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Harley Davidson 2009 Dyna Models. Service manual - page 15

sm02526

Figure 3-3. Engine Oil Flow - Bottom End

OIL RETURN

Two illustrations accompany this explanation.

•

Cam support plate oil flow is shown in

Figure 3-1

•

Bottom end oil flow is shown in

Figure 3-3

The "dual kidney" designation given to the oil pump refers to
its two scavenging functions, whereby it simultaneously draws
oil from both the cam and flywheel compartments.

Oil sucked up by the scavenge lobes passes through the
scavenge gerotors of the oil pump and is directed through a
return channel in the cam support plate (A40). See

3.5 OIL

PUMP OPERATION

Exiting a hole on the inboard side of the cam support plate,the
oil enters the upper hole in the crankcase flange (B41).

The oil flows through the upper passageway in the crankcase
(A42), enters a passageway at the front of the transmission
housing and empties into the oil pan at the front of the baffle
(Q43, R44).

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2009 Dyna Service: Engine 3-11

The oil flows to the rear of the oil pan along each side of the
baffle. Spring tension holds the unit tight against the bottom of
the pan to prevent oil from entering or escaping around the
perimeter of the baffle. At the back of the oil pan, the oil enters
the open side of the baffle where it is redirected for-ward. The
baffle plates slow the circulation of the oil through the pan to
enhance cooling.

Oil pickup occurs in the front compartment of the baffle where
a passageway in the casting (S45) directs the flow upward.
Passing through a second passageway in the trans-mission
housing (Q46), the flow of oil enters the lower passageway in
the crankcase (A1) to repeat the circuit.

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3-12 2009 Dyna Service: Engine

3.5

OIL PUMP OPERATION

GENERAL

See

Figure 3-4

. The oil pump consists of a housing containing

two gerotor gear sets, one feed and the other scavenge. Driven
by the crankshaft, the feed gerotor set distributes oil to the
engine, while the scavenge gerotor set draws oil from the cam
and flywheel compartments and returns it to the oil pan.

Each gerotor gear set has two parts, an inner and outer gerotor.
The inner and outer gerotors have fixed centers that are slightly
offset to one another. Also, the inner gerotor has one less tooth.

sm02292

Feed gerotor

Scavenge gerotor

Figure 3-4. Oil Pump Gerotors

OPERATION

See

Figure 3-5

. As the crankshaft rotates, the cavity between

the inner and outer gerotors on the inlet side of the pump
increases in volume. This creates a vacuum causing oil to be
drawn in. The cavity continues to increase until the volume is
equivalent to that of the missing tooth on the inner gerotor.
Note that the inlet and outlet sides of the pump are sealed by
the tips and lobes of the inner and outer gerotors.

See

Figure 3-6

. Continued rotation moves the pocket of oil to

the outlet side of the pump. In this area, the cavity decreases
in volume as the gerotor teeth mesh causing the oil to be
squeezed out the discharge port. As the cavity on the outlet
side is emptied, a second seal formed by the tips and lobes of
the inner and outer gerotors prevents oil on the outlet side (high
pressure) from being transferred to the inlet side (low pressure).
In operation, the gerotors provide a continuous flow of oil.

sm02317

Oil in

Seal

Outer gerotor

Inner gerotor

Figure 3-5. Inlet Side Oil Flow

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2009 Dyna Service: Engine 3-13

sm02319

Seal

Oil out

Continuous flow

Figure 3-6. Outlet Side Oil Flow

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3-14 2009 Dyna Service: Engine

3.6

BREATHER OPERATION

GENERAL

The crankcase breather system relieves crankcase pressure
produced by the downstroke of the pistons and allows crank-
case vapors vacated from each cylinder to be directed into the
air filter element. Through effective recirculation of crankcase
vapors, the system serves to eliminate the pollutants normally
discharged from the crankcase.

See

Figure 3-7

. As each piston pushes downward on its power

and intake stroke, displaced air in the flywheel compartment
is vented through the crankshaft roller bearing into the cam
compartment and then up the push rod covers (1) into the
rocker housing.

