Harley Davidson 2009 Dyna Models. Service manual

sm02580

Console fastener, long (2)

Console fastener, short (1)

Console

LED assembly

Figure 7-62. Indicator Lamps: FXDB

sm02655

LED assembly

Clips (2 pair)

Connector [21]

Figure 7-63. FXDB Connector [21]

FXD Models

See

Figure 7-64

. Remove LED assembly fasteners (4)

from LED assembly (3).

Pull LED assembly from speedometer bracket.

FXDL Models

Pull riser cover from between handlebar risers.

See

Figure 7-65

. Squeeze clips (2) together and gently

pull LED assembly (1) from handlebar cover (3).

Table 7-9. FXDC, FXDF Connector [21] Pins

Function

Wire Color

Pin On [21]

left turn

Violet

high beam

White

oil pressure

Green/yellow

right turn

Brown

neutral

Tan

+12V

Orange

ground

Black

n/a

Not used

Table 7-10. FXDB Connector [21] Pins

Function

Wire Color

Pin On [21]

right turn

Brown

oil pressure

Green/yellow

high beam

White

left turn

Violet

ground

Black

+12V

Orange

neutral

Tan

+12V

Orange

ground

Black

ground

Black

Table 7-11. FXD, FXDL Connector [20] Pins

Wire Color

Pin On [20]

Brown

White

Violet

Orange

Tan

Green/yellow

Black

Table 7-12. LED Assembly Wiring

CONNECTION

INDICATOR LAMP

Ground through switch

Oil pressure

Ground through switch

Neutral

12V when active

High beam

12V when active

Right/left turn

HOME

7-52 2009 Dyna Service: Electrical

INSTALLATION

FXDC/FXDF Models

See

Figure 7-61

. Install LED assembly (1) into console.

Make sure clips (2) engage to secure assembly in place.

Connect connector (3) [21] to main wiring harness.

See

Figure 7-60

. Place console (2) in position. Tighten

screws (1) to 18-24 in-lbs (2.0-2.7 Nm).

FXDB Models

See

Figure 7-63

. Install LED assembly (1) into console.

Engage clips (2) into tabs on LED assembly.

Connect connector (3) [21] to main wiring harness.

See

Figure 7-62

. Place console (3) in position.

Install long console fasteners (1) and short console
fastener (2). Tighten fasteners to 18-24 in-lbs (2.0-2.7
Nm).

FXD Models

See

Figure 7-64

. Install LED assembly (3) into speedo-

meter bracket.

Install LED assembly fasteners (4) into LED assembly.
Tighten fasteners (1) to 18-24 in-lbs (2.0-2.7 Nm).

FXDL Models

See

Figure 7-65

. Install LED assembly (1) into handlebar

cover.

Engage clips (2) into tabs on LED assembly.

Install riser cover between handlebar risers.

sm02653

Trim plate

Lens

LED assembly

LED assembly fasteners (2)

Figure 7-64. Indicator Lamps: FXD

sm02654

LED assembly

Clips (2 pair)

Handlebar cover

Figure 7-65. FXDL LED Assembly

HOME

2009 Dyna Service: Electrical 7-53

7.26

NEUTRAL SWITCH

GENERAL

The neutral switch is located on the transmission case. The
two terminal switch is normally closed. When the transmission
shifter is in neutral and the ignition switch is in the IGNITION
position, the switch causes the NEUTRAL indicator light to
illuminate.

REMOVAL

Verify that transmission is in NEUTRAL.

See

Figure 7-66

. Remove two elbow connectors from

neutral switch posts.

Remove neutral switch from transmission case.

INSTALLATION

See

Figure 7-67

. Inspect O-ring for cuts, tears or general

deterioration. Replace as necessary. Lightly lubricate new
O-ring with clean transmission oil before installation.

Verify that transmission is in NEUTRAL.

Install neutral switch in transmission case and tighten to
120-180 in-lbs (13.6-20.3 Nm).

NOTE

The neutral switch is not polarity sensitive The elbow con-
nectors can be installed on either post.

Install two elbow connectors onto neutral switch posts.

Test neutral switch for proper operation as follows:

Verify that transmission is in NEUTRAL.

Turn Ignition/Light Key Switch to IGNITION.

