

ADAPTER

HD-47856-3

NUT

HD-47856-6

CROW'S FOOT WRENCH

HD-47856-7

Improper tightening of sprocket nut can cause drive
component damage. (00541b)

Installing Main Drive Gear Bearing

NOTE

CROSS PLATE (Part No. HD-35316-3A) will retrofit to earlier
transmissions. Note that one end of cross plate is stamped,
"UP 6 SPEED". Mount cross plate with this end pointing up for
6 speed transmissions.

See

Figure 6-42

. Place CROSS PLATE (Part No. HD-

35316-3A) (2) on right side of transmission case as shown,
and secure with two screws (3). Position cross plate so
that large bolt hole in cross plate is lined up with center of
main drive gear bearing bore in left side of transmission
case.

Apply a light coat of graphite lubricant to the threads of 12
IN. BOLT (Part No. HD-35316-5) (1) and install through
cross plate and main drive gear bearing bore.

At left side of case, place main drive gear bearing (4),
BEARING DRIVER (Part No. HD-35316-8) (5), NICE
BEARING (6), FLAT WASHER (7) and NUT (8) over end
of bolt.

Tighten nut until main drive gear bearing bottoms against
lip cast into transmission case bearing bore.

HOME

2009 Dyna Service: Transmission 6-23

NOTE

ADAPTER (Part No. HD-47856-3) and main drive gear have
right-hand threads.

See

Figure 6-47

. Thread ADAPTER (Part No. HD-47856-

3) onto end of main drive gear until it contacts main drive
gear.

sm03057

Pilot

Retaining Ring

Figure 6-45. Install Pilot

sm03058

Figure 6-46. Place Main Drive Gear Seal Over Pilot

sm03059

Figure 6-47. Install Adapter

See

Figure 6-48

. Slide INSTALLER (Part No. HD-47856-

1) (1) over adapter until cupped end of installer is flat
against seal.

Thread NUT (Part No. HD-47856-6) (2) onto end of
adapter, until it tightens against installer.

See

Figure 6-49

. Place CROW'S FOOT WRENCH (Part

No. HD-47856-7) (1) with 1/2 inch drive breaker bar (2)
on large nut. Place an adjustable wrench (3) on flats of
hex head cast into end of adapter.

Holding adjustable wrench, tighten large nut with crow's
foot wrench until outer face of seal is flush with outer edge
of transmission bore.

NOTE

It is acceptable to recess seal as much as 0.030 in. (0.762 mm)
below outer edge of bore. Seal depth will be controlled by tool.

Remove nut, installer, adapter and pilot.

10. Install side door and transmission components. See

6.6 TRANSMISSION ASSEMBLY, Installation

11. Install sprocket and drive belt. See

5.7 TRANSMISSION

SPROCKET

. Do not adjust belt at this time.

12. Install the bearing inner race on the transmission main-

shaft. See

6.6 TRANSMISSION ASSEMBLY, Assembly

13. Install the primary chaincase housing. See

5.5 PRIMARY

CHAINCASE HOUSING, Installation

14. Install the clutch assembly, primary chain, chain tensioner

assembly and compensating sprocket components See

5.4 DRIVE COMPONENTS, Installation

15. Install the primary chaincase cover. See

5.3 PRIMARY

CHAINCASE COVER, Installation

16. Adjust the drive belt. See

1.14 REAR BELT DEFLECTION,

Inspection

17. Install exhaust system. See

4.17 EXHAUST SYSTEM,

Removal: All but FXDF

HOME

2009 Dyna Service: Transmission 6-25

3.1

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

3.17 TOP END OVERHAUL: ASSEMBLY, Breather
Assembly

10.2-13.6 Nm

90-120 in-lbs

Breather assembly bolts

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

11.3-13.6 Nm

100-120 in-lbs

Cam chain tensioner fasteners

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

14.1-17.5 Nm

125-155 in-lbs

Cam cover screws

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

10.2-13.6 Nm

90-120 in-lbs

Cam support plate screws

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

10.2-13.6 Nm

90-120 in-lbs

Cam support plate screws

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Crankcase

20.3-25.8 Nm

15-19 ft-lbs

Crankcase bolts, final

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Crankcase

13.6 Nm

10 ft-lbs

Crankcase bolts, initial

3.28 CRANKCASE, Pipe Plug and Oil Fittings

13.6-16.3 Nm

120-144 in-lbs

Crankcase pipe plugs

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

32.5 Nm

24 ft-lbs

Crank sprocket bolt, final torque

3.17 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/See special method to tighten