Air rushes under the rocker arm support plate, which is elevated
slightly, and passes through an opening at the bottom of the
plate to enter the breather baffle compartment (2).

In the baffle compartment, the flow of air passes upward
through the oil filter gauze, where the oil is removed from the
air. Two pin holes in the rocker arm support plate act as drain
holes to rid the baffle compartment of the oil separated from
the air.

Passing through the oil filter gauze, the flow of air passes
through the umbrella valve (3) into the breather compartment.
The flaps of the umbrella valve only allow air to be vented one
way, rising to allow the passage of air, but then falling back
into place to seal the vent holes as the flow of air stops.

In the breather compartment, the flow of air reverses direction
passing downward through holes aligned in the breather baffle,
rocker arm support plate and rocker housing. Exiting the rocker
housing, the air enters a passageway cast into the top of the
cylinder head. Proper orientation of the rocker housing gasket
is critical for effective sealing of this passageway.

Flowing through the cylinder head passageway, the air passes
through a drilling in the air cleaner backplate bolt (4) and then
through a breather tube (5) into the air filter element.

NOTE

Air cleaner mounting without installation of the breather tubes
allows crankcase vapors to be vented into the atmosphere in
violation of legal emissions standards.

sm02323

Push rod cover

Breather baffle compartment

Umbrella valve

Air cleaner backplate bolt

Breather tube

Figure 3-7. Breather Air Flow

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2009 Dyna Service: Engine 3-15

3.7

OIL PRESSURE

OIL PRESSURE INDICATOR LAMP

See

Figure 3-8

. The red OIL PRESSURE indicator lamp illu-

minates to indicate improper circulation of the engine oil. The
lamp illuminates when the ignition is first turned on (before the
engine is started), but should be extinguished once the engine
is running.

If the oil pressure indicator lamp remains lit, always check
the oil supply first. If the oil supply is normal and the lamp
is still lit, stop the engine at once and do not ride further
until the trouble is located and the necessary repairs are
made. Failure to do so may result in engine damage.
(00157a)

If the indicator lamp is not extinguished, it may be the result of
a low oil level or diluted oil supply. In freezing weather, the oil
feed and return lines can clog with ice or sludge. A problem in
the lamp wiring, faulty oil pressure sending unit, damaged oil
pump, plugged oil filter element, incorrect oil viscosity, broken
or weak spring in the oil pressure relief valve and/or damaged
or incorrectly installed O-rings in the engine may also cause
the indicator lamp to remain on.

To troubleshoot the problem, always check the engine oil level
first. If the oil level is OK, determine if oil returns to the oil pan.
If oil does not return, shut off the engine until the problem is
located and corrected.

sm02321

Figure 3-8. Oil Pressure Indicator Lamp

CHECKING OIL PRESSURE

TOOL NAME

PART NUMBER

OIL PRESSURE GAUGE SET

HD-96921-52D

Check operating oil pressure as follows:

Ensure engine oil is at the proper level. See

1.5 ENGINE

OIL AND FILTER

See

Figure 3-9

. Remove oil pressure switch from crank-

case. See

7.27 OIL PRESSURE SWITCH

See

Figure 3-10

. Install OIL PRESSURE GAUGE

SET (Part No. HD-96921-52D).

Install adapter (2) in oil pressure switch mounting
hole. Tighten adapter until snug.

Assemble banjo bolt (3), washer (4), oil pressure
gauge (1) banjo fitting and second washer onto
adapter and tighten until snug.

Start engine and allow to reach operating temperature.

NOTE

Engine oil should be at normal operating temperature, 230° F
(110° C), for an accurate reading.

Oil pressure should be 30-38 PSI (207-262 kPa) at 2000
RPM and normal operating temperature.

Stop engine. Remove oil pressure gauge assembly from
oil pressure switch mounting hole in crankcase.

