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Harley Davidson 2009 Dyna Models. Service manual - page 20

3.29

FLYWHEEL AND CONNECTING RODS

REMOVAL OVERVIEW

Perform all steps under

3.16 TOP END OVERHAUL:

DISASSEMBLY

Perform all steps under

3.18 BOTTOM END OVERHAUL:

DISASSEMBLY

INSPECTION

NOTE

Do not attempt to straighten connecting rods. Straightening
rods will damage both the upper bushing and lower bearing.

Replace the flywheel/connecting rod assembly if any of
the following conditions are noted:

Connecting rods are bent or twisted.

Connecting rods do not fall under their own weight or
are in a bind.

Sprocket teeth are worn in an irregular pattern or
chipped.

The crankshaft (roller) bearing inner races are
brinelled, burnt, scored, blued or damaged.

NOTE

Bluing on connecting rods is part of the hardening process and
is considered a normal condition.

Check connecting rod bearing clearance. Orient the
assembly as shown in

Figure 3-139

Holding the shank of each rod just above the bearing
bore, pull up and down on the connecting rods.

Any discernible up and down movement indicates
excessive lower bearing clearance. Replace the fly-
wheel/connecting rod assembly.

See

Figure 3-140

. Check connecting rod side play.

Insert a feeler gauge between the thrust washer and
the outboard side of the connecting rod.

Replace the assembly if rod side play exceeds 0.020
in. (0.51 mm).

NOTE

If the flywheel, connecting rods or right side bearing inner race
need to be replaced, then replace the entire flywheel assembly.

sm02310

Figure 3-139. Connecting Rod Bearing Clearance

sm02311

Figure 3-140. Connecting Rod Side Play

INSTALLATION OVERVIEW

Perform all steps under

3.19 BOTTOM END OVERHAUL:

ASSEMBLY

Perform all steps under

3.17 TOP END OVERHAUL:

ASSEMBLY

HOME

3-100 2009 Dyna Service: Engine

3.30

OIL PAN

REMOVAL

NOTE

When jacking up motorcycle, do not apply pressure directly to
the oil pan. Damage can occur unless measures are taken to
distribute the pressure (such as a block of wood placed
between the jack and the oil pan). A suitable lift which applies
pressure at the tires is the only recommended method for
raising the motorcycle.

Position motorcycle on a suitable lift.

See

Figure 3-141

. Drain fluids from oil pan.

Remove engine oil drain plug (4), fill plug/dipstick and
oil filter. Drain oil into suitable container. See

1.5 ENGINE OIL AND FILTER

Remove transmission drain plug (7). Drain transmis-
sion fluid into suitable container. See

1.11 TRANS-

MISSION LUBRICANT

Remove ten screws (8) that secure the oil pan to the
transmission housing.

Remove oil pan (5) and gasket (1). Discard gasket.

Remove baffle assembly (3) and spring (2) from oil pan.

sm02312

Gasket

Spring

Baffle assembly

Engine oil drain plug

Oil pan

Pipe plug

Transmission drain plug and O-ring

Screw (10)

Figure 3-141. Oil Tank: Dyna Glide

INSTALLATION

Clean and examine all flange surfaces. Examine drain
plug O-rings for tears or damage. Replace O-rings as
required.

See

Figure 3-141

. Insert baffle assembly (3) and spring

(2) in oil pan.

Place new gasket (1) on oil pan.

NOTE

Use a few drops of HYLOMAR to keep gasket in place and
simplify installation.

Position gasket and oil pan on transmission housing and
install with ten screws (8). Tighten to 84-108 in-lbs (9.5-
12.2 Nm) following sequence shown in

Figure 3-142

HOME

2009 Dyna Service: Engine 3-101

Wipe any foreign material from engine and transmission
drain plugs. Install plugs with O-rings. Tighten plugs to 14-
21 ft-lbs (19.0-28.5 Nm).

Remove motorcycle from lift.

Replace fluids.

Fill transmission with transmission fluid and check
level. See

1.11 TRANSMISSION LUBRICANT

Install engine oil filter and fill oil pan. Check oil level
with hot engine after inspecting for leaks. See

1.5 ENGINE OIL AND FILTER

sm02314

Figure 3-142. Oil Pan Torque Sequence

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3-102 2009 Dyna Service: Engine

TABLE OF CONTENTS

SUBJECT

............................................................................................................................

PAGE NO.