20.3-23.0 Nm

15-17 ft-lbs

Cylinder head bolts, final

3.24 CYLINDER, Inspection

20.3-23.1 Nm

15-17 ft-lbs

Cylinder head bolts, final

3.17 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head/See special method to tighten

13.5-16.2 Nm

120-144 in-lbs

Cylinder head bolts, initial

3.24 CYLINDER, Inspection

13.6-16.3 Nm

120-144 in-lbs

Cylinder head bolts, initial

3.13 ASSEMBLING MOTORCYCLE AFTER
SERVICE, Procedure

47.5-54.2 Nm

35-40 ft-lbs

Cylinder head bracket bolts

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

47.5-54.2 Nm

35-40 ft-lbs

Cylinder head bracket bolts

3.28 CRANKCASE, Cylinder Studs

3.6-27.1 Nm

10-20 ft-lbs

Cylinder stud

3.30 OIL PAN, Installation/Clean plug before
installation

19.0-28.5 Nm

14-21 ft-lbs

Drain plug, engine

3.13 ASSEMBLING MOTORCYCLE AFTER
SERVICE, Procedure

33.9-47.5 Nm

25-35 ft-lbs

Footpeg bracket screws

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

33.9-47.5 Nm

25-35 ft-lbs

Footpeg bracket screws

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

33.9-47.5 Nm

25-35 ft-lbs

Footpeg bracket screws

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

33.9-40.7 Nm

25-30 ft-lbs

Front engine mounting bracket bolts

3.17 TOP END OVERHAUL: ASSEMBLY, Push
Rods, Lifters and Covers

10.2-13.6 Nm

90-120 in-lbs

Lifter cover screws

3.30 OIL PAN, Installation

9.5-12.2 Nm

84-108 in-lbs

Oil pan screws

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

4.5-5.1 Nm

40-45 in-lbs

Oil pump screws, initial torque

3.28 CRANKCASE, Right Crankcase Half

2.8-3.9 Nm

25-35 in-lbs

Piston jet screws

HOME

2009 Dyna Service: Engine 3-1

NOTES

TORQUE VALUE

FASTENER

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

46.1 Nm

34 ft-lbs

Primary cam sprocket flange bolts, final
torque

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

20.3 Nm

15 ft-lbs

Primary cam sprocket flange bolts, initial
torque

3.19 BOTTOM END OVERHAUL:
ASSEMBLY, Cam Support Plate and Cover

20.3 Nm

15 ft-lbs

Primary cam sprocket flange bolts, initial
torque

3.17 TOP END OVERHAUL: ASSEMBLY, Rocker
Arm Support Plate

24.4-29.8 Nm

18-22 ft-lbs

Rocker arm support plate bolts

3.17 TOP END OVERHAUL: ASSEMBLY, Breather
Assembly

20.3-24.4 Nm

15-18 ft-lbs

Rocker cover bolts

3.17 TOP END OVERHAUL: ASSEMBLY, Cylinder
Head

13.6-19.0 Nm

120-168 in-lbs

Rocker housing bolts

3.26 CAM SUPPORT PLATE AND COVER, Cam-
shafts

11.3-13.6 Nm

100-120 in-lbs

Secondary cam chain tensioner fastener

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

24.4-29.8 Nm

18-22 ft-lbs

Shifter foot lever pinch bolt

3.13 ASSEMBLING MOTORCYCLE AFTER
SERVICE, Procedure

24.4-29.8 Nm

18-22 ft-lbs

Stabilizer link bolt

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