Install oil pressure switch. See

7.27 OIL PRESSURE

SWITCH

sm02293

Figure 3-9. Oil Pressure Switch

sm02322

Gauge

Adapter

Banjo bolt

Washer (2)

Figure 3-10. Oil Pressure Gauge Set

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3-16 2009 Dyna Service: Engine

3.8

TROUBLESHOOTING

DIAGNOSING VALVE TRAIN NOISE

To diagnose and correct noisy hydraulic lifters and valve train
components, use the following procedures:

With engine and oil at normal operating temperature, check
oil pressure at 2000 RPM. If oil pressure is above 50 PSI
(345 kPa) or below 5 PSI (34 kPa), inspect oil pump,
crankcase passages, and oil hoses for restrictions or
blockage. Repair or replace parts as necessary.

If oil is not reaching the hydraulic lifters, remove and
inspect. See

3.22 PUSH RODS, LIFTERS AND COVERS,

Lifter Inspection

. Clean lifter bore of all foreign material.

Replace hydraulic lifter if required.

Examine push rod, lifter and lifter block for proper fit and
any signs of unusual wear. Replace parts as necessary.

Visually inspect camshaft lobes for abnormal wear.

Check cam chain tensioning shoe for wear.

Remove cylinder head and rocker box assemblies. Check
rocker arm end play and check for binding. Inspect valve
stems for scuffing and check stem to guide clearance.
Check valve seats for signs of looseness or shifting.

Grind valves and valve seats. See

3.23 CYLINDER HEAD,

Valve and Seat Refacing

COMPRESSION TEST

TOOL NAME

PART NUMBER

CYLINDER COMPRESSION GAUGE

HD-33223-1

Satisfactory engine performance depends upon a mechanically
sound engine. In many cases, unsatisfactory performance is
caused by combustion chamber leakage. A compression test
can help determine the source of cylinder leakage. Use CYL-
INDER COMPRESSION GAUGE (Part No. HD-33223-1).

A proper compression test should be performed with the engine
at normal operating temperature when possible.

Disconnect spark plug wires, clean around plug base and
remove plugs.

Remove air cleaner. See

4.5 AIR CLEANER ASSEMBLY

Connect compression tester to front cylinder per manufac-
turer's instructions.

Make sure transmission is in neutral. With throttle body
butterfly plate in wide open position, crank engine continu-
ously through 5 to 7 full compression strokes.

Note gauge readings at the end of the first and last com-
pression strokes. Record test results.

Repeat compression test on rear cylinder.

If the final readings are 125 PSI (862 kPa) or more, and
if the final readings do not indicate more than a 10% vari-
ance between cylinders, compression is considered
normal. If compression does not meet specifications, refer
to

Table 3-25

Inject approximately 1/2 oz. (15 ml) engine oil into each
cylinder and repeat the compression tests on both cylin-
ders. Readings that are considerably higher during the
second test indicate worn piston rings.

NOTE

After installing spark plugs, be sure that throttle plate is in the
closed position before starting the engine.

Table 3-25. Compression Test Results

TEST RESULTS

DIAGNOSIS

Compression low on first stroke, tends to
build up on the following strokes, but does
not reach normal. Improves considerably
when oil is added to cylinder.

Ring trouble

Compression low on first stroke, does not
build up much on following strokes. Does
not improve considerably with the addition
of oil. Check for correct push rod length.

Valve trouble

Same reaction as valve trouble.

Head gasket
leak

CYLINDER LEAKDOWN TEST

TOOL NAME

PART NUMBER

CYLINDER LEAKDOWN TESTER

HD-35667-A

NOTE

On vehicles with automatic compression release (ACR), make
sure the ACRs are closed for this test. Either perform the test
with the ignition/light switch in the off position or with the ACR
connectors disconnected.

The cylinder leakage test will pinpoint engine problems
including leaking valves, worn, damaged or stuck piston rings
and blown head gaskets. The cylinder leakage tester applies
compressed air to the cylinder at a controlled pressure and
volume and measures the percent of leakage from the cylinder.

Use the CYLINDER LEAKDOWN TESTER (Part No. HD-
35667-A) and follow the specific instructions supplied with the
tester.

The following are some general instructions that apply to
Harley-Davidson V-twin engines:

Run engine until it reaches normal operating temperature.

Stop engine. Clean dirt from around spark plugs and
remove the spark plugs.

Remove the air cleaner and set the throttle to the wide
open position.