Verify that neutral indicator light illuminates.

sm05247

Figure 7-66. Neutral Switch

sm05246

Figure 7-67. Neutral Switch O-Ring

HOME

7-54 2009 Dyna Service: Electrical

7.27

OIL PRESSURE SWITCH

GENERAL

The oil pressure switch monitors oil pressure in the crankcase.
If the oil pressure drops below 3 psi (20.6 kPa) the oil pressure
switch is tripped and illuminates the low oil pressure indicator
light.

See

Figure 7-68

. The oil pressure switch is located on the right

side of the crankcase.

REMOVAL

See

Figure 7-68

. Remove connector (2) from oil pressure

switch (1).

Using a 15/16 in. open end wrench, remove switch from
crankcase.

sm02650

Oil pressure switch

Connector

Figure 7-68. Oil Pressure Switch

INSTALLATION

NOTE

Perform step 1 only if original switch is being re-installed. New
switches have a sealant contact patch on the threads. If new
switch is being installed, begin at step 2.

Coat threads of oil pressure switch with LOCTITE PIPE
SEALANT WITH TEFLON (PST).

See

Figure 7-68

. Install oil pressure switch (1) to crank-

case. Tighten switch to 96-144 in-lbs (10.8-16.3 Nm).

Attach connector (2) to oil pressure switch.

Test oil pressure switch for proper operation.

NOTE

If connector (2) requires replacement, see

A.17 SEALED

SPLICE CONNECTORS

HOME

2009 Dyna Service: Electrical 7-55

7.28

REAR STOPLIGHT SWITCH

GENERAL

See

Figure 7-69

. The rear stoplight switch monitors brake fluid

pressure in the rear brake line. When pressure in the line
reaches a preset level, the rear stoplight switch is tripped and
illuminates the tail light/stoplight.

REMOVAL

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

See

Figure 7-69

. Remove both connectors (2) from rear

stoplight switch (1).

Place a clean container under the rear stoplight switch
and brake line to catch escaping fluid.

Remove rear stoplight switch.

INSTALLATION

Coat threads of stoplight switch with LOCTITE 565 (thread
sealant) perpendicular to the threads. Do not allow thread
sealant to make contact with end of switch.

See

Figure 7-69

. Install rear stoplight switch (1). Tighten

switch to 12-15 ft-lbs (16.3-20.3 Nm).

Install both switch connectors (2).

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

Bleed brake system. See

1.16 BLEEDING BRAKES

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

Check stoplight for proper operation.

sm04050

Stoplight switch

Connectors

Master cylinder

Figure 7-69. Rear Stoplight Switch

HOME

7-56 2009 Dyna Service: Electrical

7.29

HORN

INSPECTION

If the horn fails to sound or does not sound satisfactorily, check
for loose, frayed or damaged wires leading to horn terminal,
discharged battery or corroded ground.

The horn is permanently sealed and non-repairable. Only the
mounting hardware is replaceable.

NOTE

No tonal adjustments may be made to this horn.

REPLACEMENT

See

Figure 7-70

. Remove nut (4) and washer (5) to detach

horn bracket (6) from vehicle.

See

Figure 7-71

. Disconnect wires from posts (1, 2) on

back side of horn.

See

Figure 7-70

. Remove screws (8) and nut (10) to

detach horn from bracket. Free wires from clamp (9).

Install new horn on bracket. Secure with screws (8), push
nuts (3) and nut (10). Fold wires under clamp (9).

See

Figure 7-71

. Attach wiring.

Connect Y/BK wire to gold post (1).

Connect BK wire to silver post (2).

See

Figure 7-70

. Attach horn to vehicle using washer (5)

and nut (4). Tighten nut to 10-15 ft-lbs (13.6-20.3 Nm).
When tightening fasteners, be sure the horn does not
contact the horn cover or other parts.

sm02647

Horn

Cover

Push nut (2)

Acorn nut

Washer

Bracket

Rubber mount

Screw (2)

Clamp

10. Nut

Figure 7-70. Horn

is03886

Gold post and Y/BK wire

Silver post and BK wire

Figure 7-71. Horn Wiring

HOME

2009 Dyna Service: Electrical 7-57

7.30

ACTIVE EXHAUST

GENERAL

The active exhaust system utilizes an actuator valve located
in the rear exhaust pipe which is connected to a servo motor
via a cable. The valve position automatically adjusts to enhance
engine performance.

The active exhaust module is located in front of the battery
box. The attached cable is routed to a bellcrank located on the
rear exhaust pipe.