24.4-29.8 Nm

18-22 ft-lbs

Stabilizer link bolt

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

46.1-52.9 Nm

34-39 ft-lbs

Transmission mounting bolts, final torque

3.15 INSTALLING ENGINE IN CHASSIS, Pro-
cedure

20.3 Nm

15 ft-lbs

Transmission mounting bolts, initial
torque

HOME

3-2 2009 Dyna Service: Engine

3.2

SPECIFICATIONS

Table 3-1. General Specifications

DATA

GENERAL

Number of cylinders

4-cycle, 45 degree, air-cooled

V-twin

Type

91 ft-lbs @ 3000 RPM

Torque
(with shorty, dual exhaust)

123 Nm @ 3000 RPM

3.75 in.

Bore

95.25 mm

4.375 in.

Stroke

111.13 mm

96 cubic in.

Piston displacement (approx.)

1584 cc

5500 RPM

Maximum sustained engine
speed

1000 RPM +/- 50

Idle speed

Table 3-2. Oil Pump Specifications

DATA

OIL PUMP

Twin geroter, dual scavenge, crank

mounted and driven, internal oil pump,

dry sump

Type

30-38 PSI (207-262 kN/m

) at 2000 RPM

and normal operating temperature of

230° F (110° C)

Pressure

5 micron media, filtered between pump

and engine

Filtration

Table 3-3. Rocker Arms Specifications

IN.

ROCKER ARMS

0.013-0.051

0.0005-0.0020

Shaft fit in bushing (loose)

0.08-0.33

0.003-0.013

End clearance

0.051-0.102

0.002-0.004

Bushing fit in rocker arm (tight)

Table 3-4. Rocker Arm Shaft Specifications

IN.

ROCKER ARM SHAFTS

0.018-0.056

0.0007-0.0022

Shaft fit in rocker arm support
plate (loose)

Table 3-5. Hydraulic Lifter Specifications

IN.

HYDRAULIC
LIFTERS

0.02-0.05

0.0008-0.0020

Fit in crankcase
(loose)

Table 3-6. Cylinder Head Specifications

IN.

CYLINDER HEAD

0.051-0.084

0.0022-0.0033

Valve guide in head (tight)

0.076-0.114

0.003-0.0045

Valve seat in head (tight)

51.36

2.022

Valve stem protrusion (min)

0-0.152

0-0.006

Head gasket surface (flatness)

Table 3-7. Valve Specifications

IN.

VALVES

0.0254-0.0762

0.001-0.003

Exhaust: fit in guide

0.0254-0.0762

0.001-0.003

Intake: fit in guide

1.02-1.58

0.040-0.062

Seat Width

51.10-51.61

2.012-2.032

Stem protrusion from cylinder
head boss

HOME

2009 Dyna Service: Engine 3-3

Table 3-8. Valve Springs Specifications

IN.

VALVE
SPRINGS

61.2 kg @ 47.0 mm

135 lbs @ 1.850 in.

Closed

141.5 kg @ 33.0 mm

312 lbs @ 1.300 in.

Open

59.1 mm

2.325 in.

Free length

Table 3-9. Piston

REPLACE IF WEAR

EXCEEDS

PISTON

IN.

0.036-0.064

0.0014-0.0025

Fit in cylinder (loose)

0.00-0.013

0.0002-0.0005

Piston pin fit (loose)

0.254-0.508

0.010-0.020

Top compression

Ring end
gap

0.356-0.610

0.014-0.024

2nd compression

0.254-1.27

0.010-0.050

Oil control ring

0.030-0.094

0.0012-0.0037

Top compression

Ring side
clear-
ance

0.030-0.094

0.0012-0.0037

2nd compression

0.079-0.231

0.0031-0.0091

Oil control rails

Table 3-10. Connecting Rod Specifications

IN.