The piston in the cylinder being tested must be at top dead
center of compression stroke (both valves closed) during
the test.

To keep the engine from turning over when air pressure
is applied to the cylinder, engage transmission in highest
gear and lock the rear brake.

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2009 Dyna Service: Engine 3-17

NOTE

Before performing the cylinder leakage test, verify that the
tester itself is free from leakage to obtain the most accurate
test results. With a soap solution (applied around all tester fit-
tings), connect the cylinder leakdown tester to the compressed
air source and look for any bubbles that would indicate leakage
from the tester.

Following the manufacturer's instructions, perform a cyl-
inder leakage test on the front cylinder. Make a note of
the percent of leakage. Leakage greater than 10% indic-
ates internal engine problems.

Listen for air leaks at throttle body intake, exhaust pipe,
and head gasket. Air escaping through the throttle body
indicates a leaking intake valve. Air escaping through the
exhaust pipe indicates a leaking exhaust valve.

NOTE

If air is escaping through valves, check for correct push rod
length.

Repeat procedure on rear cylinder.

NOTE

After installing spark plugs, be sure that throttle plate is in the
closed position before starting the engine.

DIAGNOSING SMOKING ENGINE OR HIGH
OIL CONSUMPTION

Perform both a compression test and a cylinder leakage test.
See

3.8 TROUBLESHOOTING, Compression Test

and

3.8 TROUBLESHOOTING, Cylinder Leakdown Test

. If further

testing is needed, remove suspect head(s) and inspect for the
following:

Check Prior To Cylinder Head Removal

Oil level overfull.

Oil carryover.

Breather hose restricted.

Restricted oil filter.

Check After Cylinder Head Removal

Oil return passages for clogging.

Valve guide seals.

Valve guide to valve stem clearance.

Gasket surface of both head and cylinder.

Cylinder head casting's porosity allowing oil to drain into
combustion chamber.

O-ring damaged or missing from oil pump/crankcase
junction.

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3-18 2009 Dyna Service: Engine

3.9

HOW TO USE THIS SECTION

TOP END REPAIR

NOTE

During top end disassembly, the engine may be left in the
chassis for service.

If servicing only cylinder head components, pistons, cylinders
and/or upper rod bushings, two options are available depending
upon engine status. See

3.14 REMOVING ENGINE FROM

CHASSIS

•

3.10 TOP END SERVICE, Engine in Chassis

•

3.10 TOP END SERVICE, Engine Removed from Chassis

BOTTOM END REPAIR

NOTE

Servicing components in the cam compartment requires only
partial disassembly. This can be done with the engine left in
the chassis.

After disassembling as far as the cylinder heads you may find
that bottom end repair is necessary. Bottom end service may
require either partial or complete disassembly of the engine.

•

To service the cam compartment, see

3.11 BOTTOM END

SERVICE, Engine in Chassis

•

To service components in the flywheel compartment, the
engine must be removed and the crankcase halves split.

See

3.11 BOTTOM END SERVICE, Engine Removed

From Chassis

TYPICAL SYMPTOMS

Symptoms indicating a need for engine repair are often mis-
leading, but generally if more than one symptom is present,
possible causes can be narrowed down to make at least a
partial diagnosis. An above normal consumption of oil, for
example, could be caused by several mechanical faults. But
when accompanied by a blue-gray smoke from the exhaust,
and when low compression is present, it indicates the rings
need replacing. Low compression by itself, however, indicates
improperly seated valves, not worn rings.

Certain "knocking" noises may be caused by loose bearings,
others by piston slap, a condition where piston or cylinder or
both out of tolerance, allowing the piston to slap from front to
rear of the cylinder as it moves up and down.

Most frequently, valves, rings, pins, bushings, and bearings
need attention at about the same time. If the symptoms can
be narrowed down through the process of elimination to indicate
that any one of the above components is worn, it is best to give
attention to all of the cylinder head and cylinder parts.