REMOVAL

See

Figure 7-72

. Remove active exhaust cable housing

(1) from notch in shroud (2). Remove ferrule (3) from active
exhaust module to free cable (4).

See

Figure 7-73

. Remove module fasteners (4) and

washers (3) from battery box (1).

sm02645

Active exhaust cable housing

Shroud

Ferrule

Active exhaust cable

Active exhaust module connector [179]

Figure 7-72. Active Exhaust Module

sm02643

Battery box

Active exhaust module

Washer (2)

Module fastener (2)

Rear exhaust pipe, all but FXDF

Cable

Clip

Head pipe, FXDF

Figure 7-73. Active Exhaust

REPAIR

NOTE

See

Figure 7-72

. Active exhaust module shroud (2) can be

replaced. Replace shroud if active exhaust cable housing (1)
is a loose fit in shroud.

Remove fasteners securing shroud.

Replace shroud. Replace fasteners and tighten securely.

INSTALLATION

See

Figure 7-72

. Install ferrule (3) into slot shown. Wrap

cable counterclockwise around active exhaust module
shroud as shown.

Clip cable housing into active exhaust module housing
(2).

Place active exhaust module into position in front of battery
box.

Install fasteners (4) and washers (3). Tighten to 36-60 in-
lbs (4.1-6.8 Nm).

See

Figure 7-74

Figure 7-75

. After installation, be sure

active exhaust cable is routed correctly and does not

HOME

7-58 2009 Dyna Service: Electrical

contact the exhaust pipe, battery cover or transmission
case.

sm02642

Active exhaust module

Active exhaust cable

Clamp

Bellcrank

Cable tie

Figure 7-74. Active Exhaust Cable: All but FXDF

sm03818

Active exhaust module

Active exhaust cable

Clamp (2)

Bellcrank

Figure 7-75. Active Exhaust Cable: FXDF

HOME

2009 Dyna Service: Electrical 7-59

7.31

MAIN WIRING HARNESS

GENERAL

The main wiring harness is routed through the frame backbone
and has enough slack designed into it so that it can be pulled
out of the front end of the backbone to access the connectors
located inside the frame.

NOTE

See

B.1 CONNECTORS, Connector Locations

for a description

of all connector locations.

REMOVAL

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)

NOTE

Disarm HFSM or TSSM before removal.

Disconnect battery cables, negative cable first.

Remove battery.

Remove battery tray. See

7.9 BATTERY TRAY AND

BATTERY CABLES

Remove instrument console.

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

NOTE

To verify proper installation, make note of all wire routing and
connector locations before removal. In particular, pay close
attention to the locations of cable straps and anchors which
must be replaced.

See

Figure 7-76

. Disconnect fuel pump/sender connector

[141].

For FXDC/FXDF models, remove the remaining three
main harness connectors. The three are:

Key switch [33].

Indicator lamps [21] (8-Place Mini-Deutsch).

Speedometer [39] (NOTE: Reset boot and switch
must be removed from console).

Remove fuel tank. See

4.6 FUEL TANK

. This includes

detaching fuel gauge connector [117].

Remove exhaust. See

4.17 EXHAUST SYSTEM

10. Remove rear brake master cylinder. See

2.15 REAR

BRAKE MASTER CYLINDER

11. On HDI vehicles, remove active exhaust module connector

[179] located in front of electrical caddy.

12. Remove electrical caddy and ignition coil. See

7.3 ELEC-

TRICAL CADDY

ed02966

Figure 7-76. Fuel Pump Connector [141] (Typical)

13. See

Figure 7-77

. Remove harness shield by pushing both

tabs of shield in at the same time.

14. Pull harness connectors from inside frame.

15. Disconnect the following connectors:

Right handlebar controls [22] (6-place Deutsch).

Left handlebar controls [24] (6-Place Deutsch).

Instruments [20].

Turn signals [31].

(FXDL/FXDB models) Instruments [21].

Headlamp [38].

NOTE

In next step, note location of ground wires before removal to
verify proper installation.

16. See

Figure 7-78

. Remove ground wires from studs on

frame.

HOME

7-60 2009 Dyna Service: Electrical

17. Disconnect connectors located under seat:

Accessory connector [4].

Tail lamp harness connector [7].

Rear oxygen sensor [137].

Security siren connector [142] if security siren
installed.

B+ connector [160].