CONNECTING ROD

0.018-0.030

0.0007-0.0012

Piston pin fit (loose)

0.13-0.38

0.005-0.015

Side play between fly-
wheels

0.0102-0.0432

0.0004-0.0017

Connecting rod to
crankpin (loose)

Table 3-11. Flywheel Specifications

IN.

FLYWHEELS

0.0-0.254

0.000-0.010

Runout (shaft measured
in case)

0.0-0.102

0.000-0.004

Runout (measured in
truing stand)

0.076-0.330

0.003-0.013

End play

Table 3-12. Crankshaft/Sprocket Shaft Bearing

Specifications

IN.

CRANK-
SHAFT/SPROCKET
SHAFT BEARINGS

0.005-0.038

0.0002-0.0015

Roller bearing fit (loose)

0.097-0.137

0.0038-0.0054

Bearing fit in crankcase
(tight)

0.010-0.036

0.0004-0.0014

Bearing inner race on
crankshaft (tight)

HOME

3-4 2009 Dyna Service: Engine

3.3

SERVICE WEAR LIMITS

GENERAL

Wear limits are given here as a guideline for measuring used
engine components. Replace components when they exceed
values listed here.

Table 3-13. Rocker Arm/Rocker Arm Shaft

REPLACE IF WEAR EXCEEDS

ROCKER ARM/ROCKER
ARM SHAFT

IN.

0.089

0.0035

Shaft fit in bushing (loose)

0.635

0.025

End clearance

0.089

0.0035

Shaft fit in rocker arm
support (loose)

Table 3-14. Hydraulic Lifter

REPLACE IF WEAR EXCEEDS

HYDRAULIC LIFTER

IN.

0.076

0.003

Fit in crankcase

0.038

0.0015

Roller fit

0.559

0.022

Roller end clearance

Table 3-15. Cam Support Plate

REPLACE IF

CAM SUPPORT PLATE

IN.

More than 2.29

More than 0.090

Cam chain tensioner shoe

1/2 thickness of shoe

More than

21.704

More than

0.8545

Crankshaft bushing max-
imum ID

27.998

1.1023

Camshaft bore

Table 3-16. Cylinder Head

REPLACE IF

CYLINDER HEAD

IN.

Less than

0.051

Less than

0.002

Valve guide in head (tight)

Less than

0.051

Less than

0.002

Valve seat in head (tight)

More than

52.553

More than

2.069

Valve stem protrusion

More than

0.152

More than

0.006

Head warpage

Table 3-17. Cylinder

REPLACE IF WEAR EXCEEDS

CYLINDER

IN.

0.051

0.002

Taper

0.051

0.002

Out of round

0.152

0.006

Warpage of gasket sur-
faces: top

0.102

0.004

Warpage of gasket or O-
ring surfaces: base

Table 3-18. Cylinder Bore

REPLACE IF WEAR EXCEEDS

CYLINDER BORE

IN.

95.301

3.752

Standard

95.428

3.757

0.005 in. oversize

95.555

3.762

0.010 in. oversize

Table 3-19. Piston

REPLACE IF WEAR

EXCEEDS

PISTON

IN.

0.076

0.003

Fit in cylinder (loose)

0.020

0.0008

Piston pin fit (loose)

0.762

0.030

Top compression

Ring end
gap

0.864

0.034

2nd compression

1.27

0.050

Oil control rails

0.114

0.0045

Top compression

Ring side
clearance

0.114

0.0045

2nd compression

0.254

0.010

Oil control rails

Table 3-20. Connecting Rod

REPLACE IF WEAR

EXCEEDS

CONNECTING ROD

IN.

0.051

0.002

Piston pin fit (loose)

0.508

0.020

Side play between flywheels

0.051

0.002

Fit on crankpin (loose)

Table 3-21. Breather Assembly

REPLACE IF WEAR

EXCEEDS

BREATHER ASSEMBLY

IN.