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2009 Dyna Service: Engine 3-19

3.10

TOP END SERVICE

ENGINE IN CHASSIS

Table 3-26. Engine In Chassis

COMPONENT REPAIR
PROCEDURE

SERVICE PROCEDURE

Remove parts to gain access to all components above cylinder deck. See

3.12 STRIPPING MOTORCYCLE FOR SERVICE

Disassemble top end. See

3.16 TOP END OVERHAUL: DISASSEMBLY

Inspect and repair.

BREATHER ASSEMBLY

See

3.20 BREATHER ASSEMBLY

Inspect and repair.

ROCKER ARM SUPPORT

See

3.21 ROCKER ARM SUPPORT PLATE

Inspect and repair.

PUSH RODS, LIFTERS AND COVERS

See

3.22 PUSH RODS, LIFTERS AND

COVERS

Inspect and repair.

CYLINDER HEAD

See

3.23 CYLINDER HEAD

Inspect and repair.

CYLINDER

See

3.24 CYLINDER

Inspect and repair.

PISTON

See

3.25 PISTON

Assemble top end. See

3.17 TOP END OVERHAUL: ASSEMBLY

Assemble motorcycle. See

3.13 ASSEMBLING MOTORCYCLE AFTER SER-

VICE

Note: * If no other work is to be done, you may advance to

3.17 TOP END OVERHAUL: ASSEMBLY

when this step is completed

during top end service.

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3-20 2009 Dyna Service: Engine

ENGINE REMOVED FROM CHASSIS

Table 3-27. Engine Removed From Chassis

COMPONENT REPAIR
PROCEDURE

SERVICE PROCEDURE

Remove engine from motorcycle. See

3.14 REMOVING ENGINE FROM

CHASSIS

Disassemble top end. See

3.16 TOP END OVERHAUL: DISASSEMBLY

Inspect and repair.

BREATHER ASSEMBLY

See

3.20 BREATHER ASSEMBLY

Inspect and repair.

ROCKER ARM SUPPORT

See

3.21 ROCKER ARM SUPPORT PLATE

Inspect and repair.

PUSH RODS, LIFTERS AND COVERS

See

3.22 PUSH RODS, LIFTERS AND

COVERS

Inspect and repair.

CYLINDER HEAD

See

3.23 CYLINDER HEAD

Inspect and repair.

CYLINDER

See

3.24 CYLINDER

Inspect and repair.

PISTON

See

3.25 PISTON

Assemble top end. See

3.17 TOP END OVERHAUL: ASSEMBLY

Install engine in motorcycle. See

3.15 INSTALLING ENGINE IN CHASSIS

Note: * If no other work is to be done, you may advance to

3.17 TOP END OVERHAUL: ASSEMBLY

when this step is completed

during top end service.

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2009 Dyna Service: Engine 3-21

3.11

BOTTOM END SERVICE

ENGINE IN CHASSIS

Table 3-28. Engine In Chassis: Cam Compartment Service

COMPONENT REPAIR
PROCEDURES

SERVICE PROCEDURE

Remove parts to gain access to all components above cylinder deck. See

3.12 STRIPPING MOTORCYCLE FOR SERVICE

Dissassemble top end. See

3.16 TOP END OVERHAUL: DISASSEMBLY

Inspect and repair.

BREATHER ASSEMBLY.

See

3.20 BREATHER ASSEMBLY

Inspect and repair.

ROCKER ARM SUPPORT PLATE.

See

3.21 ROCKER ARM SUPPORT PLATE

Inspect and repair.

PUSH RODS, LIFTERS AND COVERS.

See

3.22 PUSH RODS, LIFTERS AND

COVERS

Disassemble bottom end. See

3.18 BOTTOM END OVERHAUL: DISASSEMBLY

Inspect and repair.

COVER AND CAM SUPPORT PLATE

See

3.26 CAM SUPPORT PLATE AND

COVER

Inspect and repair.

OIL PUMP

See

3.27 OIL PUMP

Assemble bottom end. See

3.19 BOTTOM END OVERHAUL: ASSEMBLY

Assemble motorcycle. See

3.13 ASSEMBLING MOTORCYCLE AFTER SER-

VICE

Note: * If no other work is to be done, you may advance to

3.19 BOTTOM END OVERHAUL: ASSEMBLY

when this step is

completed during bottom end service.