FUEL SYSTEM

NOTES

TORQUE VALUE

FASTENER

4.15 FUEL PUMP, Installation

2.3 Nm

20 in-lbs

Top plate fasteners

4.15 FUEL PUMP, Installation

2.3 Nm

20 in-lbs

Top plate fasteners

HOME

4-2 2009 Dyna Service: Fuel System

4.3

ELECTRONIC FUEL INJECTION (EFI)

TROUBLESHOOTING

See the electrical diagnostic manual for troubleshooting and
diagnostic information.

HOME

4-4 2009 Dyna Service: Fuel System

4.4

IDLE SPEED

GENERAL

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN

HD-44750

Idle speed can only be set using a computer based diagnostic
package called DIGITAL TECHNICIAN (Part No. HD-44750),
available only to Harley-Davidson dealers.

HOME

2009 Dyna Service: Fuel System 4-5

4.5

AIR CLEANER ASSEMBLY

REMOVAL

See

Figure 4-1

. Remove screw (1) and air cleaner cover

(2).

Gently pull both rubber breather tubes (7) from the ele-
ment.

Slide clip-nut (5) to the left to allow access to third screw.
Remove three screws (4), bracket (6) and filter element
(8).

Gently pull the breather tubes from the breather bolts on
the backplate.

Do not use gasoline or solvents to clean filter element.
Flammable cleaning agents can cause an intake system
fire, which could result in death or serious injury. (00101a)

Inspect filter element. See

1.8 AIR CLEANER AND

EXHAUST SYSTEM

. Replace the filter element if damaged

or if filter media cannot be adequately cleaned.

Inspect seal ring (3) for cracks or tears. Verify that it seals
tightly to backplate. Replace as required.

Alternately back out both breather bolts (9) (metric) a few
turns a time while pulling backplate (10) away from
induction module.

Continue previous step until breather bolts are clear.
Remove backplate (10), gasket (11) and gasket (12).
Discard gaskets.

Wipe inside of air cleaner cover (2) and backplate (10)
with damp cloth to remove dust.

HOME

4-6 2009 Dyna Service: Fuel System

sm03759

Breather tube (2)

Cover screw

Air cleaner cover

Filter element

11mm breather bolt (2)

Seal ring

10.

Screw (3)

Backplate

11.

Gasket

Clip nut

12.

Bracket

Gasket

Figure 4-1. Air Cleaner Assembly

INSTALLATION

See

Figure 4-1

. Position new gasket (12) on backplate.

Insert two breather bolts (9) (metric) into backplate. Thread
bolts loosely into each cylinder head. Final tighten bolts
to 22-24 ft-lbs (29.8-32.5 Nm).

Position new gasket (11) on filter element (8). Make sure
gasket holes are aligned with screw holes.

Attach breather tubes (7) to breather screws on backplate.

Install air filter element (8) and bracket (6) using three
screws (4). Tighten to 40-60 in-lbs (4.5-6.8 Nm). Slide
clip-nut (5) to the right and into place.

Insert breather tubes (7) into holes in filter element.

Install air filter cover (2).

Apply a drop of LOCTITE THREADLOCKER 243
(blue) to threads of air cleaner cover screw (1).

Install air cleaner cover and tighten screw to 36-60
in-lbs (4.1-6.8 Nm).

BACKPLATE ASSEMBLY: HDI MODELS

See

Figure 4-2

. HDI models have unique backplates. These

parts may be distinguished by:

•

A different intake with a solenoid-operated trap door
assembly at the mouth of the intake.

•

An intake solenoid connector (2) on the backplate.

Perform the same routine maintenance on HDI models, but
also check that the trap door in the backplate operates properly.

HOME

2009 Dyna Service: Fuel System 4-7

sm02601

Intake module

Intake solenoid connector [178]

Air cleaner backing plate

Figure 4-2. Backplate: HDI Models

HOME

4-8 2009 Dyna Service: Fuel System

4.6

FUEL TANK

GENERAL

Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)

The fuel tank is treated to resist rusting. However, when the
motorcycle is not operated for a long period of time, see

1.27 STORAGE

for specific information regarding fuel tank

treatment.

For information on the tank-mounted fuel gauge, see the
electrical diagnostic manual and

7.19 FUEL GAUGE

REMOVAL

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)

Remove electrical caddy cover.

Purge the fuel supply line of high pressure gasoline.

See

Figure 4-3

. Remove the fuel pump fuse from the

fuse block.

Start the engine and allow the vehicle to run.

When the engine stalls, operate the starter for 3
seconds to remove any remaining fuel from the fuel
lines.