0.13

0.005

Breather cover warpage

0.13

0.005

Breather baffle warpage

HOME

2009 Dyna Service: Engine 3-5

Table 3-22. Valve Stem to Guide

REPLACE IF WEAR EXCEEDS

VALVE STEM TO GUIDE

IN.

0.0965

0.0038

Intake

0.0965

0.0038

Exhaust

Table 3-23. Flywheel

REPLACE IF WEAR EXCEEDS

FLYWHEEL

IN.

0.305

0.012

Runout (shaft measured
in case)

0.127

0.005

Runout (measured in
truing stand)

0.330

0.013

End play

Table 3-24. Crankshaft Roller Bearing

REPLACE IF

CRANKSHAFT ROLLER
BEARING

IN.

More than 0.038

More than

0.0015

Roller bearing fit (loose)

Less than 0.097

Less than

0.0038

Bearing fit in crankcase
(tight)

Less than 0.010

Less than

0.0004

Inner race on crankshaft
(tight)

HOME

3-6 2009 Dyna Service: Engine

3.4

ENGINE OIL FLOW

OIL FEED

NOTE

The oiling system is carefully designed for optimum efficiency.
All oil holes and passageways are specially sized. Exercise
caution to avoid enlarging oil holes during cleaning. Any
modification of the oiling system will adversely affect oil pres-
sure or cooling and lubrication efficiency.

Two illustrations accompany this explanation.

•

Cam support plate oil flow is shown in

Figure 3-1

•

Top end oil flow is shown in

Figure 3-2

Oil flows from the oil pan through an internal passageway at
the front of the transmission housing, and enters the lower
passageway (A1) cast into the rear right side of the crankcase.

Running through a passageway in the crankcase, oil exits a
hole in the crankcase flange (B2) and enters a hole on the
inboard side of the cam support plate. Passing through a
channel in the cam support plate (A3), the oil enters the feed
side of the oil pump. See

3.5 OIL PUMP OPERATION

. The

feed gerotors of the pump direct the flow up a second channel
in the cam support plate (A4).

A drilling in this channel connects to a pressure relief valve
mounted in the bypass port of the cam support plate (A5).
When the oil pressure exceeds the setting of the relief valve
spring 35 psi (241.3 kPa), the orifice opens to bypass excess
oil back to the feed side of the pump (A3).

Oil not returned to the feed side exits a hole on the inboard
side of the cam support plate and passes through a hole in the
crankcase flange (B6). Flowing through a passageway in the
crankcase, where a reading is taken by the oil pressure sending
unit (B7), the oil exits the lower off-center hole in the oil filter
mount (D8).

After circulating through the oil filter, the flow of oil is directed
back into the crankcase through the center hole in the oil filter
mount (D9). Exiting a passageway in the crankcase through a
hole in the crankcase flange (B10), the flow of oil reenters the
cam support plate.

Filtered oil is then routed to the top and bottom ends of the
engine as described in

3.4 ENGINE OIL FLOW, Top End

and

3.4 ENGINE OIL FLOW, Bottom End

which follow.

TOP END

Two illustrations accompany this explanation.

•

Cam support plate oil flow is shown in

Figure 3-1

•

Top end oil flow is shown in

Figure 3-2

Oil passes through a channel in the cam support plate exiting
the inboard side through two holes near the top (A11, A12).
Entering two holes in the crankcase flange (B13, B14), one
leading to the front cylinder and the other to the rear, the oil
travels through passageways in the crankcase to the hydraulic
lifter bores (D15).

Exiting a hole in each lifter bore (E16), the oil flows around the
lifter and enters a hole at the side of the lifter body. As the
chamber inside the lifter body is filled, the push rod socket rises

to achieve the no-lash fit of the valve train components. The
flow of oil then exits a hole centered in the lifter socket and
runs up the hollow push rods.

NOTE

Note that there is one additional hole drilled into the inside lifter
bores while the oblong hole circulates oil around the lifter body
as described, the round hole (E17) feeds oil to the piston jets
in the flywheel compartment.