HOME

3-22 2009 Dyna Service: Engine

ENGINE REMOVED FROM CHASSIS

Table 3-29. Engine Removed: Flywheel Compartment Service or Complete Engine Overhaul

COMPONENT REPAIR
PROCEDURES

SERVICE PROCEDURE

Remove engine from motorcycle. See

3.14 REMOVING ENGINE FROM CHASSIS

Dissassemble top end. See

3.16 TOP END OVERHAUL: DISASSEMBLY

Inspect and repair.

BREATHER ASSEMBLY.

See

3.20 BREATHER ASSEMBLY

Inspect and repair.

ROCKER ARM SUPPORT PLATE.

See

3.21 ROCKER ARM SUPPORT PLATE

Inspect and repair.

PUSH RODS, LIFTERS AND COVERS.

See

3.22 PUSH RODS, LIFTERS AND

COVERS

Inspect and repair.

CYLINDER HEAD

See

3.23 CYLINDER HEAD

Inspect and repair.

CYLINDER

See

3.24 CYLINDER

Inspect and repair.

PISTON

See

3.25 PISTON

Disassemble bottom end. See

3.18 BOTTOM END OVERHAUL: DISASSEMBLY

Inspect and repair.

COVER AND CAM SUPPORT PLATE

See

3.26 CAM SUPPORT PLATE AND

COVER

Inspect crankcase and repair.

CRANKCASE

See

3.28 CRANKCASE

Inspect and repair flywheel/connecting rod
assembly.
See

3.29 FLYWHEEL AND CONNECTING

RODS

Assemble bottom end. See

3.19 BOTTOM END OVERHAUL: ASSEMBLY

Assemble top end. See

3.17 TOP END OVERHAUL: ASSEMBLY

Install engine in motorcycle. See

3.15 INSTALLING ENGINE IN CHASSIS

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2009 Dyna Service: Engine 3-23

3.12

STRIPPING MOTORCYCLE FOR SERVICE

PROCEDURE

NOTE

If performing top end service (or both cam compartment and
top end), follow all the steps listed. If servicing cam compart-
ment components only, perform steps 1 though 8.

Position motorcycle on a suitable lift.

Remove seat.

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)

Disconnect battery cables, negative cable first.

Remove heat shields and exhaust. See

4.17 EXHAUST

SYSTEM

Remove two screws and rear brake pedal and right footpeg
bracket. Disconnect assembly from master cylinder actu-
ator lever.

Remove air cleaner cover and backplate. See

4.5 AIR

CLEANER ASSEMBLY

When servicing the fuel system, do not smoke or allow
open flame or sparks in the vicinity. Gasoline is extremely
flammable and highly explosive, which could result in
death or serious injury. (00330a)

Drain fuel from fuel tank into suitable container. See

4.6 FUEL TANK

Unclip vapor valve, disconnect fuel gauge connector,
remove one end of fuel tank crossover tube and remove
fuel tank. See

4.6 FUEL TANK

Loosen and remove throttle control cables from induction
module. See

4.10 INDUCTION MODULE

10. Remove spark plug cables from spark plugs. Remove

spark plugs to avoid damaging them.

11. Remove right side stabilizer link nut, Allen bolt and spacer

from frame tab. Remove two bolts from horn bracket and
cylinder heads. Remove stabilizer link and horn bracket
as an assembly.

12. Remove induction module connectors and induction

module. See

4.10 INDUCTION MODULE

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3-24 2009 Dyna Service: Engine

3.13

ASSEMBLING MOTORCYCLE AFTER SERVICE

PROCEDURE

NOTE

If top end service was performed (or both cam compartment
and top end), follow all the steps listed. If only cam compart-
ment components were serviced start with step 5.

Install induction module. Install induction module con-
nectors. See

4.10 INDUCTION MODULE

NOTE

If the stabilizer link bolt cannot be installed without pushing the
engine to the right or left, perform the vehicle alignment pro-
cedure. See

2.12 VEHICLE ALIGNMENT

Install horn bracket/stabilizer link assembly to frame tab
and cylinder heads. Place spacer between frame tab and
stabilizer link. Make sure horn ground wire is installed
beneath bracket on front cylinder.