Gasoline can drain from quick-connect fitting when
removing fuel line. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. Wipe up spilled fuel immediately and dispose of
rags in a suitable manner. (00267a)

Do not twist fuel line fitting, as fuel line can crack causing
a fuel leak. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00274a)

See

Figure 4-4

. Pull up on chrome sleeve of quick-connect

fitting (1) and pull down on fuel supply line (2) to discon-
nect.

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

Disconnect negative battery cable.

Remove instrument panel.

For FXDC/FXDF models, see

7.21 INSTRUMENTS:

FXDC/FXDF

For FXDL, FXDB models, see

7.22 INSTRUMENTS:

FXDB/FXDL

For FXD models, see

7.19 FUEL GAUGE

sm02188

Figure 4-3. Fuel Pump Fuse

sm02211

Quick connect fitting

Fuel supply line

Figure 4-4. Fuel Supply Line Fitting

See

Figure 4-5

. Unplug fuel pump module connector [141].

Gasoline can drain from the crossover line when discon-
nected from fuel tank. Gasoline is extremely flammable
and highly explosive, which could result in death or ser-
ious injury. Wipe up spilled fuel immediately and dispose
of rags in a suitable manner. (00259a)

HOME

2009 Dyna Service: Fuel System 4-9

Drain fuel tank.

Obtain a short section of hose (5/16 inch I.D.). Insert
bolt in one end of hose and install hose clamp to verify
that end is securely plugged.

See

Figure 4-6

. Cut clamp (2) from one end of cros-

sover hose (3). Quickly replace crossover hose on
fuel tank fitting with open end of short hose while dir-
ecting flow of gasoline from free end of crossover
hose into suitable container.

See

Figure 4-7

. Disconnect crossover hose (1) and con-

tinuous venting vent line (9).

Remove the front mounting bolt (2), flat washers (3), and
acorn nut (4).

10. Remove the rear mounting bolt (5), flat washers (6), and

acorn nut (7).

11. See

Figure 4-6

. Disconnect fuel gauge connector [117]

(1) located under left side of fuel tank.

sm02028

Figure 4-5. Fuel Pump Module Connector [141]

sm02189

Fuel gauge connector [117]

Clamp

Crossover hose

Figure 4-6. Fuel Gauge Connector and Crossover Hose

sm02682

Flat washer (2)

Crossover line

Front mounting fastener

Acorn nut

Fuel cap

Flat washer (2)

Acorn nut

Continuous venting system vent line

10.

Vapor valve

Rear mounting fastener

Figure 4-7. Fuel Tank (Left: FXDL, FXDB, Center: FXDC, FXDF, Right: FXD)

HOME

4-10 2009 Dyna Service: Fuel System

CLEANING AND INSPECTION

Remove fuel pump. See

4.15 FUEL PUMP

Remove fuel gauge sending unit. See

7.20 FUEL GAUGE

SENDER

Clean the tank interior with commercial cleaning solvent
or a soap and water solution. Shake the tank to agitate
the cleaning agent.

Flush the tank thoroughly after cleaning and allow it to air
dry.

Inspect the interconnect lines, continuous venting system
vent line (if applicable) and fuel line for cuts, cracks or
holes. Replace lines as needed.

Inspect the tank for leaks and other damage. If a damaged
tank cannot be successfully repaired, replace it.

Install fuel gauge sending unit. See

7.20 FUEL GAUGE

SENDER

Install fuel pump. See

4.15 FUEL PUMP

INSTALLATION

TOOL NAME

PART NUMBER

HOSE CLAMP PLIERS

HD-97087-65B

Excessive pressure can build in the fuel tank if vapor valve
is not mounted vertically with long fitting to top. Leaks
due to excessive pressure can cause a fire or explosion,
which could result in death or serious injury. (00265a)

See

Figure 4-8

. Install continuous venting system vent

line (9) to vapor valve (10).

Place a washer (3, 6) over each bolt (2, 5) and insert the
bolts through the tank mounting lugs and frame bracket
tubes.

Install acorn nuts (4, 7) and tighten to 15-20 ft-lbs (20.3-
27.1 Nm).

NOTE

In next step, be sure crimped end of clamp faces toward front
of vehicle.

Connect the crossover tube (1). Install new hose clamp
using HOSE CLAMP PLIERS (Part No. HD-97087-65B).

Connect the fuel feed line. Install new hose clamp using
HOSE CLAMP PLIERS.

Connect the fuel gauge connector located under left side
of fuel tank. See

7.19 FUEL GAUGE

Install instrument panel.

For FXDC/FXDF models, see

7.21 INSTRUMENTS:

FXDC/FXDF

For FXDL, FXDB models, see

7.22 INSTRUMENTS:

FXDB/FXDL

For FXD models, see

7.19 FUEL GAUGE

Check for leaks.