Exiting holes at the top of the hollow push rods, oil enters a
hole at the bottom of the intake and exhaust rocker arms.
Lubricating the rocker arm bushings, oil flows down the rocker
arm shafts and exits a pin hole in the outboard side of each
rocker arm housing (F18) where it sprays the valve springs
and the top of the valve stem.

Oil runs down to the low side of the rocker housing and enters
the exhaust valve spring pocket where a drain hole (G19) leads
to a passageway in the cylinder head casting.

Oil exits the bottom of the cylinder head and passes through
a dowel pin (H20) on the "down side" of the cylinder flange.
The oil runs through a vertical passageway in the cylinder,
passes through a second dowel pin on the "down side" of the
cylinder deck (I21) and enters the left crankcase half.

Flowing through a horizontal passageway in the left crankcase
half (J22), oil runs through a third dowel pin (K23) to the right
crankcase half where it travels through another passageway
before emptying into the cam compartment (B23, B24).

Oil collecting in the cam compartment is picked up by one of
two scavenge lobes on the oil pump (B25).

HOME

2009 Dyna Service: Engine 3-7

sm02375

Figure 3-2. Engine Oil Flow - Top End

BOTTOM END

Three illustrations accompany this explanation.

•

Cam support plate oil flow is shown in

Figure 3-1

•

Top end oil flow is shown in

Figure 3-2

•

Bottom end oil flow is shown in

Figure 3-3

Oil traveling through the horizontal passage at the top of the
cam support plate (enroute to the front and rear cylinders) also
passes through a hole at the top of each camshaft bore to

lubricate the journals of the plain bearing cams. On the inboard
side of the passage leading to the rear cylinder, oil sprays out
through a pin hole to lubricate the secondary cam chain.

The flow of oil to the rear cylinder also travels down the vertical
passage at the rear of the cam support plate (A27) and exits
a hole on the outboard side to supply oil to the primary cam
chain tensioner (A28).

The flow of oil in the vertical passage at the center of the cam
support plate (A29) passes through a hole on the inboard side
to supply oil to the secondary cam chain tensioner and also

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2009 Dyna Service: Engine 3-9

sprays out through a pin hole on the outboard side to lubricate
the primary cam chain (A30). The flow of oil then passes
through a hole in the crankshaft bushing where it enters a
drilling in the crankshaft (L31).

Oil runs down the center of the crankshaft and then up across
drilling into the right side of the flywheel. The flow exits a drilling
in the crank pin bore, enters the crank pin and then sprays out
through three holes to lubricate the lower rod bearing set.

The oil splash and mist created by the action of the flywheel
lubricates the crankshaft bearing and the camshaft needle
bearings in the right crankcase half. This same action serves
to lubricate the sprocket shaft bearing in the left crankcase half
(M32).

Since the oil mist also lubricates the cylinder walls, three holes
on each side of the piston (in the area of the third ring land)
evacuate excess oil scraped from the walls on the pis-ton
downstroke.

The piston jets (N33), which receive a supply of oil from the
intake lifter bores, spray the underside of the piston for cooling
of the piston crown and skirt area. A check valve in each jet
opens only when the oil pressure reaches 12-15 PSI (82.7-
103.4 kPa), at which point the engine is operating above idle
speed. At idle speeds (9-12 PSI (62.1-82.7 kPa)), the valve
remains closed to prevent over oiling and to provide proper
system operating pressure.

Oil spray from each piston jet also enters a hole at the bottom
of each pin boss (O34) for lubrication of the piston pin. The
spray also allows a portion of the oil to reach the upper rod
bushing (D35).

Surplus oil falls back to the bottom of the flywheel compartment
where it collects in the sump area (P36). Oil in the sump is
drawn to the cam compartment through an internal channel
(P37, C34) that connects with the second scavenge lobe of
the oil pump (B35).

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3-10 2009 Dyna Service: Engine

Harley Davidson 2009 Dyna Models. Service manual - page 14