Tighten the stabilizer link bolt to 18-22 ft-lbs (24.4-
29.8 Nm).

Tighten two cylinder head bracket bolts to 35-40 ft-
lbs (47.5-54.2 Nm).

Install spark plugs to cylinder heads. Connect spark plug
cables to spark plugs. See

1.20 SPARK PLUGS

Install throttle cables to induction module.

Install fuel tank, fuel gauge connector, fuel tank crossover
tube and vapor valve. See

4.6 FUEL TANK

Connect fuel hose to fuel tank.

Install backplate and air cleaner cover. See

4.5 AIR

CLEANER ASSEMBLY

Install master cylinder actuator lever. Install right footpeg
bracket and rear brake pedal with two screws. Tighten to
25-35 ft-lbs (33.9-47.5 Nm).

Install heat shields and exhaust. See

4.17 EXHAUST

SYSTEM

10. Connect negative battery cable.

After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)

11. Install seat.

12. Remove motorcycle from lift.

HOME

2009 Dyna Service: Engine 3-25

3.14

REMOVING ENGINE FROM CHASSIS

PROCEDURE

NOTE

Removal begins on the RIGHT SIDE of the motorcycle.

Position motorcycle on a suitable lift.

Remove seat.

Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)

Disconnect battery cables, negative cable first.

Remove air cleaner cover and backplate. See

4.5 AIR

CLEANER ASSEMBLY

To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)

Cut hose clamp and remove fuel feed line (large O.D.)
and vacuum line (small O.D.) from throttle body.

Drain fuel from fuel tank into suitable container. Remove
fuel tank. See

4.6 FUEL TANK

Loosen and remove throttle control cables from induction
module. See

4.10 INDUCTION MODULE

Remove heat shields and exhaust. See

4.17 EXHAUST

SYSTEM

Using a 5/16 in. Allen bit, remove two screws and rear
brake pedal and right footpeg bracket. Remove cotter pin
and clevis pin and disconnect assembly from master cyl-
inder actuator lever.

10. Disconnect the following connectors.

Crank position sensor connector [79].

Stator/voltage regulator connector [46].

Oil pressure sending unit connector [140].

11. Drain oil from primary chaincase. See

1.10 PRIMARY

CHAIN

12. Loosen pinch bolt and remove shifter foot lever from

primary chaincase.

13. Using a 5/16 in. Allen bit, remove two screws and left side

footpeg and bracket.

14. Remove primary chaincase cover and primary chaincase.

See

5.5 PRIMARY CHAINCASE HOUSING

15. Remove spark plug cables from spark plugs. Remove

spark plugs to avoid damaging them.

16. Remove right side stabilizer link nut, Allen bolt and spacer

from frame tab. Remove two bolts from horn bracket and
cylinder heads. Remove stabilizer link and horn bracket
as an assembly.

17. Remove MAP sensor connector [80] from MAP sensor.

18. Note routing of clutch cable before removing. Disconnect

clutch cable from clutch lever. Unclip cable at left side
frame downtube and pull cable through chassis to right
side of motorcycle. Leave cable installed on transmission.
See

2.25 CLUTCH CONTROL

19. Place wire loom or other protective material on both front

downtubes to prevent damage.

20. Position jack under transmission. Place a block of wood

between jack and oil pan to prevent damage to oil pan
and raise jack just enough to support transmission.

21. Using a ratchet and ratchet strap, secure transmission to

chassis (vertically) to prevent transmission from shifting
position.

22. Remove four bolts and washers that connect engine to

transmission.

23. Remove two bolts and washers that secure engine to front

engine mount bracket.

24. Remove engine oil dipstick.

25. Using a suitable hoist, remove engine from chassis from

the right side.

NOTE

The engine is positively located to the transmission with two
dowels that fit in the lower mounting bolt holes and extend out
approximately 0.5 in. (12.7 mm) from the transmission. The
engine may have to be rotated counterclockwise slightly to
disengage the locating dowels.

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3-26 2009 Dyna Service: Engine

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