18. Disconnect starter solenoid [128].

19. Disconnect two neutral switch post terminals located on

top of transmission.

sm02641

Figure 7-77. Harness Shield

sm02216

Figure 7-78. Vehicle Ground Studs

20. Remove rear stop light switch terminals. See

7.28 REAR

STOPLIGHT SWITCH

21. Remove starter post nut, positive battery cable and main

wiring harness ring terminal from starter post.

22. Disconnect rear fender extension from fender.

23. See

Figure 7-79

. Slide wire harness retainer up frame

tubes. Remove harness retainer from frame and harness.

24. Remove the following connectors located in fuel tank area:

MAP sensor connector [80].

Horn wires.

IAT sensor connector [89].

ET sensor connector [90].

IAC connector [87].

TP sensor connector [88].

Front [84] and rear [85] fuel injector connectors.

25. Disconnect voltage regulator connector [77], crank position

sensor connector [79], stator connector [46] and front
oxygen sensor [138]. See

7.6 VOLTAGE REGULATOR

26. Disconnect oil pressure switch connector [120].

27. On HDI vehicles, remove intake solenoid connector [178]

from air cleaner backing plate.

28. Disassemble voltage regulator connector.

NOTE

The upper portion of the wiring harness is now free. Be careful
to note routing before pulling harness out of position.

29. Attach a long thin wire to the top end of the wiring harness

before pulling harness through frame backbone.This guide
wire will aid in pulling the new harness back through the
backbone.

30. Gently pull wiring harness out of rear of frame tube.

HOME

2009 Dyna Service: Electrical 7-61

sm02639

Wire harness retainer

Vent line

To front of vehicle

Rear brake light switch

Front engine harness

Figure 7-79. Main Wire Harness (Typical)

INSTALLATION

NOTES

•

Be sure to replace all cable straps and anchors.

•

Do not remove factory installed wire harness tape securing
connectors to harness unless necessary.

Guide wiring harness back into frame backbone. Pull the
front of the harness through using the guide wire while
pushing the harness through the frame tube opening.

Connect the following connectors.

Right handlebar controls [22] (6-place Deutsch).

Left handlebar controls [24] (6-Place Deutsch).

Instruments [20].

Turn signals [31].

(FXDL/FXDB models) Instruments [21].

Headlamp [38].

NOTE

Be sure to leave enough slack in harness at front of vehicle so
when front wheel is turned, harness does not bind.

Install connectors into frame. Install harness shield.

To ease installation, wrap voltage regulator terminals with
electrical tape.

See

Figure 7-79

. Route engine harness (which contains

voltage regulator connector [77], crank position sensor
connector [79], stator connector [46] and front oxygen
sensor [138] wiring to front of vehicle as shown. Install the
oxygen sensor and crank position sensor connectors in
front electrical caddy (see

7.17 CRANK POSITION

SENSOR (CKP)

). Connect the engine harness and stator

connectors to the voltage regulator.

Route rear brake switch wiring (4) as shown and connect
to rear brake switch.

Route neutral switch wiring and connect to neutral switch.

Route starter solenoid wiring and connect to starter
solenoid.

Install rear brake master cylinder and rear brake control.
See

2.15 REAR BRAKE MASTER CYLINDER

10. Secure front engine harness with harness clamps.

11. Install wire harness retainer (1).

12. Connect rear fender extension to rear fender.

NOTES

•

See

Figure 7-79

. To prevent contact with rear fork, front

engine harness (5) and rear brake switch wiring must be
secured in wire harness retainer (1).

•

If equipped with jiffy stand sensor (HDI models only), route
the sensor harness up along the vent line (2) and secure
in the same retainer cavity as the vent line.

13. Connect oil pressure switch [120].

14. See

Figure 7-80

. Connect vehicle speed sensor connector

[65].

15. See

Figure 7-81

. Secure harness grounds to studs.

16. Route top engine harness to fuel tank area.

17. Connect:

MAP sensor connector [80].

Horn wires.

IAT sensor connector [89].

ET sensor connector [90].

IAC connector [87].

TP sensor connector [88].

Front [84] and rear [85] fuel injector connectors.

18. Install electrical caddy and wiring. See

7.3 ELECTRICAL

CADDY

HOME

7-62 2009 Dyna Service: Electrical

19. See

Figure 7-83

. Mate connectors located under seat:

Accessory connector [4].

Tail lamp harness connector [7].

Rear oxygen sensor [137].

Security siren connector [142] if security siren
installed.

B+ connector [160].