Vapor Valve

Keep vent and vapor valve lines away from exhaust and
engine. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00263a)

See

Figure 4-8

. The vapor valve (2) is clipped to the frame

member just ahead of the fuel tank. Mark the two hoses (1, 4)
connected to the upper and lower fittings of the vapor valve
before removing it from its clip (3). When installing the vapor
valve, place the valve back into the clip with the long necked
end at the top.

NOTE

On California models, the hose from the vapor valve bottom
fitting goes to the charcoal EVAP canister. On non-California
models, the bottom fitting hose is vented to the atmosphere.

sm02602

Continuous venting system vent line

Vapor valve

Clip

Valve vent line

Figure 4-8. Vapor Valve Installation (Typical)

HOME

2009 Dyna Service: Fuel System 4-11

4.7

THROTTLE POSITION SENSOR (TPS)

GENERAL

Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the throttle position
sensor (TP sensor).

REMOVAL

Remove seat.

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

Disconnect negative battery cable.

Remove air cleaner backplate. See

. Unplug TP sensor connector [88].

Remove two fasteners to detach TP sensor from throttle
body. Discard fasteners.

sm02353

Figure 4-9. Throttle Position Sensor

INSTALLATION

NOTE

Throttle must be closed for proper installation of throttle position
sensor.

See

Figure 4-10

. Inspect O-ring (2) in groove of throttle

position sensor for cuts, tears or signs of deterioration.
Install new O-ring if necessary.

Fit pocket (3) of throttle position sensor over throttle shaft
while engaging index pin (1) with hole on machined flange
of induction module.

Install two new fasteners (4) to fasten throttle position
sensor to induction module. Tighten screws to 18 in-lbs
(2.0 Nm).

Using the throttle lever mechanism, open and close the
throttle plates to check for proper operation. Be sure that
the mechanism operates smoothly without binding or
sticking.

Connect TP sensor connector [88].

Install air cleaner assembly. See

4.5 AIR CLEANER

ASSEMBLY

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)

Install seat.

sm02603

Index pin

O-ring

Pocket

Fasteners

Figure 4-10. Throttle Position Sensor Installation

HOME

4-12 2009 Dyna Service: Fuel System

4.8

INTAKE AIR TEMPERATURE SENSOR (IAT)

GENERAL

Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the intake air temper-
ature sensor (IAT sensor).

REMOVAL

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

Disconnect negative battery cable.

Remove air cleaner backplate. See

. Unplug IAT sensor connector [89].

Remove fastener to detach IAT sensor. Discard fastener.

INSTALLATION

See

Figure 4-12

. Inspect O-ring (1) in groove of intake air

temperature sensor for cuts, tears or signs of deterioration.
Install new O-ring if necessary.

See

Figure 4-11

. Insert sensor into induction module with

electrical connector facing toward the left side of the
motorcycle.

See

Figure 4-12

. Install fastener (2) and tighten to 15-20

in-lbs (1.7-2.3 Nm).

Connect IAT sensor connector [89].

Install air cleaner assembly. See

4.5 AIR CLEANER

ASSEMBLY

Connect negative battery cable.

sm02354

Figure 4-11. Intake Air Temperature Sensor Location

sm02355

O-ring

Fastener

Figure 4-12. Intake Air Temperature Sensor

HOME

2009 Dyna Service: Fuel System 4-13

4.9

ENGINE TEMPERATURE SENSOR (ET)

GENERAL

Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the engine temper-
ature sensor (ET sensor).

REMOVAL

Purge the fuel supply line of high pressure gasoline.

See

Figure 4-13

. Remove the fuel pump fuse from

the fuse block.

Start the engine and allow the vehicle to run.

When the engine stalls, operate the starter for 3
seconds to remove any remaining fuel from the fuel
lines.

See

Figure 4-14

. Pull up on chrome sleeve of quick-con-

nect fitting (1) and pull down on fuel supply line (2) to dis-
connect.

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

Disconnect negative battery cable.

See

Figure 4-15

. Pull back boot to reveal ET sensor at

back of front cylinder.

Unplug ET sensor connector [90] by pulling external latch
outward and using rocking motion to remove.

See

Figure 4-16

. Loosen ET sensor using socket. When

sensor starts to turn easily, finish removing by hand.

sm02188

Figure 4-13. Fuel Pump Fuse

sm02211

Quick connect fitting

Fuel supply line

Figure 4-14. Fuel Supply Line Fitting

sm02604

Figure 4-15. Engine Temperature Sensor

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4-14 2009 Dyna Service: Fuel System

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