20. On HDI vehicles, install active exhaust module connector

[179] located in front of electrical caddy.

21. Install fuel tank. See

4.6 FUEL TANK

. This includes con-

necting fuel gauge connector [117].

22. Install instrument console.

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

23. Install exhaust. See

4.17 EXHAUST SYSTEM

sm02733

Figure 7-80. Vehicle Speed Sensor

sm02216

Figure 7-81. Vehicle Ground Studs

sm02638

Tail lamp connector location

B+ connector location

Accessory connector location

Unused

Figure 7-82. Under Seat Connector Mounting Locations

HOME

2009 Dyna Service: Electrical 7-63

sm02637

Cable strap anchor

Rear O2 sensor connector [137]

IAT sensor connector [89]

Tail lamp connector [7]

Cable strap anchor

HFSM antenna

Cable strap anchor

Figure 7-83. Under Seat Wiring

Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)

24. Install battery and battery tray.

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)

25. Install seat.

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

26. Turn ignition ON. Test all electrical components for correct

operation.

HOME

7-64 2009 Dyna Service: Electrical

7.32

HANDLEBAR SWITCH ASSEMBLIES

GENERAL

The switches are of rugged construction and feature a superior
seal to protect electrical contacts and components from dirt
and moisture in harsh environments.

The left handlebar switches include the headlamp HI - LO
switch, horn and left turn signal switch. The right handlebar
switches include the engine start and RUN - OFF switch and
right turn signal switch. The individual switches are non-
repairable and must be replaced if they malfunction.

NOTES

•

On certain models, the turn signal wiring is routed through
the lower switch housings and handlebars.

•

To replace or repair individual switches in either the right
or left handlebar switch assemblies, see

7.33 RIGHT

HANDLEBAR SWITCH

7.34 LEFT HANDLEBAR

SWITCH

REPAIR PROCEDURES

TOOL NAME

PART NUMBER

ROBINAIR HEAT GUN

HD-25070

ULTRA TORCH UT-100

HD-39969

HEAT SHIELD ATTACHMENT

HD-41183

See

7.33 RIGHT HANDLEBAR SWITCH

and

7.34 LEFT

HANDLEBAR SWITCH

. The removal and installation steps

listed apply when replacing the entire switch assembly, switch
housing or handlebars.

The information below is useful when repairing handlebar
switch assemblies.

To better access wires and avoid damaging conduit with
radiant heating device, push conduit back and secure with
extra 7.0 in. (177.8 mm) cable strap in kit.

Strip 0.5 in (12.7 mm) of insulation off switch wires. Twist
stripped ends of switch wires until all strands are tightly
coiled.

Cut dual wall heat-shrink tubing, supplied in repair kit into
1.0 in. (25.4 mm) segments. Slide tubing over each wire
of new switch assembly.

Splice existing and new switch wires, matching wire colors.
Solder the spliced connections. For best results, do one
wire at a time.

Center the heat-shrink tubing over the soldered splices.

Be sure to follow manufacturer's instructions when using
the UltraTorch UT-100 or any other radiant heating device.
Failure to follow manufacturer's instructions can cause a
fire, which could result in death or serious injury. (00335a)

•

Avoid directing heat toward any fuel system component.
Extreme heat can cause fuel ignition/explosion resulting
in death or serious injury.

•

Avoid directing heat toward any electrical system com-
ponent other than the connectors on which heat shrink
work is being performed.

•

Always keep hands away from tool tip area and heat shrink
attachment.

See

Figure 7-84

. Using the ULTRA TORCH UT-100 (Part

No. HD-39969) or ROBINAIR HEAT GUN (Part No. HD-
25070) with HEAT SHIELD ATTACHMENT (Part No. HD-
41183) or other suitable radiant heating device, uniformly
heat the heat-shrink tubing to insulate and seal the
soldered connections. Apply heat just until the meltable
sealant exudes out both ends of tubing and it assumes a
smooth cylindrical appearance.

Inspect the melted sealant for solder beads. Excess solder
or heat may force some solder out with the melted sealant.
Use a small needle nose pliers to remove any solder
found. Briefly heat the connection to reseal the tubing if
solder beads were removed. Use less solder or reduce
heating time or intensity when doing subsequent splices.

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

sm00082

Ultra Torch UT-100

Robinair Heat Gun

Heat Shield Attachment

Figure 7-84. Radiant Heating Devices

HOME

2009 Dyna Service: Electrical 7-65

7.33

RIGHT HANDLEBAR SWITCH

REMOVAL

NOTE

The removal and installation steps listed apply when replacing
the entire switch assembly, switch housing or handlebars.

Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and
plunger on the front stoplight switch. (00324a)

Remove maxi-fuse.

See

Figure 7-85

. Place the 5/32 in. (4 mm) thickness

cardboard insert between the brake lever and lever
bracket.

Using a T25 TORX drive head, loosen but do not remove
the upper and lower switch housing screws.

Using a T27 TORX drive head, remove the two screws
with flat washers securing the handlebar clamp to the
master cylinder housing. Remove the brake lever/master
cylinder assembly and clamp from the handlebar.

Remove the upper and lower switch housing screws.

Remove the friction shoe from the end of the tension
adjuster screw.

NOTE

The friction shoe is a loose fit and may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.

Loosen cable adjusters. See

1.15 THROTTLE CABLES

Remove the brass ferrules from the notches on the inboard
side of the throttle control grip. Remove the ferrules from
the cable end fittings.

Remove the throttle control grip from the end of the
handlebar.

10. Pull the crimped inserts at the end of the throttle and idle

control cable housings from the lower switch housing. For
best results, use a rocking motion while pulling. Place a
drop of light oil on the retaining rings, if necessary.
Remove the cables from the switch housing.

sm02635

Figure 7-85. Install 5/32 in. (4 mm) Thickness Cardboard

Insert

INSTALLATION

See

Figure 7-86

. Push the throttle and idle control cables

into the lower switch housing until they snap in place. Note
the different diameter inserts crimped into the end of the
throttle and idle cable housings.

Push the silver insert (2) of throttle cable housing into
the hole in front of tension adjuster screw (3).

Push the gold insert (1) of idle cable housing into the
hole at the rear of tension adjuster screw (3).

NOTE

To aid assembly, place a drop of light oil on the retaining rings
of the crimped inserts. Always replace the retaining rings if
damaged or distorted.

See

Figure 7-87

. Route the cable (2) to the upper switch

housing as shown.

Slide the throttle control grip over the end of the right
handlebar until it bottoms against the closed end. Rotate
the grip so that the ferrule notches are at the top. To pre-
vent binding, pull the grip back about 1/8 in. (3.2 mm).

With the concave side facing upward, install the friction
shoe so that the pin hole is over the point of the adjuster
screw.

NOTE

The friction shoe is a loose fit and may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.

HOME

7-66 2009 Dyna Service: Electrical

See

Figure 7-88

. Position lower switch housing beneath

the throttle control grip. Install the brass ferrules (4) onto
the cable so that the end fittings seat in the ferrule recess.
Seat the ferrules in their respective notches (3) on the
throttle control grip. Verify that the cables are captured in
the grooves (2) molded into the grip.

Position the upper switch housing over the handlebar and
lower switch housing.

Verify that the wire harness conduit runs in the depression
at the bottom of the handlebar. Be sure that the upper
switch housing harness will not be pinched under the
handlebar when the switch housing screws are tightened.

Start the upper and lower switch housing screws, but do
not tighten.

sm02636

Idle cable insert (gold insert, rear hole)

Throttle cable insert (silver insert, front hole)

Tension adjuster screw

Figure 7-86. Right Lower Switch Housing

sm02634

End fittings

Upper switch housing cable

Figure 7-87. Route Cable to Upper Switch Housing

sm01084

Throttle cable (silver insert, front hole)

Groove in throttle grip

Notch

Brass ferrule

Idle cable (gold insert, rear hole)

Figure 7-88. Throttle Cable Attachment

See

Figure 7-89

. Position the brake lever/master cylinder

assembly inboard of the switch housing assembly, enga-
ging the tab (2) on the lower switch housing in the groove
(3) at the top of the brake lever bracket.

10. Align the holes in the handlebar switch clamp with those

in the master cylinder housing and start the two screws
(with flat washers). Position for rider comfort. Beginning
with the top screw, tighten to specification using a T27
TORX drive head. Refer to

Table 7-13

11. Using a T25 TORX drive head, tighten lower and upper

switch housing screws to specification. Refer to

Table 7-13

NOTE

Always tighten the lower switch housing screw first so that any
gap between the upper and lower housings is at the front of
the switch.

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2009 Dyna Service: Electrical 7-67

Harley Davidson 2009 Dyna Models. Service manual - page 23